Aluminum use in the average automobile could jump from 327 lbs nowadays to as much as 807 over the next decade as traditional mild steel is replaced in several applications by other materials.

Misha Riveros-Jacobson, president of Alcoa Advanced Transportation Systems, tells the spring meeting of the Aluminum Association that public demand for a greener environment and greater fuel efficiency will force policy makers to boost fuel economy standards and cut carbon dioxide emissions, opening the door for lighter-weight materials.

She suggests that aluminum will be a large part of the 480 lbs that will be up for grabs. Still, she admits there will be healthy competition: “Aluminum is in a race with magnesium, newer steels and plastics to supply that floating 480 lbs.”

Riveros-Jacobson and other speakers noted that health and safety and environmental considerations would play a key role in the performance of new automobiles. Federal safety regulations and fuel economy standards, as well as a recent Supreme Court decision that the U.S. Environmental Protection Agency has the right to regulate emissions of carbon dioxide under the terms of the Clean Air Act, all play a part in encouraging auto manufacturers to reduce vehicle weight by using more light weighting materials.

John German, manager of environmental and energy analyses for American Honda Motor Co., highlighted a growing body of research that shows vehicle safety is primarily a design issue, not a weight issue. “Lightweight materials can both reduce overall fatalities and improve fuel economy,” says German.

Cal Vickers, senior director of the purchasing group for Nissan North America, tells the meeting that his company's Smyrna, Tenn., plant already uses aluminum hoods and trunks on its Maxima and Altima models to lower the weight of the vehicles. But he admits that Nissan “isn't fully optimizing aluminum” yet.

Former senior vice president of Toyota, Dennis Cuneo says the car companies have been looking to reduce fuel consumption through alternative fuel and lighter materials and in turn meet consumer preferences for vehicles.