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Ducker 2015 North American Light Vehicle Aluminum Content Study

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Aluminum Extrusion Aids Auto Lightweighting

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As auto makers drive for improved fuel economy, aluminum – and aluminum extrusions – are making a major contribution by helping car builders reduce vehicle weight, even while accommodating additional safety, convenience and entertainment content. Ducker Worldwide estimates that in 2014 the average North American passenger vehicle contained about 28 pounds of aluminum extrusion – a number that should grow to nearly 50 pounds per vehicle by 2025.



The above graphic shows just some of the extrusion applications, and alloys, that can be found in today’s production vehicles, as aluminum and extrusion use moves from limited production specialty vehicles into the mainstream.

Some recent high points:


Chevrolet introduces the 7th generation Corvette Stingray with standard all-aluminum frame. Comprised of aluminum extrusions and castings , the new frame reduced weight by 45 kg (99 pounds) while providing 60% increased stiffness.

launches their award-winning Model S. The aluminum-intensive design, featuring extensive use of aluminum sheet along with multiple castings and extrusions (like the roof bow shown at right) yields a body-in-white weighing 25% less than a key segment competitor. Aluminum extrusions also find application in the battery box, rear suspension and side impact system.




Ford launches the aluminum-intensive F150, the highest volume North American vehicle and the highest volume aluminum-intensive application. Roughly 50 pounds of automotive aluminum extrusions are used in the front end and roof structure. With a body in white (crew cab and bed) at 400 pounds lighter than conventional competitors, the F-150 offers Increased load capacity and improved economy.




Cadillac introduces their aluminum-intensive CT6, designed to compete with Germany’s high performance luxury sedans. Aluminum extrusions are found throughout the structure, and include multi-hollow rocker and engine cradle components. The result is a weight savings of over 200 pounds vs. high-strength steels and a body in white lighter, yet stiffer than the BMW 5 series.