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This diversity of semi-finished
products makes it possible to:
• Design structural elements
with special functions such as
shapes with grooves for screw
heads, hydraulic circuits, inertia
shapes, snap-locks, welding
flanges etc.
• Save on time and cost for
assembly and finishing. This can
compensate for the added raw
material cost of structures made
from aluminium alloys compared
with equivalent steel structures.
• Reduce stress due to welding
by placing castings at assembly
intersections or using special
extrusions to divert welding
stresses into less stressed areas of
a fabricated structure.
• Design complex cast or forged
shapes.
2.5. Easy to work with
Aluminium alloys used in the
manufacture of commercial vehicles
and their accessories are
easy to process. They lend themselves
to a variety of shaping and
joining techniques that will be
reviewed in chapters 7, 8 & 9.
In a nutshell, aluminium can
easily be
• cut: sawing, shearing, water jet,
laser or plasma cutting
• machined: milling, drilling
• bent
• joined: welding, adhesive bonding,
bolting and riveting
Furthermore, being light, aluminium
is easy to handle in the
workshop.
Various aluminium products
21
EUROPEAN ALUMINIUM ASSOCIATION
To achieve emission reductions, it
is not only important to develop
low-emission engines, but also to
use them in the most rational
way possible. Saving weight with
aluminium is a good way of
achieving this objective as
explained below.
Aluminium contributes to the
reduction of CO2 emissions from
road transport as follows:
• When carrying heavy goods, it
increases the load capacity of
vehicles and therefore improves
transport performance, allowing
more goods to be carried per
trip. In this case, one ton saved
on the dead weight of an articulated
truck saves 1,500 liters of
diesel fuel over 100,000 km.
• When carrying voluminous
goods, it reduces the overall
weight, lowering fuel consumption
per kilometer. In this case,
one ton saved on the dead
weight of an articulated truck
saves 600 liters of diesel fuel over
100,000 km.
• When carrying passengers, it
reduces the overall weight and
lowers fuel consumption. One
ton saved on an urban bus saves
between 1,700-1,900 liters of
diesel fuel per 100,000 km.
Taking primary production, use
stage and end-of-life recycling
into account, life-cycle savings
have been estimated as follows:
• 1kg of aluminium in today’s
average articulated truck saves
28kg of CO2
• 1kg of aluminium in an urban
bus typically saves 40-45kg of CO2
3.2. Aluminium as
a complement to EURO IV
& EURO V engines
The European Environment
Directives for trucks date back to
1988, while the first standard
limiting emissions of nitrogen
oxides (NOx) and particulates
(PM) from heavy-duty diesel
engines were introduced at the
beginning of the 1990’s.
The EURO IV and EURO V standards
represent a dramatic reduction
of NOx and PM emissions.
However, they also impose new
combustion processes and
exhaust after-treatment techniques
representing an additional
weight-penalty up to 300kg.
Using more aluminium components
allows the manufacturer to
compensate for this weight
penalty. The payload can therefore
be preserved and even
increased.
3. Environmental and social Benefits
3.1. Aluminium reduces CO2 emissions
22
ALUMINIUM IN COMMERCIAL VEHICLES CHAPTER III WHY USING ALUMINIUM 22 | 23
In the context of its Road Safety
Action Programme, the European
Commission is looking into the
introduction of crash energy
absorption criteria for trucks. The
aluminium industry has already
developed several solutions for
the automotive and railway sectors
and would be ready to take
up this challenge for trucks.
Regarding metal deformation
that energy-absorbing elements
undergo upon impact, aluminium
systems make it possible
to absorb significantly more
crash energy per unit of weight
than traditional systems. As a
rule of thumb, the light-weighting
potential exceeds 40%.
For this reason, aluminium is very
well suited for front, rear and
side bumpers.
Aluminium elements can also be
used to improve the energy
absorbing potential of front and
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