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design is simply copied from
steel. Designs optimised for aluminium
are based on specific
sections (20 to 40% higher
beams), smooth transitions and
clever joints, which normally
give 40-60% weight saving over
competing metals (see Chapter
III), as explained below.
1) A good light-weight trailer
has to be as strong as a traditional
model. If this would be
the sole criteria, the weight saving
obtained with aluminium
would be maximized (up to
60%) and high strength steel
solutions would provide about
half the weight saving achievable
with aluminium (about
30%).
2. Aluminium chassis
2.1. How is an aluminium chassis designed and what are the weight savings
achievable?
Chassis for aluminium tipper (Benalu)
32
ALUMINIUM IN COMMERCIAL VEHICLES CHAPTER IV FREQUENTLY ASKED QUESTIONS 32 | 33
2) A minimum stiffness is generally
required.
• If this stiffness has to be equal
with standard steel models,
weight savings obtained with
aluminium will be around 45%
with a superior strength, but
high strength steel cannot
achieve any weight saving.
• If the minimum stiffness
required is lower than the one of
standard steel models, weight
savings obtained with aluminium
will be somewhere between
45% & 60% and weight savings
obtained with high strength
steel somewhere between zero
and half of what can be
achieved with aluminium.
3) Vehicles durability must be
insured. As aluminium vehicles
are much more intensively used
than conventional ones, their
resistance to fatigue must be
higher. This result is obtained
with a proper design. Among of
a lot of others, higher sections,
smooth transitions and clever
joints are keys to success.
2.2. Are there different aluminium chassis designs?
Each manufacturer has its own
design, which to a high degree
depends on the working conditions
the vehicle is made for and
on the specific manufacturing
experiences of the chassis producer
(e.g. some prefer fully
welded constructions whereas
others prefer mixed welded and
bolted constructions). It is also
important to underline that aluminium
vehicles are much more
intensively used than conventional
ones, and this fact is
taken into account in the design
of vehicles. Apart from that,
there are two dominating
design philosophies in the chassis
world.
In countries like Italy, where
equal stiffness with steel models
seems to be a must, deflection is
the main criteria, and this generally
leads to longer lifetime than
conventional models, coupled
with an attractive weight saving.
In other countries, equal lifetime
with steel models will be the
main criteria. A good design will
lead to, at least, an equivalent
lifetime, stiffness within requirements
(even though it may be
slightly lower than steel models),
but the weight saving will
be maximized.
In any case, they will usually be
stronger than classic models,
and the risk for starting yield
failure from static overload will
be lower for aluminium chassis.
Chassis for aluminium tipper (Leciñena)
33
EUROPEAN ALUMINIUM ASSOCIATION
The lifespan of a chassis is a design
issue and not a material issue.
Aluminium chassis are mostly
used in transport segments
where the load factors are the
highest (solid & liquid bulk
tanks, tippers), nevertheless well
designed vehicles can easily
exceed 20 years of service life.
2.3. Is the life of an aluminium chassis shorter than a steel chassis?
2.4. How does aluminium compete with high strength steel?
We should make a distinction
between pure aluminium and
aluminium alloys.
Pure aluminium is never used in
commercial vehicles. A wide
variety of aluminium alloys do
exist, including high strength
solutions.
What is seldom communicated
is that all alloys based on the
same parent metal have nearly
the same elastic properties.
This means that if someone is
looking for a lightweight alternative
to a standard chassis
while keeping the same stiffness,
the only solution is to
change the material e.g. switching
from steel to aluminium (see
Chapter III).
Bolted aluminium chassis for tipper
(Menci)
34
ALUMINIUM IN COMMERCIAL VEHICLES CHAPTER IV FREQUENTLY ASKED QUESTIONS 34 | 35
Yes, there are a lot of tipper
variants and all of them can be
built using dedicated aluminium
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