Editor's Note: A hypertext-enhanced version of this article can be found at www.tms.org/pubs.journals/JOM/0108/ Although the use of aluminum in cars has been increasing for the past two decades, progress has been limited in developing aluminum auto bodies. In fact, most aluminum substitution has come in the form of castings and forgings in the transmission, wheels, etc. Car manufacturers have developed allaluminum cars with two competing designs: conventional unibody and the spaceframe. However, aluminum is far from being a material of choice for auto bodies. The substitution of aluminum for steel is partly influenced by regulatory pressures to meet fuel efficiency standards by reducing vehicle weight, and to meet recycling standards. The key obstacles are the high cost of primary aluminum as compared to steel and added fabrication costs of aluminum panels. Both the aluminum and the automotive industries have attempted to make aluminum a cost-effective alternative to steel. This paper analyzes the cost of fabrication and assembly of four different aluminum car body designs,making comparisons with conventional steel designs at current aluminum prices and using current aluminum fabrication technology. It then attempts to determine if aluminum can be an alternative to steel at lower primary aluminum prices, and improved fabrication processes.

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