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Lighter cars, more efficiency, aluminum makers say

NEW YORK (Reuters) - If automakers use more aluminum and less steel in hybrid and electric-powered vehicles, they could cut the cost to consumers by $3,000 per vehicle, an aluminum industry-backed report says.

"As automakers gear up for a new generation of plug-in electric vehicles, the high cost of battery power remains a barrier," said Michael Bull, director of Automotive Technology for aluminum products maker Novelis, Inc.

"By upgrading from traditional steel to an advanced aluminum body structure, the vehicle's stored energy requirements can be cut by about 10 percent, which could save up to $3,000 per vehicle since less power and energy is required to move the lighter vehicle," Bull said in remarks to be given on Tuesday at the Center for Automotive Research's (CAR) "Business of Plugging In" conference in Detroit.

Bull, who was representing the Aluminum Association at the conference, told Reuters in an interview on Monday that currently about 10 percent of a vehicle body is constructed of aluminum, with the rest made of steel. The average weight is between 3,900 and 4,100 pounds.

There was universal acknowledgment, he said, that making cars and trucks lighter would increase their fuel efficiency and cut costs by reducing the battery energy requirements.

"The solution lies in lowering the vehicle's weight with aluminum as part of a holistic approach to also include advanced powertrains and batteries, enhanced thermal management, improved aerodynamics, and reduced rolling resistance," Bull said.

The report, by the Aluminum Association and Ricardo, a technical research consultancy, said making lighter vehicles, with more aluminum, would increase the driving range.

"Reduce the mass of the vehicle 20 percent, go 20 percent farther," it said. "As with conventional vehicles, the lighter vehicles have faster accelerations."

It cited Tesla Motors' Roadster, Fisker Automotive's luxury vehicle and Bright Automotive's van, which all use lightweight aluminum platforms for their vehicles.

"Many of the current hybrid vehicles are progressively adding lower weight components to improve the overall vehicle performance," said the report, financed by aluminum producers Alcoa Inc (AA.N) Hindalco Industries' (HALC.BO) Novelis, Rio Tinto's (RIO.L) Alcan Inc, Kaiser Aluminum Corp (KALU.O) and others.

Aluminum is making "steady penetration" into the auto market, "and if we could get to a point where 10 percent of vehicles are all aluminum we'd be happy," Bull told Reuters.

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