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SUMMARY: IMPACT OF LIFE CYCLE EMISSIONS WHEN LIGHTWEIGHTING
WITH ADVANCED HIGH-STRENGTH STEEL VS. ALUMINUM
The federal government regulates fuel economy and greenhouse gas (GHG) emissions associated with
the operation of passenger cars and light trucks. To meet increasingly stringent targets, automakers are
implementing new technology in various areas of the vehicle including: improved powertrain systems,
increased aerodynamics, reduced rolling resistance and reduced curb weight. The steel industry has worked
collaboratively with automakers to help with vehicle lightweighting while achieving the same high vehicle
performance and value for the consumers. Lightweighting with steel is possible because of new advanced
high-strength steel (AHSS) grades replacing lower strength grades. This higher strength allows for less
material (thickness of the sheet metal) to be used to achieve the same or improved performance. The focus
on fuel economy and tailpipe emissions only, combined with the significant tightening of these standards is
pushing automakers to alternate, high cost materials for incrementally small gains in meeting the standards.
Figure 1 shows a comparison of body structural materials by their relative mass reduction potential and
compares this with GHG emissions for material production. This simple comparison raises the question
of whether or not replacing steel is the best answer for the environment. To fully evaluate this hypothesis,
the Steel Recycling Institute (SRI), a business unit of the American Iron and Steel Institute (AISI), conducted a
comprehensive study to assess the total environmental impact of vehicles lightweighted with AHSS and
aluminum. The study assesses the GHG emissions and energy consumption associated with the entire life
cycle of a vehicle; comprising the vehicle production phase (including materials production), use (driving)
phase, and end-of-life phase.
Figure 1 – Material Production GHG Em
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