Alcoa Defense has applied innovative technology it developed for high-performance cars and the aerospace market in a project for the U.S. Army showcasing the ability of aluminum to make the next generation of military vehicle lighter, faster, stronger – and more fuel efficient.
WASHINGTON--(BUSINESS WIRE)--Alcoa Defense has applied innovative technology it developed for high-performance cars and the aerospace market in a project for the U.S. Army showcasing the ability of aluminum to make the next generation of military vehicle lighter, faster, stronger – and more fuel efficient.
“FED represents the first time we have been able to integrate a comprehensive suite of Alcoa’s lightweighting technologies into one vehicle”
Alcoa (NYSE:AA) has created an aluminum structure for the Army’s Fuel-Efficient Ground Vehicle Demonstrator (FED) that will make the vehicle up to 10 percent lighter than a comparably sized steel vehicle and reduce fuel consumption by 6-7 percent because the lighter vehicle frame enables a lighter engine, driveline and chassis. Alcoa supplied the FED’s aluminum chassis and cab structure with integral underbody armor protection to Ricardo Inc., the project’s lead engineering contractor. During the initial stages of design, Alcoa collaborated with Ricardo to determine which Alcoa solutions could best help achieve FED’s goals.
The FED project was launched by the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) in 2008 to develop a prototype vehicle that would showcase fuel efficient technologies, while maintaining the vehicle’s performance, payload capacity and protection of soldiers. If the Army, which operates the world’s largest fleet of ground vehicles, can improve fuel efficiency by just one percent, it will result in 6,000 fewer soldiers being put at risk by driving highly targeted fuel convoys in combat locations.
Lightweighting military vehicles via aluminum structures also enhances performance, which is why platforms that traditionally require maximum speed and agility, such as airplanes and sports cars, incorporate many aluminum technologies that originated with Alcoa. For instance, lighter aluminum vehicles can accelerate and brake faster than their heavier, steel-intensive counterparts. Additionally, aluminum is up to 50 percent lighter, yet provides more structural stiffness than steel.
“FED represents the first time we have been able to integrate a comprehensive suite of Alcoa’s lightweighting technologies into one vehicle,” said Alcoa Defense President Dave Dobson. “We are excited to have the opportunity to showcase all of our technologies for making vehicles lighter, faster and stronger in one groundbreaking platform.”
In addition to a welded aluminum spaceframe, other Alcoa innovations on the FED vehicle include:
With Alcoa’s all-aluminum cab and chassis structure serving as the vehicle’s foundation, Ricardo Inc. will integrate all other technologies and components into the vehicle, which is scheduled to debut at the Association of the United States Army (AUSA) Winter Symposium and Exposition in Ft. Lauderdale, Fla.
TARDEC embarked on the FED project to help achieve the Army’s long-term goal of reducing fuel consumption on the battlefield and its dependence on oil. The innovative solutions featured in the FED vehicle may become widely adopted by other military branches to enhance fuel efficiency in the next generation of tactical wheeled vehicles.
To demonstrate that FED’s aluminum technologies can be cost-effectively incorporated into future vehicle fleets, Alcoa built the prototype structure with the same cost-reduction considerations it applies to all OEM platforms. For instance, whenever possible, Alcoa uses aluminum product forms, such as forgings, extrusions and castings, that streamline production and decrease machining costs because their shapes very closely match the structures final form. To further reduce costs and streamline manufacturing for OEMs that typically specialize in steel structures, Alcoa also constructs aluminum subassemblies or full structures that OEMs can integrate into their vehicles. This support capability makes it much easier for OEMs to use the technologies featured in FED in production vehicles.
About Alcoa Defense
Alcoa Defense partners with industry leaders to design systems and materials that increase the speed, reach, agility and survivability of military platforms. In addition to delivering lightweight, innovative solutions in multiple product forms, Alcoa Defense manufactures subassemblies, prototypes and complete aluminum structures that original equipment manufacturers can integrate into their platforms for land, air and sea. More information can be found at AlcoaDefense.com.
About Alcoa
Alcoa is the world’s leading producer of primary aluminum, fabricated aluminum and alumina. In addition to inventing the modern-day aluminum industry, Alcoa innovation has been behind major milestones in the aerospace, automotive, packaging, building and construction, commercial transportation, consumer electronics and industrial markets over the past 120 years. Among the solutions Alcoa markets are flat-rolled products, hard alloy extrusions, and forgings, as well as Alcoa® wheels, fastening systems, precision and investment castings, and building systems in addition to its expertise in other light metals such as titanium and nickel-based super alloys. Sustainability is an integral part of Alcoa’s operating practices and the product design and engineering it provides to customers. Alcoa has been a member of the Dow Jones Sustainability Index for nine consecutive years and approximately 75 percent of all of the aluminum ever produced since 1888 is still in active use today. Alcoa employs approximately 59,000 people in 31 countries across the world. More information can be found at www.alcoa.com.
