Aluminum Versus Steel Car Bodies
Aluminum vs. Steel Car Bodies
Cars have been on the road since 1868, and the materials they’ve been made from have evolved like their body styles. From wood to steel, iron, plastics, and composites, there have been a lot of changes in the body of the modern car. The two most ubiquitous are probably steel and aluminum. But which is better, and why?
The material of the future?
Aluminum has been recently popping up as the go-to material for the automobile body. Aluminum fans say it is the best option for advanced, next-gen cars; from pickup to electric.
Looking at the periodic table, aluminum is nearly half as dense as iron. But, does being a lighter material make for a lighter car? The aluminum guys say, yes. Manufacturers like Tesla and Ford have chosen aluminum bodies to save weight that is taken up instead, by batteries or payload capacity
Lower mass, higher cost
Lower mass, higher cost
“Steeling” the show
Of course, there are many who disagree. The car’s body and chassis account for over half of the vehicle’s total weight. That means the material can make big differences in weight, strength and stiffness. According to some, steel’s tensile strength is up to 2,000MPa, which is nearly four times stronger than the toughest aluminum alloys that are available in today’s market. The price of aluminum materials is also about two to three times higher than steel. Another disadvantage of aluminum is the thickness. Aluminum has to be made wider than steel to have the same performance. While it may weigh the same, and offer similar performance, parts must be made wider. This can have an impact on the driving experience. When all parts are aluminum, space and efficiency of the vehicle’s interior are also compromised.
The safety game
Some say aluminum bodies are safer than steel due to better energy absorption. Also, crush zones made larger will fold into more predictable patterns. The counter-argument is that it is not the material that is in question, but what you design with that material. A vehicle can be made safe with materials other than steel, but the design and combination of materials used is what is important. To say aluminum is “safer” than steel would then be technically incorrect.
So why, then, do aluminum-bodied vehicles come with five-star safety ratings? Some say that the new, higher-end vehicles offer extra engineering that earns that five-star rating, rather than it being any advantages of aluminum.
Recycle and Reuse
Aluminum can be recycled through advanced recycling processes. Steel may have an advantage in that it is the most recycled material in the world. The process of recycling steel is simple. Steel’s ferrous property allows for simpler scrapyard sorting. Steel alloys can be re-melted and remixed to produce any steel alloy. Aluminum is more expensive to recycle than steel and requires that different grades be separated before melting can take place to preserve the grades.
Some grades of aluminum are known to be challenging to work with, while steel is well known for its higher ductility and yield. It is a difference that sometimes makes steel the choice for some car manufacturers.
The road ahead
The battle of steel over aluminum, or aluminum over steel, appears to be an ongoing one. In the quest for improving technology, both weight and cost must be considered. It’s easy to see why the argument of aluminum or steel being the best option for your car, has a very long road ahead.
Whichever material you decide to go for, we’ll be here for all of your automotive needs! Our certified technicians have experience working with all kinds of materials and are here Monday – Sunday so you can be back on the road ASAP. Simply give us a call at (305) 908-5548 or request an appointment with us online.