Partial explanation for weight gain.

YEH · Jun 23, 2014

Asian automakers still reluctant to embrace aluminum

Hyunjoo Jin
Meeyoung Cho
Reuters
June 22, 2014 - 12:01 am ET

SEOUL -- About four years ago, Hyundai Motor Co. considered shifting from steel to aluminum body parts for the Genesis sedan to make it lighter, more fuel-efficient and more competitive with German luxury marques, two people familiar with the matter said.

Its affiliate Kia Motors Corp. made a similar move, building test versions of its premium K9 sedan, called K900 in the United States, using aluminum in body panels including the door, hood and trunk lid, two other people told Reuters.

But the South Korean duo, which together rank fifth in global auto sales, opted for steel instead, deterred by the cost and, according to two of those individuals, hamstrung by close ties with sister steelmaker Hyundai Steel Co.

As western carmakers such as Audi AG and Ford Motor Co. lead the way in using aluminum, which is lighter but more expensive than steel, their Asian rivals are reluctant to invest in the costly retooling required that would disrupt existing manufacturing processes and supplier relationships.

http://www.autonews.com/article/201...utomakers-still-reluctant-to-embrace-aluminum

Heavy Hyundai

The previous version of Hyundai's Genesis had an aluminum hood, but the company switched to steel for the current model, launched in late 2013, making it heavier and less fuel efficient than its predecessor, two of the people said.

An aluminum car hood weighs about half of one made of steel, according to Novelis. Every 10 percent reduction in vehicle weight improves fuel economy by 6-8 percent, according to the U.S. Department of Energy.

In 2010, when Hyundai began developing the current-generation Genesis, shaving weight and increasing fuel economy was a concern, said one of those familiar with the matter.

At a meeting at the automaker's research center on the outskirts of Seoul, engineers proposed expanding the use of lightweight aluminum from the hood to other outer body panels and even frames, said the person, who was present. But Hyundai went in the opposition direction, swapping aluminum with steel even for the hood, because of its ties with Hyundai Steel and the higher costs associated with aluminum.

"This was a step backward for Hyundai," the person said.

The latest Genesis gained as much as 390 pounds (177 kg) from its predecessor, launched in 2008, and weighs 181 pounds more than BMW's rival 535i.

U.S. chief Dave Zuchowski said Hyundai has "put a lot of additional weight into structural rigidity" to pass tougher U.S. crash tests. "We used to say we'd like to reduce the weight in the car 10 percent as we bring them out. In this world, with ... crash requirements and things like that, you're not going to be able to do that," he told reporters in Detroit last month.

So - the switch from the hood being aluminum to high tensile steel and the extra steel used up front to pass the off-set crash test, along with the added insulation and tech should explain much of the weight gain.

Think the change from an aluminum to a steel hood is a mistake (the rising valuation of the Won probably played a role), but at the same time, can understand why Hyundai does not make extensive use of aluminum or other higher cost weight reducing materials throughout as it would just jack up the price too much and at this juncture, Hyundai's luxury offerings need to offer the value quotient.

But at the same time, they cannot fall behind too much when it comes to fuel economy (even in the luxury segment, buyers look at FE, esp. when there is a large disparity) - but maybe making prudent use of aluminum and advances in steel would do the trick (aluminum is about 15% lighter than high tensile steel - so if they can get that down to around 8-10%, then the cost of using aluminum wouldn't be worth the weight savings).

Mark_888 · Jun 23, 2014

The use of steel instead of aluminum for the hood alone is very little difference. The first generation Genesis also used aluminum for suspension parts (non consumable ones), and looks like they added some extra high strength steel for crash protection.

sandy · Jun 23, 2014

I wonder what effect on repair costs and insurance rates the switch to steel from aluminum will have? My un-educated guess is hefty increases and some unsatisfactory results as your local body shop acquires the new equipment and expertise needed.

trotti · Jun 23, 2014

sandy said:
I wonder what effect on repair costs and insurance rates the switch to steel from aluminum will have? My un-educated guess is hefty increases and some unsatisfactory results as your local body shop acquires the new equipment and expertise needed.

For what it may be worth, my six-month premium for the '15 5.0 coming from the '12 R-Spec was a $4 increase. I also had to replace the aluminum hood on the '12 because of a simple dent. Had it been steel, it could have been popped out. I think it makes the car cheaper to insure and service/maintain.

For what it's worth, the paintless dent repair guy I used loved pulling dents out of the old R-Spec because, his words, "the steel is such good quality they come out easier."

italiabrain · Jun 24, 2014

sandy said:
I wonder what effect on repair costs and insurance rates the switch to steel from aluminum will have? My un-educated guess is hefty increases and some unsatisfactory results as your local body shop acquires the new equipment and expertise needed.

I would think it would be the other way around as steel is the older material body shops always worked with before aluminum came on the scene rather recently. I can't imagine there will be any issue along the lines of corvette owners having to find competent shops for fiberglass. Even cars that use aluminum typically have some steel on the body.

My biggest gripe with this (I would have never imagined they switched to steel on the hood) is how religiously I'm going to have to watch for stone chips. I'd pay extra for an aluminum hood just to know that missing a stone chip for a week wouldn't result in rust...

sandy · Jun 24, 2014

You're right....I meant to say the switch to aluminum from steel.

gselvo · Jan 16, 2017

I just discovered a problem with the aluminum hood on my 2009 - galvanic action. The metal grill and the aluminum hood don't like each other. The paint is corroding in spots, presumably where the grill has fasteners to the hood. Going to look for some kind of sacrificial anode.

Midnightsun · Jan 17, 2017

The only advantage to aluminum is weight savings. As mentioned, it costs more, expensive to repair as most of the time replacement is required. Is much weaker in all respects and makes it more difficult to fabricate a safe car. I remember when the G2 was announced, they touted the fact that high strength steel was being used in several areas to improve rigidity and strength throughout which is did do in a big way. This material was coming from Hyundai's newly acquired steel plant. Obviously owning what I assume is a mega steel production facility seals the deal on the material type to be used for their cars.

Partial explanation for weight gain.

YEH

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