Materials Matter: Why Steel Beats Aluminum in the Sustainability Debate (2024)

There is a general consensus within the automotive industry that favors electric vehicles (EVs) as the most feasible solution to decreasing greenhouse gas (GHG) emissions. For the integration of EVs into the existing fleet of cars to happen fast and in significant numbers, automakers have to optimize the range of their EVs. With the current technological limitations in electric motors and batteries, carmakers are collectively seeking lighter materials for maximum range.

Materials Matter: Why Steel Beats Aluminum in the Sustainability Debate (1)

More and more automakers are adding EVs to their fleet. (Source: Engineering and Technology)

While all this sounds promising for the environment, EVs don’t automatically translate into lower GHG emissions. According to World Auto Steel (WAS), the emissions from vehicle production will be greater than the amount of emissions from driving. As such, it is becoming increasingly important for manufacturers, policymakers and consumers alike to view material options by considering its life cycle assessment (LCA).

World Auto Steel Case Study

WAS conducted a case study in which they compared two popular lightweight materials for EVS; aluminum and Advanced High-Strength Steel (AHSS). The study followed the University of California Santa Barbara Automotive Energy & GHG Model (UCSB Model) for a comprehensive analysis of each material’s total energy use throughout its entire life cycle, from production to end of life recycling. For the study, WAS examined 1,000,000 BEVs of equal range that were made up of either entirely aluminum or AHSS.

Materials Matter: Why Steel Beats Aluminum in the Sustainability Debate (2)

BEVs made of AHSS require over 15 percent less energy than aluminum cars. (Source: World Auto Steel)

The study found that automakers can make over 17 percent more BEVs made of AHSS than aluminum BEVs with the same amount of energy. In other words, with the energy it takes to make 1 million aluminum BEVs, automakers can make 1.17 million AHSS BEVs.

Why is AHSS More Energy Efficient?

Aluminum production requires 8 times more energy per kilogram than steel production because the production process of aluminum is much more complicated and involves more steps than steel production. The aluminum BEVs in the study used up 30 percent more energy than those made from AHSS throughout its entire life cycle. Plus steel is 100 percent recyclable and can be reused almost indefinitely.

Materials Matter: Why Steel Beats Aluminum in the Sustainability Debate (3)

There are many sources of emissions output involved in the entire life cycle of a vehicle. (Source: World Auto Steel)

This poses a serious need to reexamine existing policies and regulations that only seek to reduce tailpipe emissions. By also taking into account emissions from the production of materials all the way to how a car is disposed at the end of its life cycle, automakers can grasp a better picture of the real impact of their choices on the environment.

A Sustainable Choice

As a solution-providing partner for automakers, steelmaker POSCO designed the perfect AHSS for cars that is lightweight, extremely strong, highly formable and environmentally friendly. POSCO GIGA STEEL belongs to the highest category for tensile strength of greater than 1GPa (Gigapascal). It can withstand more than 100 kg of force per square millimeter, making it 3 times stronger than aluminum. It is also 3.5 times cheaper than aluminum and 2.1 times cheaper to manufacture.

SEE ALSO: Infographic: Driving the Future with POSCO GIGA STEEL

Materials Matter: Why Steel Beats Aluminum in the Sustainability Debate (4)

POSCO GIGA STEEL is three times stronger than aluminum.

In 2016, POSCO sold 9 million tons of steel sheets for cars, making up 10 percent of the entire global automotive market for steel sheets. POSCO GIGA STEEL was designed to further improve the performance and efficiency of POSCO’s auto partners around the world. As the auto industry heads towards a future where environmentally-friendly EVs become the norm, POSCO will strive to equip its auto partners with the materials and tools necessary to stay ahead and competitive.

Materials Matter: Why Steel Beats Aluminum in the Sustainability Debate (2024)

FAQs

Materials Matter: Why Steel Beats Aluminum in the Sustainability Debate? ›

Aluminum production requires 8 times more energy per kilogram than steel production because the production process of aluminum is much more complicated and involves more steps than steel production.

Is steel or aluminium more sustainable? ›

The sustainability benefits of aluminum

Unlike steel, the process of recycling aluminum requires less energy and time. The Aluminum Association also found that “Aluminum is 100 percent recyclable and retains its properties indefinitely.

Why is steel a sustainable material? ›

Steel: The Most Sustainable Choice. Structural steel is 93% recycled and 100% recyclable, making it a material that is circular for generations. Instead of going to the landfill or an incinerator, decommissioned bridges and buildings go right back into the supply chain to become steel again and again.

How bad is aluminum for the environment? ›

Large parts of both the aquatic and terrestrial ecosystems are affected.In the aquatic environment, aluminium acts as a toxic agent on gill-breathing animals such as fish and invertebrates, by causing loss of plasma- and haemolymph ions leading to osmoregulatory failure.

Does it take more energy to produce aluminum or steel? ›

It is true that a lot of energy is required to make Aluminium. CSIRO calculate that the embodied energy (all the energy used to make the material) for aluminium is 211 GJ per tonne, compared to 22.7 GJ per tonne for steel.

Why is steel better than aluminium? ›

What is the weight difference of aluminum vs steel? Even with the possibility of corrosion, steel is harder than aluminum. Most spinnable tempers and alloys of an aluminum dent, ding or scratch more easily as compared to steel. Steel is strong and less likely to warp, deform or bend underweight, force or heat.

Why steel is better than aluminum? ›

STRENGTH. Despite being at risk for corrosion, steel is still harder than aluminum. While aluminum does increase in strength in colder environments, it is generally more prone to dents and scratches than steel. Steel is less likely to warp or bend from weight, force, or heat.

Is steel good or bad for the environment? ›

Making steel is among the most carbon-intensive manufacturing processes, producing about 7% of carbon dioxide emissions globally. Steel production is part of a broader industrial sector that accounted for about 30% of the greenhouse gas emissions in the U.S. in 2021, according to the Environmental Protection Agency.

Which material is more sustainable? ›

Sustainable materials should consist of natural fibers such as cotton, linen, or hemp. Organic and biological materials and fibers are produced without harmful pesticides and chemicals, making them better for the environment and your health.

Is steel sustainable for the environment? ›

A: Yes, steel is considered one of the most sustainable and environmentally friendly materials for construction, thanks to its recyclable and reusable nature.

Why should you avoid aluminum? ›

Exposure to high levels of aluminum may result in respiratory and neurological problems. Aluminum (in compounds combined with other elements) has been found in at least 596 of the 1,699 National Priority List (NPL) sites identified by the Environmental Protection Agency (EPA).

Why is aluminum bad for humans? ›

Recent studies on environmental poisoning have shown that aluminum can be a major threat to humans, animals, and plants [24–26]. Overdose of aluminum provides oxidative stress in the brain, liver, and kidney. It is possible to enhance free radicals and change antioxidant capacity of the enzymes.

Why is aluminum sustainable? ›

Aluminium can be recycled repeatedly without losing its properties, making it a highly sustainable material. In fact, recycling aluminium uses up to 95% less energy than producing new aluminium from raw materials.

What is the carbon footprint of steel vs aluminum? ›

It should be noted that for 1 kg of steel, approximately 2.75 kg of CO2e is emitted, while for 1 kg of aluminum, almost three times that amount of CO2e is generated.

Is steel aluminum environmentally friendly? ›

Steel and aluminum are the material of choice in various industries ranging from construction to transportation as well as consumer products. Although both metals require energy to produce, they can be highly sustainable choices when used properly.

Which metal produces the most energy? ›

Answer - (A) In these metals Potassium produces the highest energy. This is because as we move down the group the size of the ion increases and thus ionisation energy decreases, ansd we know amongst these metals alkali metals (sodium, liyhium, potas…

Which metal is the most sustainable? ›

sustainable properties of aluminum

Aluminum is also considered one of the most efficient and sustainable materials. The process of melting Aluminum down to its molten form does not change any properties of the metal.

What is the most sustainable type of metal? ›

Aluminum has high sustainability and environmentally friendly abilities. Aluminum is one of the most recycled metals and typically produces the same quality product after recycling. When you use recycled aluminum, you save a lot of energy that could have gone into the creation of raw aluminum.

Is aluminium more sustainable? ›

Recyclable and Sustainable

The recycling process creates high quality aluminium which loses none of the physical properties of primary aluminium and also uses just 5% of the energy it takes to create primary aluminium. This is why aluminium in generally regarded as the worlds most sustainable building material.

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