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The Partnership for a New Generation of Vehicles (PNGV) is scheduled for production in the year 2005. Lightweight materials will play an important role in achieving the PNGV's up-to-80 mpg goal. This study explores the usage of aluminum in a PNGV. An analysis of closed-loop PNGV aluminum recycling in the future is presented. This study also addresses the important issues affected by this increased wrought aluminum volume on current recycling infrastructure. 80% closed-loop recyclability of aluminum scraps for the PNGV can be achieved with improved dismantling and shredder separation technologies as well as the knowledge of alloy selection.

The use of aluminum in automotive applications is growing. The 1991 calendar year automobiles used over 190 pounds per vehicle. The growth for aluminum applications is expected to be significant over the next ten years. Expected changes in end use and alloy mix pose challenges to the recycling system. These challenges need consideration by both the automotive and aluminum industries. This paper discusses these challenges and presents detailed analysis of the weight and chemistry aspects of automotive aluminum recycling. It also demonstrates a feasible and efficient recycling system in which post-consumer scrap is consumed in new production.