US researchers develop aluminium alloys that cut truck engine weight by 15%

Researchers in the United States have demonstrated new aluminium alloys that can reduce the weight of truck engines by about 15 per cent while improving fuel efficiency by more than 10 per cent in tests carried out on a General Motors prototype engine.

The work was led by the Oak Ridge National Laboratory (ORNL), which operates under the US Department of Energy. The Office of Transportation Technologies funded the project and carried it out in collaboration with General Motors.

The research focused on a Low Mass High Efficiency (LMHE) engine. The prototype was designed to meet requirements for strength, durability, performance and long-term operation while reducing overall engine weight.

During the project, ORNL tested two aluminium alloys. The first was ACMZ, also known as AlCuMnZr, a cast aluminium alloy. The other was DuAlumin3D, an aluminium alloy developed for 3D printing. Together, the materials helped lower engine weight without limiting strength or durability.