U.S. Department of Energy - Energy Efficiency and Renewable Energy

Vehicle Technologies Program

Fact #310: March 8, 2004
Average Material Consumption for a Domestic Automobile

The amount of high- and medium-strength steel, aluminum, and plastics used in automobiles has been growing, while the amount of regular steel sheet and iron has declined. The change to lighter weight materials has helped the average automobile to be about 250 pounds lighter in 2004 than in 1977. Steel (all kinds combined) makes up more than half of the weight of an automobile.

Graph showing the average material consumption to manufacture a domestic automobile for the years 1977, 1985, 1991, 2000, and 2004.

Supporting Information

Average Material Consumption for a Domestic Automobile
Selected Years 1997–2004 (in pounds)
  2004 2000 1991 1985 1977
Regular steel sheet, tube, and bar 1,361.0 1,373.0 1,341.0 1,481.5 1,995.0
High- and medium-strength steel 395.0 339.0 240.5 217.5 125.0
Stainless steel 75.5 53.0 37.0 29.0 26.0
Other steels 28.0 22.5 41.5 54.5 56.0
Total steel 1,859.5 1,787.5 1,660.0 1,782.5 2,202.0
Iron 308.0 352.5 431.0 468.0 540.0
Aluminum 289.5 245.5 166.0 138.0 97.0
Plastic and plastic composites 257.5 248.5 238.0 211.5 168.0
Fluids, lubricants 198.5 198.0 174.0 184.0 200.0
Rubber 152.0 144.0 135.5 136.0 150.0
Glass 99.5 98.5 86.0 85.0 87.5
Copper and brass 51.5 46.0 46.0 44.0 38.5
Powder metal parts 41.5 36.0 23.5 19.0 15.5
Magnesium parts 10.0 8.0 3.0 2.5 1.0
Zinc die castings 8.5 11.5 17.5 18.0 38.0
Other materials 133.0 110.0 78.5 99.0 128.0
Total 3,409.0 3,286.0 3,059.0 3,187.5 3,665.5

Source: American Metal Market.
Note: 2004 data are projected.

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