The benefits of lighter auto bodies are discussed, and aluminum is compared to steel as an alternative material for auto body construction. The concept of a structural index, lambda, is developed using the simple example of a hollow beam of wall thickness, t, with a cantilever load case. It is shown that the bending stiffness, K, of the beam can be defined as a function of tlambda , that 1 ≤ lambda ≤ 3, and that lambda can be used to predict the weight savings from material substitution where stiffness is held constant. It is then demonstrated that lambda can be used to predict the weight savings from material substitution in the more complex cases of the joints of a light truck cab.
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