📈 The Rise and Fall of U.S. Primary Aluminum Production (1900-2024)

U.S. primary (smelter) aluminum production grew from 2,296 tons in 1900 to 13,000 tons in 1913, maintaining a global market share of approximately 35%. World War I spurred a surge in production, reaching 52,210 tons and capturing 53% of global output. However, the Great Depression led to a sharp decline, reducing U.S. primary aluminum production to one-third of its previous levels between 1930 and 1934.

World War II provided a significant boost to the U.S. aluminum industry, with production skyrocketing from 149,000 tons in 1939 to 835,000 tons in 1943. During this period, the U.S. share of global production increased from 21% to 43%. Post-war growth continued, culminating in a peak production of 4.65 million tons in 1980, accounting for 33% of global output.

However, U.S. primary aluminum production began to decline in the late 20th century, dropping to around 3.7 million tons between 1998 and 2000, with its global share falling to 16%. This downward trend persisted into the 21st century, with production plummeting to just 670,000 tons in 2024, representing a mere 0.9% of global output.

Aluminum production consists of two key processes: primary production (extracting aluminum from natural ore) and secondary production (recycling aluminum scrap). The secondary process, which involves remelting and purifying aluminum from used materials—such as beverage cans, car parts, and building components—is far more energy-efficient, requiring only 5% of the energy needed for primary production. This efficiency significantly reduces greenhouse gas emissions and conserves natural resources. Today, recycled aluminum accounts for about one-third of global aluminum supply. In 2023, total world aluminum production was estimated at approximately 105 million tons (Mt), including 70 Mt of primary aluminum and 35 Mt of secondary aluminum.

The U.S. reached peak total aluminum production in 1999 at 7.48 million tons, comprising 3.78 million tons of primary aluminum and 3.70 million tons of secondary aluminum. That year, the U.S. exported 1.64 million tons and imported 3.39 million tons, resulting in net imports of 1.75 million tons.

By 2024, total U.S. aluminum production had declined to 4.27 million tons, with secondary production accounting for 84% (3.60 million tons) of the total, compared to about 33% globally. The U.S. exported 3.00 million tons and imported 5.46 million tons of aluminum, leading to net imports of 2.46 million tons.