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  5. > Aluminum in Passenger Vehicles—Trends, Implications, and Opportunities

Most OEMs Expected to Produce a Model with at Least 500 Pounds of Aluminum by 2025

This study presents the current trends in aluminum usage in cars and light trucks. It analyzes automotive manufacturer and supplier strategies and provides an overview of aluminum usage patterns in vehicle systems. It offers insights on aluminum usage by original equipment manufacturer (OEM) brand, vehicle segment, and key vehicle models, and identifies advantages of aluminum compared with other material choices. A comparative analysis of OEM aluminum strategies including manufacturing activities and joining techniques is included. The study concludes with a future outlook, strategic recommendations, and 3 big predictions about what will affect the industry.

Executive Summary—Key Findings
OEMs are investing in alternate materials to lower vehicle weight, increase fuel efficiency, reduce CO2 emission, and improve safety and noise and vibration characteristics.
Aluminum in Passenger Vehicles: Key Findings, Global, 2015–2025

1 Automotive original equipment manufacturers (OEMs) are expected to reduce overall average fleet weight by at least kg per year in an effort to meet stringent fuel efficiency and carbon dioxide (CO2)
emission goals. By 2025, out OEMs are expected to mass produce at least 1 aluminum-intensive vehicle (AIV).

2 Audi and Tesla among luxury OEMs and Ford among mass-market OEMs are expected to have aluminum proliferate in to models across several vehicle segments by 2025. With aluminum content expected to reach at least pounds per vehicle (PPV) by 2025, China is expected to be major supplier.

3 Aluminum is being used more in body in white (BIW) applications, and especially in body structures and closures, where use is expected to increase % by 2025. Resistance spot welding, ultrasonic welding, self-pierce riveting, collar joining, and other joining advancements are expected to increase aluminumto-aluminum and alternate material amalgamation.

4 Aluminum is expected to become the backbone of OEMs’ multimaterial strategy by 2025 alongside Gen3 steel grades and composites, which also continue to grow. Strategic applications are expected across passenger cars, SUVs, and pickups.

5 North America and Europe are early adopters of aluminum as a primary material choice in highermargin vehicles. Advancements in newer grades of aluminum alloys (7xxx and 8xxx series) and their
applications in intricate, thin-walled, leak-proof, and fatigue-resistant profiles are expected to further increase use.

Table Of Contents

Aluminum in Passenger Vehicles—Trends, Implications, and Opportunities
1. EXECUTIVE SUMMARY

Executive Summary
Executive Summary—Key Findings
Executive Summary—Stringent CO2 Emissions Goals, CAFE Targets
Executive Summary—Lightweighting is No Longer a Diet, But a Habit
Executive Summary—Aluminum-intensive Cars, SUVs, and Pickups
Executive Summary—Aluminum in a Multimaterial Strategy
Executive Summary—Key Aluminum Alloys and Target Applications
Executive Summary—Exhibit A: Tesla Model S
Executive Summary—Current and Future Outlook
Executive Summary—Associated Multimedia

2. RESEARCH SCOPE, OBJECTIVES, BACKGROUND, AND METHODOLOGY

Research Scope, Objectives, Background, and Methodology
Research Scope
OEMs Considered in the Scope of this Study
Research Aim and Objectives
Key Questions This Study Will Answer
Research Background
Research Methodology

3. OVERVIEW OF AUTOMOTIVE OEM MATERIAL STRATEGIES

Overview of Automotive OEM Material Strategies
Automotive Material Demand Evolution
Advantages Offered by Alternative Materials
Aluminum Usage in Vehicles

4. KEY DRIVERS AND RESTRAINTS OF ALUMINUM USAGE IN PASSENGER VEHICLES

Key Drivers and Restraints of Aluminum Usage in Passenger Vehicles
Primary Driver—US CAFE Standards
Secondary Driver—CO2/Greenhouse Gas Emission Norms
Tertiary Driver—Crash Impact Regulations
Restraint—Gen 3 Steel Grades
Restraint—Non-metals Including CFRP
Restraint—AIV Repair Costs
Other Restraints

5. ALUMINUM USAGE TRENDS IN PASSENGER VEHICLES

Aluminum Usage Trends in Passenger Vehicles
Material Strategies of Global OEMs
Increasing OEM Focus on Aluminum-to-Aluminum Amalgamation
Aluminum in Multimaterial Joining
Aluminum Usage Trends in Current-generation Vehicles
Aluminum Usage in Vehicles

6. VEHICLE SYSTEM AND COMPONENT-LEVEL ALUMINUM APPLICATIONS

Vehicle System and Component-level Aluminum Applications
Automotive Industry Aluminum Consumption
Aluminum Consumption by Segment
Aluminum Applications in Vehicle Systems
Key Areas of Aluminum Consumption
Body and Closure Aluminum Usage
Global Aluminum Production

7. DEEP-DIVE ANALYSIS OF KEY OEMS' AIVS

Deep-dive Analysis of Key OEMs' AIVs
OEMs' Aluminum Efforts and Focus Areas
Exhibit B—Ford Motor Company F-150
Exhibit C—Toyota Motor Corp.
Exhibit D—Tesla Motors

8. COMPARATIVE ANALYSIS OF OEM ALUMINUM IMPLEMENTATION STRATEGIES

Comparative Analysis of OEM Aluminum Implementation Strategies
OEM Focus on Aluminum and Alternative Materials
Material Intensity Vehicle Matrix
Aluminum Applications

9. IMPORTANT SUPPLIER ACTIVITIES IN THE ALUMINUM SPACE

Important Supplier Activities in the Aluminum Space
Key Aluminum Suppliers and Strategies
Exhibit E—Novelis Aluminum Strategy and Deep-dive Analysis
Exhibit F—Alcoa Aluminum Strategy and Deep-dive Analysis

10. KEY CONCLUSIONS AND RECOMMENDATIONS

Key Conclusions and Recommendations
Key Conclusions
Strategic Recommendations
Current and Future Outlook
The Last Word—3 Big Predictions
Legal Disclaimer

11. APPENDIX

Appendix
Market Engineering Methodology

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