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Aluminum in Passenger Vehicles—Trends, Implications, and Opportunities

  • November 2015
  • 68 pages
  • Frost & Sullivan
Report ID: 3435665

Summary

Table of Contents

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.

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