More than 90% of aluminium can be recovered and reused at the end of a vehicle's life cycle, making it one of the most extensively recycled materials.
13 Jul 2024 | 8830 Views | By A. S. Ganesan, Jindal Aluminium
Sustainability is a major focus for the automotive industry today. With growing concerns about climate change, sustainability has become a key priority in the automotive sector. As advancements continue, it’s clear that assessing and reducing carbon emissions to achieve net-zero status is not just an option for automakers—it’s a necessity. ...
This is an Autocar Pro Plus article. Subscribe to continue reading.
Sustainability is a major focus for the automotive industry today. With growing concerns about climate change, sustainability has become a key priority in the automotive sector. As advancements continue, it’s clear that assessing and reducing carbon emissions to achieve net-zero status is not just an option for automakers—it’s a necessity. Consequently, manufacturers are intensifying efforts to shrink their environmental footprint through a comprehensive strategy encompassing electrification, sustainable materials adoption, and greener operational practices.
This integrated approach is critical given vehicles' substantial impact, contributing approximately 290 gigagrams (Gg) of PM2.5 annually and accounting for about eight percent of India's total greenhouse gas (GHG) emissions.
Engineered aluminium shines as a symbol of advancement in the sustainability journey. Renowned for its lightweight and high-strength properties, engineered aluminium is revolutionising vehicle design by enabling significant weight reductions. This advancement not only enhances fuel efficiency and performance but also significantly contributes to environmental sustainability by lowering emissions. Additionally, more than 90% of aluminium can be recovered and reused at the end of a vehicle's life cycle, making it one of the most extensively recycled materials. This recycling process conserves 95% of the energy required to produce new aluminium, underscoring its significant environmental and economic benefits.
The Growing Adoption of Engineered Aluminium in the Automotive Industry
Aluminium has emerged as the 2nd most utilised metal in vehicle manufacturing, experiencing rapid growth in the automotive sector. This trend underscores its increasing importance in the industry, driven by consumer preferences for sustainability and stringent emission regulations affecting vehicles, whether they are battery electric (BEVs), hybrids, or internal combustion engine (ICE) vehicles. Aluminium's distinct properties make it highly suitable for automotive applications:
Extruded aluminium is well-suited for automotive body structures because it offers a compelling blend of lightweight properties and exceptional strength. Compared to steel, aluminium is generally 10% to 40% lighter, depending on the specific application. By integrating extruded aluminium components, vehicle weight is significantly reduced, leading to improved fuel efficiency and reduced emissions. Moreover, in electric vehicles (EVs), the expanded utilization of aluminium plays a crucial role in extending driving range by counterbalancing battery weight. This not only lowers overall ownership expenses but also accommodates the integration of additional safety features, which is particularly critical amid the industry's transition towards electrification.
Beyond body structures, extruded aluminium can be effectively used in suspension parts such as knuckles, control arms, and links. These extruded parts provide enhanced resilience and stiffness, resulting in better handling and stability.
Furthermore, aluminium extrusions play a crucial role in vehicle safety, capable of absorbing twice the crash energy compared to mild steel on a pound-for-pound basis. Its high malleability and ductility provide automakers with extensive design flexibility across various applications—from car frames to engines, battery casings, doors, windows, wheels, and numerous smaller components.
Moreover, aluminium's inherent corrosion resistance and durability significantly enhance vehicle longevity, reducing the need for frequent maintenance and lowering overall ownership costs. This extended lifespan underscores aluminium's role in ensuring long-term product reliability and economic efficiency.
Cutting-Edge Developments in Aluminium Casting Alloys for Automotive Use
Historically, aluminium die-casting alloys have been utilised to create various automotive components, including engine parts, suspension systems, and gears. Recent advancements in die-casting technology, however, have made it possible to manufacture several body parts as a single, unified piece. This technological progress is poised to significantly enhance the adoption of aluminium die casting, particularly with the growing commercialisation of EVs.
Recent findings from the EPSTEM (Eurasia Proceedings of Science, Technology, Engineering & Mathematics) indicate a substantial projected increase in the demand for aluminium die-casting components within the EV industry. The ability to manufacture components as a unified unit not only streamlines production processes but also contributes to overall efficiency improvements and weight reduction in electric vehicles. These elements are crucial for improving the performance of vehicles and realising environmental benefits.
The study forecasts a projected rise in the average aluminium alloy content per vehicle by approximately 20 kilograms by 2025, underscoring the increasing importance of aluminium casting in the automotive sector.
One of the emerging manufacturing techniques highlighted in the research is high-pressure, thin-walled aluminium die casting, expected to lead the way in future applications. This method is anticipated to continue growing in popularity, extending well into the year 2040. High-pressure die casting (HPDC) is particularly suited for achieving high production rates, with approximately half of the world's light metal castings currently produced using this technology.
Final Say
Looking ahead, as automotive technologies advance and regulatory pressures intensify, the adoption of aluminium extrusions is expected to rise. Automakers are increasingly turning to aluminium extrusions not only to meet stringent emissions standards but also to innovate in vehicle design and enhance safety features. This trend underscores aluminium extrusions' pivotal role in driving the future of automotive engineering towards higher performance, improved safety standards, and a more sustainable transportation ecosystem.
A. S. Ganesan is the Associate Vice President for Domestic Sales and Marketing, Jindal Aluminium. Views expressed are his own.