Automotive experts agree on coexistence of steel, aluminium and plastic for new age cars

During a panel discussion last week at the 2019 CAR Management Briefing Seminars, representatives from steel, aluminium and plastic industry seem to be agreeing with working together rather than competing with each other in the auto sector.

Most of the automotive experts agreed on a mixed-materials approach for vehicles that allows the use of different materials in strategic areas in order to produce safe, strong, lighter-weight and affordable vehicles.  

"All materials will be significant players," said Mario Greco, chairman of the aluminium transportation group of the Aluminum Association, a trade group.

According to him, the future architectures for electric and autonomous vehicles will require different materials to optimize weight and safety and with smart usage of multiple materials, designers would create interiors with a different user experience.

He cited General Motors that uses a combination of steel, aluminium, magnesium and other lightweight materials on vehicles like 2020 Chevrolet Corvette, Cadillac CT6 and Chevrolet Silverado and GMC Sierra pickups.

He agreed that aluminium industry has humbly accepted the fact that not all cars will convert to full aluminium bodies as predicted after Ford F-150.

According to a survey conducted by the Center for Automotive Research on nine automakers about materials on future vehicles, aluminium is the overwhelming choice for closures, doors, tailgates, trunks and hoods.

"Aluminum has been the fastest growing metal in body structures; it has taken over for steel where it has been right to do so," Greco said.

However, a complete switch to aluminium requires a new manufacturing system. Ford had to redesign its plants for building the F-series pickups.

"It's a decision that goes beyond individual vehicles to strategy," Greco said. "Ford was very strategic and based its decision on volume and regulatory strategy."

The steel industry has also given healthy competition to aluminium by developing ultra-high-strength steel that is cost effective compared with other lighter materials. Hence, a mix material strategy is chosen by most of the automakers for flexibility in design and for fuel economy, safety and performance.