Use of automotive aluminium sheet to increase significantly

The demand for automotive aluminium sheet will grow at an unprecedented rate, recent studies conducted across major geographies give clear indication of the trend. The years of 2014 and 2015 were recognized as inflection points for the switch from traditional steel to aluminium and other light materials in automobiles, including the replacement of advanced high strength steel (AHSS) with aluminium.

In general, the use of aluminium and other light materials will feature predominantly in heavy vehicles, like pick-ups and SUVs, while AHSS will most likely retain its dominance in light and small vehicles, which should lead to a structural weight reduction of approximately 220 lbs (approximately 100kg).

This comes in the wake of Corporate Average Fuel Economy (CAFE) targets getting doubled from 2012 to 2025. n light of this, vehicle lightweighting is set to play a critical role in meeting these requirements, resulting in a substantial change in engineering methods and use of materials.

A car with aluminium automotive sheet components will generate a higher impact on the environment during its raw material and production phases, but a much lower impact during its product-use phase, and most important of all, a lower impact in its whole LCA (Life Cycle Assessment). On this basis, aluminium should continue to replace steel in the automotive industry. In a comparative analysis of aluminium and steel conducted by Gustavo Zini, of the University of Buenos Aires School of Engineering, showed 8.2 per cent less energy consumption in favour of aluminium during the entire vehicle life cycle, as well as 10.3 per cent lower CO2 emissions.

Forecasts provided by Ducker Worldwide, a global leading provider of information on trends occurring in the automotive industry, says the total aluminium content for the 17.4 million vehicles produced in the US in 2015 is approximately 7 billion pounds, which is an average of about 400 lbs (180 kg) per vehicle. As a result, total North American light vehicle aluminium consumption increased by 28 per cent between 2012 and 2015. The increase stems from an equal combination higher vehicle production and more aluminium content per vehicle. By 2025, aluminium will comprise more than 75 per cent of pickup-truck body parts, 24 per cent of large sedans, 22 per cent of SUVs and 18 per cent of minivan body and closure parts, forecasts Ducker Worldwide.

Globally, light vehicle aluminium content will approach 35 billion pounds by 2025, making light vehicles the most important global market for aluminium. World average aluminium content will rise to 550 lbs (250 kg) per vehicle in 2025. Ducker Worldwide predicts aluminium’s share of the average automotive materials mix in the world is likely to double to 16 per cent in 2025. The average aluminium content in cars in North America alone is set to increase to 19 per cent of a car’s curb weight by then.

The highest content of aluminium in automobiles will occur in North America and Europe, while Asia (and especially China) will remain the largest market for light vehicles.