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Aluminium Automobiles

Lightweighting the future: How material innovation is reshaping automotive manufacturing mobility
End User
India’s automotive industry is coming into a phase in which vehicles are expected to provide more while consuming less. Consumers want a better range, greater safety, powerful performance and more features, but they also expect vehicles to remain affordable and reasonable. This creates a difficult engineering challenge. Every additional battery module, sensor, safety element or electronic system adds weight. A heavier vehicle requires more energy to move, reducing efficiency and increasing op ...
Replacing copper in EVs: The aluminium motor transition and the hidden defect trap costing suppliers in millions
End User
EXECUTIVE SUMMARY: The macro mandate: Global automakers are desperate to increase EV range and reduce vehicle weight. The heaviest components are the battery and the traction motor. To slash weight, OEMs are issuing a clear mandate to their Tier 1 suppliers: replace heavy copper motor windings with lightweight aluminium. The cost-cutting trap: Suppliers are rushing to produce "Copper Clad Aluminium" (CCA) windings to win these lucrative OEM contracts. However, attempting to cut corners by ...

Primary AL
The ToZero (Towards Zero Waste in Aluminum BiW Manufacturing) project has demonstrated that recycled automotive aluminium scrap can be transformed into powder suitable for laser powder bed fusion (LPBF), supporting efforts to increase the use of recycled materials in additive manufacturing. Supported under Italy's Accordi per l'Innovazione programme, the project involved Valland, Politecnico di Torino, Politecnico di Bari and the Fontana Group, with Valland leading the additive manufacturing ...
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