The amount of aluminium in cars produced in Europe is rising. On average, a car will contain almost 180 kg of aluminium in 2019, which is 20% more than in 2016. This trend is expected to continue to almost 200 kg of aluminium in 2025.
This is according to the survey 'Aluminum Content in Cars', conducted by DuckerFrontier on behalf of European aluminium industry trade association European Aluminium. Among other things, the survey shows that significantly more aluminium is used in electric vehicles and plug-in hybrids than in the average vehicle.
Lightweight and strong
Car manufacturers' preference for aluminium is largely due to its light weight, according to the study; reducing the weight of a vehicle makes a vehicle more energy efficient and reduces fuel consumption. Among other things, this helps reduce environmental impact. At the same time, the material is strong and able to absorb energy in an accident to protect occupants. European Aluminium states that this makes aluminium car parts safer than steel variants, while being 50% lighter.
"Aluminium is a real enabler for electromobility. The combination of aluminium sheet material, extrusion and casting provides the perfect solution for electric vehicles. Both for protecting batteries and reducing the weight of vehicles to improve performance or range," explains Dieter Höll, executive chairman of the Automotive & Transport Board of European Aluminium.
Electrification of cars
The electrification of cars is therefore a more important driver behind the growing use of aluminium in cars. The material is used in all kinds of components, ranging from housings for batteries and electric motors to the entire bodywork. The amount of aluminium used in a vehicle varies by segment. By 2025, it will be at least 2.9 kg for vehicles in the A-segment and up to 38 kg in the D-segment.
European Aluminium also highlights the close cooperation between aluminium industry companies and car manufacturers to develop new materials. Over the past two decades, for instance, hundreds of new alloys have been developed to meet the needs of car manufacturers. These needs range from greater strength and better formability to greater ability to absorb energy. At the same time, aluminium is also used in innovations that help make the transition to electric driving, such as charging stations, power cables and wind farms.
Car production rises
The report also reveals that car production in Europe is set to rise in the coming years. While the number of vehicles produced this year is still expected to decline from 16.8 million units in 2018 to 16.7 million units this year, it will rise from 2020 at a compound annual growth rate of 1.54% to 18.3 million units in 2025. Volkswagen is by far the largest manufacturer with more than two million vehicles produced. Mercedes-Benz, Audi, BMW and Ford follow.
In addition, the industry association predicts that the production of electric vehicles - including plug-in hybrids - will grow rapidly in the coming years. Until 2025, production is expected to grow at a compound annual growth rate of 33.1%. Whereas 597,420 electric vehicles are rolling off the assembly line this year, it will be 3,324,607 units by 2025, according to the study.
A summary of the research report is available here.
