Global light vehicle materials market- forecasts to April 2015 SAMPLE

Transcription

1 Global light vehicle materials market- forecasts to 2029

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4 Table of contents 1: Introduction About this service Definitions : PESTER analysis Political Economic Social... 0 Technological... 0 Environmental... 0 Regulatory : Companies M Accuride Corporation Aichi Steel... 0 Alcoa, Inc... 0 Aleris... 0 Asahi Kasei Plastics... 0 Autoneum... 0 BASF SE... 0 Overview... 0 Investments in facilities... 0 Acquisitions and divestments... 0 Joint ventures and technology partnerships... 0 Customers... 0 R&D... 0 Bayer MaterialScience... 0 Benteler... 0 Biomer... 0 Bodine Aluminum... 0 CIE Automotive SA... 0 Cooper-Standard Automotive Inc... 0 Dow Automotive Systems... 0 Dräxlmaier Group... 0 DuPont (E. I. du Pont de Nemours and Company)... 0 Evonik... 0 Faurecia... 0 Freudenberg & Co. KG... 0 Gestamp Automocion... 0 Page 4

5 Henkel... 0 Key Plastics... 0 Kobe Steel... 0 JFE Steel Corporation... 0 LG Chem... 0 ContiTech... 0 Honeywell... 0 Lanxess... 0 Overview... 0 Investments... 0 Acquisitions... 0 R&D... 0 Magna International Inc... 0 Merger and acquisition activity... 0 Infrastructure... 0 Martinrea International Inc Minda Corporation... 0 NanoSteel Company... 0 Novelis... 0 Oerlikon Balzers... 0 Posco... 0 PPG Industries... 0 Products... 0 Merger and acquisition activity... 0 Infrastructure... 0 PT Astra Otoparts... 0 Saint-Gobain... 0 Samvardhana Motherson Group... 0 Shiloh Industries... 0 Showa Denko... 0 Solvay... 0 Stadco... 0 Sumitomo Corporation... 0 Tata Steel... 0 Teijin... 0 Tenedora Nemak... 0 ThyssenKrupp AG... 0 Toray Industries... 0 Toyo Tire & Rubber... 0 Toyoda Gosei... 0 Page 5

6 Trelleborg AB... 0 Victrex... 0 Woodbridge Group... 0 ZF : Materials Alternative materials: potential weight saving versus cost Aluminium... 0 Applications... 0 Constellium s aluminium crash management system... 0 Audi Space Frame... 0 Novelis supplying aluminium sheet to General Motors... 0 Heat shield from Federal-Mogul... 0 JLR's increasing use of aluminium... 0 Alcoa's MagnaForce... 0 Aluminium sheet from Kobe Steel... 0 Cadillac ATS... 0 Engine cooling... 0 Ford F-150 pickup... 0 GM's aluminium welding technology... 0 Honda's steel-aluminium jointing solution... 0 Tesla Model S... 0 Turbocharger... 0 Carbon fibre... 0 Armoured vehicles... 0 BMW using carbon fibre in its i3 electric vehicle... 0 Bentley's Continental Supersports model... 0 Carbon ceramic disc brakes... 0 Body panels... 0 Carbon fibre reinforced plastics... 0 Seating... 0 Carbon fibre roof for Ferrari Superamerica Daimler invests in carbon fibre... 0 Ford invests in carbon fibre... 0 GM invests in carbon fibre... 0 JCI's solution... 0 Coatings... 0 Colour trends... 0 BASF's research... 0 DuPont's research... 0 PPG's research... 0 Other... 0 Magnesium... 0 Roofs... 0 Page 6

7 Seating... 0 Organic materials... 0 Acoustical foam... 0 Doors... 0 Engine parts... 0 Floor mats... 0 Instrument panels... 0 Interiors... 0 Seating... 0 Tyres... 0 BMW's photovoltaic (PV) solar cells... 0 Ecological plastic in the Prius... 0 Mercedes-Benz uses coconut matting, crushed olive stones and even sawdust... 0 Ford's approach to using alternative materials... 0 Plastics and composites... 0 Examples of alternative materials to steel... 0 Technology developments... 0 Airbags... 0 Bioplastic for vehicle interior parts... 0 Brake pedal... 0 Bumper market... 0 Charge air ducts... 0 Composite material door panels... 0 Composite plastic tailgate... 0 Door panels... 0 Engine cooling... 0 Environmentally friendly ( green ) products... 0 ESP applications... 0 Fuel system applications... 0 General Motors' 'smart materials' developments... 0 Glass fibre compounds... 0 Glazing... 0 Tailgate... 0 Spoiler... 0 Wheels... 0 Interior applications... 0 Ford and Coca-Cola develop vehicle interior fabric... 0 Resins... 0 Roof systems... 0 Sealing applications... 0 Material from Trelleborg... 0 Windshield sealing system for the Opel Astra GTC... 0 Seat belts... 0 Page 7

8 Seats... 0 Suspension system... 0 Transmission crossbeam... 0 Steel... 0 Bumpers... 0 Fuel tanks... 0 Seats... 0 Wheels... 0 Other materials... 0 Alternative material to nylon 12 resin... 0 BASF's car seat cover... 0 BASF's sound absorbent resin... 0 Recycling... 0 Batteries... 0 Bumpers... 0 Glazing... 0 Interiors... 0 Tyres... 0 Continental's tyre recycling process... 0 Ford makes gaskets and seals from recycled tyres... 0 Michelin's TREC project... 0 Motor oil... 0 Plastics... 0 Steel... 0 Evaluation of a clutch pedal... 0 Cost of CO2 saving... 0 Waste packaging : Forecasts Steel Steel as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Iron... 0 Iron as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Aluminium... 0 Aluminium as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Plastics... 0 Plastics as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Glass... 0 Glass as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Other materials... 0 Other materials as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Page 8

9 6: Archive Front-end modules IAC develops blow foaming process for air ducts Interior films from 3M... 0 Nissan s SpecV version of its GT-R halo car... 0 PSA Peugeot Citroen looks for aluminium partners... 0 Emerging markets... 0 India... 0 Page 9

10 Tables Alternative materials: potential weight saving versus cost Examples of alternative materials to steel... 0 Evaluation of a clutch pedal... 0 Cost of CO2 saving... 0 Steel as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Iron as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Aluminium as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Plastics as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Glass as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Other materials as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, Page 10

11 Introduction For some time, the automotive industry has been under pressure to change the way it designs and builds vehicles, due to factors such as the increasing impact of passenger and pedestrian safety requirements and the competitive intensity caused by globalisation and manufacturing in low cost economies. Furthermore, governmental pressure in Europe and North America to reduce CO2 emissions has prompted vehiclemakers and their supply base to develop automotive technology to meet those strict emission limits. Consequently, more vehicles are incorporating components aimed at mass reduction, parts consolidation to reduce assembly costs and more efficient recycling. The vehiclemakers need to improve overall fuel economy in vehicles has led to the trend toward minimising vehicle weight. The use of performance materials such as high-strength steel and aluminium is on the rise and heavier traditional materials, such as steel and iron, are being replaced whenever possible. About this service This sector service reviews and forecasts the main materials used in vehicle manufacture, namely: In addition, it reviews the use of other materials such as organic, carbon fibre and magnesium. Our forecasts cover each of the above materials as a percentage of total kerb weight of a medium-sized passenger car. Steel Aluminium Plastics Iron Glass Page 11

12 Definitions For the purpose of this intelligence, we have concentrated our forecasts on the five main materials used in vehicle manufacture, namely steel, aluminium, plastics, iron and glass. For each material, our forecasts set out the percentage of total kerb weight of a medium-sized passenger car, e.g. VW Golf, Ford Focus. Page 12

13 PESTER analysis Political For some time, the automotive industry has been under pressure to change the way it designs and builds vehicles, due to the increasing impact of passenger and pedestrian safety requirements and the competitive intensity caused by globalisation. Furthermore, governmental pressure in Europe and North America to reduce CO2 emissions has prompted automakers and their supply base to develop automotive technology to meet those strict emission limits. Consequently, more vehicles are incorporating components aimed at mass reduction, parts consolidation to reduce assembly costs and more efficient recycling. Economic Automakers are driven to design lightweight cars that will meet increasing fuel efficiency requirements - XX.X miles per gallon by and satisfy consumer appetite for high-quality vehicles. They are finding that they can lose vehicle weight and gain styling with engineering thermoplastics and composite materials. Adopting lightweight polymers and polyurethane composites to replace traditional materials such as glass and metal in exterior applications, including window glazing and body panel components, can help reduce vehicle mass while retaining strength. The use of plastics, aluminium, magnesium and different grades of steel are all under scrutiny by the vehicle makers in a bid to optimise factors. While the use of plastics in vehicles has significantly increased over the last five years, the steel industry has also proved flexible by reducing the weight of components without sacrificing strength. The automaker's need to improve overall fuel economy in vehicles has led to the trend toward minimising vehicle weight. Page 13

14 Companies This section is not intended to include all material manufacturers. Instead, it draws attention to a growing list of companies which have developed or advanced the use of materials used in vehicle manufacture. XM In the automotive OEM segment, 3M s product family encompasses: acoustics (NVH); adhesives; attachment tapes and fasteners; emission control materials, films; flouropolymers; glass bubbles; light management, tape-attached components; and wheel weights. Applications of these products can be found in a number of manufacturing segments, including: Body-In-White (BIW); Chassis and Wheels; Powertrain; Exterior and Glass; and Interior. In October 2012, 3M and Ceradyne entered into a definitive agreement for XM's acquisition of Ceradyne for US$XX.XX per share. The proposed transaction has an aggregate value of approximately US$XXXm. Ceradyne develops and manufactures technical ceramics for applications in the automotive, oil and gas, solar, industrial, electronics and defence industries. In November 2012, 3M received clearance from the Austrian Federal Competition Authority with respect to its previously announced tender offer for all issued and outstanding shares of common stock of Ceradyne at a price of US$XX per share. In August 2014, 3M completed its acquisition, through Sumitomo XM, of Sumitomo Electric Industries' XX percent interest in Sumitomo XM for JPYXXbn (US$XXXm). 3M is now the sole owner and the business will be known as XM Japan. Sumitomo XM was established in 1961 as a joint venture between XM, Sumitomo Electric Industries and NEC. In 2003, 3M acquired NEC's XX percent stake, which increased XM's interest to XX percent. Accuride Corporation Accuride Corporation is one of the largest and most diversified manufacturers of commercial vehicle components in North America. Page 14

15 Materials According to VCD Verkehrsclub Deutschland, reducing the weight of a vehicle by XXX kilograms lowers fuel consumption by X.X litres over a distance of XXX kilometres and cuts carbon dioxide emissions by X.X kilograms over the same distance. Lightweight structures are now more important than ever given the trend toward future-oriented drive technologies such as electric mobility. Although the car is built from many different materials, its main structure known as the body in white (BIW) is usually made of steel pressings welded together to form a strong and stiff frame. According to Tata Steel, this method of construction accounts for XX.X percent of all cars produced in the world. The remaining X.X percent is mostly constructed with aluminium BIW, while a very small number (less than X.XX percent) are constructed from carbon fibre composite. The BIW of a vehicle accounts for XX percent of the vehicle mass, says Tata Steel. The weight of the closures (doors, bonnet and boot/rear hatch), chassis (suspension parts) and driveline bring the total amount of steel and other ferrous metals to more than XX percent. Tata Steel reports that, in recent years, the amount of ferrous metal has declined, mostly driven by manufacturers replacing iron with aluminium for engine castings. The percentage of sheet steel per car has also dropped, mainly due to: higher levels of equipment, trim and sound-proofing; more aluminium used in wheels and suspension parts; more moulded plastics, especially under the bonnet. The environmental and economic requirements for reduced fuel consumption have also led to an increase in the use of lightweight materials for components that bolt on to a conventional steel vehicle, but at a cost. The following table indicates the potential weight savings of using alternative materials to steel and the additional cost involved. Alternative materials: potential weight saving versus cost Source: VAG, IEA 2005, TNO/Ricardo, PSA, Ford, Corus Research Waste packaging Federal Mogul has developed a novel product that helps General Motors eliminate noise in a vehicle s cabin using recycled waste packaging and other by-products normally discarded at a vehicle manufacturing plant. Page 15

16 Forecasts This section sets out our estimates and forecasts of the use of the main materials used in vehicle manufacture, namely steel, iron, aluminium, plastics and glass across XX of the world s largest light vehicle markets - which collectively account for more than XX percent of world light vehicle production. Our forecasts range is from 2009 through to 2019 with spot forecasts for 2024 and For each material, our forecasts set out the percentage of total kerb weight of a medium-sized passenger car, e.g. VW Golf, Ford Focus. Today, such cars in Europe weigh in at around X,XXX kg (or X.X metric tons) compared to about XXX kg in the 1970s. In North America, an average sized passenger cars weighs approximately X,XXX kg. Smaller European cars, such as the Fiat Punto currently weigh about XXXX kg whereas larger cars, such as a Xx4, typically weigh approximately X,XXX kg. Despite its impact on fuel consumption, the average mass of vehicles has increased over the past XX years. For example, a Ford Escort weighed in at around XXX pounds in By 1998, a Ford Focus weighed approximately X,XXX pounds. As the slide opposite shows, the VW Golf GTI has gained weight too. According to the European Aluminium Association, the weight increase across all vehicle models is due to more stringent legislative requirements and changing customer demands (i.e. growing vehicle size, extra comfort and safety features) and that, in turn has caused an increase in weight of other components, such as brakes, engines and transmissions. Page 16

17 Steel The use of plastics, aluminium, magnesium and different grades of steel are all under scrutiny by the vehicle makers in a bid to optimise factors. Page 17

18 Archive This section of the intelligence service contains archived pages of significant interest, but which no longer require updating. Front-end modules A stripped down version of Chang an Automobile s CXXX model was displayed at the 2011 Shanghai motor show. It featured plastic front-end module using SABIC Innovative Plastics so-called stamax long glass fibre polypropylene resin. The innovation is claimed to have cut part weight by up to XX percent and total vehicle weight by about four kilograms. The FEM integrates the radiator, headlamps, lock bridges and bumper beams. IAC develops blow foaming process for air ducts programme. In addition to air duct applications, other vehicle applications are under consideration says IAC. International Automotive Components (IAC) has developed a blow foaming process for HVAC duct components featured on a model year 2014 North American vehicle. IAC's manufacturing facility in Madisonville, Kentuck provides air ducts for the programme, and annual volumes in the first year are expected to be some XXX,XXX units. Claimed benefits of the new blow foaming process include: eliminates the need for secondary foaming pieces and reduces part count required in typical blow moulding processes, thereby reducing manufacturing costs; and reduces BSR (buzz, squeak and rattle) and provides improved NVH characteristics due to its improved sound absorption properties, reducing airflow noise by an estimated XX percent when travelling through the duct. Blow foaming was introduced in Japan by JSP in 2002 and the arrangement for distribution and licensing in North America is exclusive to IAC for this Page 18

19 Other materials as a percentage of total kerb weight of medium-sized passenger cars assembled in all major car producing regions, 2XXX-2XXX Region North America XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX Mercosur XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X Western Europe XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X Central Europe XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X Russia XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X Japan XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X China XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X India XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X Korea XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X Thailand XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X Other Asia XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X Iran XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X South Africa XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.X Australia XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX XX.XX Source: just-auto Page 19

20 2015 All content copyright Aroq Limited. All rights reserved. If you would like to find out about our online multi-user services for your team or organisation, please contact: Mike Chiswell Senior QUBE Business Manager Tel: +44 (0) Toll free from US: Page 20