Aluminium penetration in cars B.Gilmont, P.Ragnarsson & C.Leroy European Aluminium Association Richard Schultz & Nicole Kallwies-Meuser Ducker Worldwide
Introduction The EAA has commissioned Ducker Worldwide to assess the aluminium content in cars produced in Europe Data is collected on a bottom-up basis, meaning the market has been analyzed on an OEM, platform-by-platform and product-by-product basis Primary research with OEMs, automotive suppliers, aluminium producers and other expert sources A sample of 57 vehicle models representing 44 % of the 2012 EU forecast production were chosen for the detailed analysis The sample result was then extrapolated to EU27 average content In 2012 the average car produced in EU 27 contains 140 kg Aluminium
Fiat 500(312) Fiat Panda(139) Volkswagen Up Renault Clio(X98) Renault Megane(X95) Lancia Ypsilon(846) Toyota Yaris(850L) Opel Meriva(GM S4470) Citroen C3(A51) Citroen C3 Picasso(A58) Volkswagen Polo(VW250) Opel Zafira(GM A3370) Volkswagen Golf(VW370) Peugeot 208(A9) Opel Astra(GM P3400) Peugeot 5008(T87) Audi A1(AU210) Alfa Romeo Gulietta Ford C-Max(C344) Citroen C4(B7) BMW 1 (F20) Ford Focus(C346) Volkswagen Touran(VW368) Ford Kuga(C394) Volkswagen Passat(VW471) Mini Countryman(R60) Peugeot 508(W2) Honda Civic(2HC) Volvo C30(Y279) Audi A4(AU481) Opel Insignia(GM G3700) Mercedes-Benz B-Class(W246) Audi A3(AU370) Volvo XC60(Y413) Audi Q3(AU316) Volvo S60(Y283) Mercedes-Benz C-Class(W204) BMW 3 (F30) Land Rover Range Rover Evoque(L538) Audi Q5(AU416) Volkswagen Touareg(VW526) Jaguar XF(X250) Mercedes-Benz E-Class(W212) Audi Q7(AU716) Porsche Cayenne(E2) Audi A6(AU571) BMW 5 (F10) Audi TT(AU324) Porsche Panamera(970) Audi A7(AU573) Mercedes-Benz S-Class(W221) BMW 7 (F01/F02) Mercedes-Benz S-Class(W222) Jaguar XK(X150) Jaguar XJ(X351) Audi A8(AU641) Land Rover Range Rover(L405) Kilograms per Sample Vehicle 600 500 Aluminium content in specific models* Complete Bodies and Suspensions 400 300 200 100 Below average aluminum content Aluminum hoods and suspensions Aluminum Intense (Doors and/or partial body and suspensions) 0 *Aluminium content in kg has not been validated by each OEM
Total aluminium use for specific models* BMW 3 (F30) Mercedes-Benz E-Class(W212) BMW 5 (F10) Ford Focus(C346) Audi A6(AU571) Opel Astra(GM P3400) Volkswagen Polo(VW250) Mercedes-Benz C-Class(W204) Volkswagen Passat(VW471) Peugeot 208(A9) Audi A4(AU481) BMW 1 (F20) Top 15 vehicles compared with total automotive aluminium use per year in EU 27: BMW 3-series, Mercedes E-class and BMW 5 series represent ~9 % of the total The 15 top vehicles represent ~25% of the total Mercedes-Benz B-Class(W246) Audi Q5(AU416) 0 20000 40000 60000 80000 Yearly tonnage per model *Aluminium content in kg has not been validated by each OEM
Kilograms per Vehicle Average aluminium content per OEM* 400 350 300 342.7 292.1 275.9 Weighted Average 2012 Aluminum Content by OEM for the Sample Vehicles 250 226.3 218.4 218.2 200 181.6 150 140.1 130.3 126.8 125.5 119.6 100 96 91.1 82.6 50 0 *Aluminium content in kg has not been validated by each OEM
Average aluminium content by segment 350 300 250 200 150 100 50 0 2012 EU Total Average of 140 kg 70 96 105 130 175 290 128 A A/B B C D E Full Frame E D C B A 2012 Aluminum Share of Curb Weight per segment 8% 10% 9% 11% 16% 0% 5% 10% 15% 20% Segment Curb Weight kg Aluminum kg Percent A 930 70 8% B 1183 105 9% C 1358 130 10% D 1534 175 11% E 1795 290 16%
Main development 2006-2012 All other Components including Trim & Sun Roofs 2006-2012 EU Aluminum (kg) Content Increase Wheels with Spares Chassis & Suspension Engines with Mounts Transmission & Driveline Bumper Beams & Crash Boxes Heat Shields Body & IP Beams Closures Brakes Heat Exchangers 0.3 0.2 0.2 0.9 0.7 0.7 1 0.7 2.2 5.6 6.7 Plus Wheels with Spares 32% Chassis & Suspension 54% Transmission & Driveline 5% Engines with Mounts 5% Bumper Beams & CB 25% Heat Shields 21% Body & IP Beams 25% Closures 29% Brakes 4% Heat Exchangers 6% All other Components including Trim & Sun Roofs 5% The total increase in EU light vehicle aluminium content from 2006 to 2012 is estimated at 19.2 kg or 16% The increase in aluminium content in North American cars for the same period is estimated at 13 kg or 9% 40% of the aluminium growth in the sample results from structural components in car body and suspension. Currently, the EU leads the world in the use of hightech aluminum automotive components 0 1 2 3 4 5 6 7 8 Increase (kg)
Aluminium product forms Total EU 2012 140 kg/vehicle Rolled 13% Extruded 10% Forged 4% Cast 73% Aluminium extruded and rolled products are expected to represent 40-45% of the mix in the longer term Rolled aluminium products are mainly used for heat exchangers and closures. Aluminium bonnets and fenders are now state of the art. 21% of the cars produced today in Europe have an aluminium bonnet Aluminium extrusions are particularly used in crash management systems (CMS). Nearly 40% of front CMS produced today are made of aluminium.
Grams CO 2 per kilometer, normalized to NEDC What is driving further aluminium penetration Tough CO2 emission standards all across the world Source: www.theicct.org 270 250 230 210 190 170 Solid dots and lines: historical performance Solid dots and dashed lines: enacted targets Solid dots and dotted lines: proposed targets Hollow dots and dotted lines: unannounced proposal US-LDV California- LDV Canada- LDV EU Japan China S. Korea Australia 150 130 110 China 2020: 117 Japan 2020: 105 90 EU 2020: 95 2000 2005 2010 2015 2020 2025 [1] China's target reflects gasoline fleet scenario. If including other fuel types, the target will be lower. [2] US and Canada light-duty vehicles include light-commercial vehicles. US 2025:107
Further aluminium penetration 200 180 160 140 120 100 80 60 40 20 0 121 2012 Forecast 2015-2020 180 Ducker forecasts that the average aluminium content could 150 rise to 180 kg/car in 2020 if 140 134 lightweighting was encouraged This assumes that the aluminium penetration into small and medium cars follows the evolution recorded in the upper segments
Kilograms per Vehicle Further aluminium penetration Required increase of aluminum content to reach an average of 180 kg / car 350 300 15 A, B and C segment are key to continued growth 250 Added by 2020 200 35 2012 150 100 50 34 96 55 130 175 290 15 128 40 140 0 A/B C D E Full Frame Total
Conclusion The amount of aluminium used per car produced in Europe almost tripled between 1990 and 2012, increasing from 50kg to 140 kg This amount is predicted to rise to 160 kg by 2020, and could even reach as much as 180 kg if small and medium cars follow the evolution recorded in the upper segments The weight savings achieved thanks to todays aluminium content leads to an average annual fuel saving of 65 litres per car The EU currently leads the world in the use of high tech aluminium automotive components concludes Richard Schultz, Managing Director of Ducker Worldwide.