Aluminium penetration in cars

B.Gilmont, P.Ragnarsson & C.Leroy

European Aluminium Association

Richard Schultz & Nicole Kallwies-Meuser

Ducker Worldwide

No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or 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

No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
 Kilograms per Sample Vehicle

0
100
200
300
400
500
600
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)

*Aluminium content in kg has not been validated by each OEM

Citroen C4(B7)
BMW 1 (F20)
Ford Focus(C346)
Volkswagen Touran(VW368)
Ford Kuga(C394)
Volkswagen Passat(VW471)
Below average aluminum content

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)
and suspensions
Aluminum hoods

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)
and suspensions)

Audi TT(AU324)
Porsche Panamera(970)
Audi A7(AU573)
Aluminium content in specific models*

Mercedes-Benz S-Class(W221)
(Doors and/or partial body
Aluminum Intense

BMW 7 (F01/F02)
Mercedes-Benz S-Class(W222)
Complete
Bodies and

Jaguar XK(X150)
Suspensions

Jaguar XJ(X351)
Audi A8(AU641)
No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide

Land Rover Range Rover(L405)

 Total aluminium use for specific models*

BMW 3 (F30)

Mercedes-Benz E-Class(W212)

BMW 5 (F10)
Top 15 vehicles compared with
Ford Focus(C346)
total automotive aluminium use
Audi A6(AU571)
per year in EU 27:
Opel Astra(GM P3400)

Volkswagen Polo(VW250) BMW 3-series, Mercedes E-class

Mercedes-Benz C-Class(W204) and BMW 5 series represent ~9 %
Volkswagen Passat(VW471) of the total
Peugeot 208(A9)

Audi A4(AU481) The 15 top vehicles represent ~25%

BMW 1 (F20)
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

No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
 Average aluminium content per OEM*
400

342.7
Weighted Average 2012 Aluminum Content by OEM
350
for the Sample Vehicles
292.1
300 275.9
Kilograms per Vehicle

250 226.3 218.4 218.2

200 181.6

150 140.1
130.3 126.8 125.5 119.6
96 91.1
100 82.6

50

*Aluminium content in kg has not been validated by each OEM

No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
 Average aluminium content by segment
2012 Aluminum Share
350 of Curb Weight per segment
300
2012 EU Total 290
Average of 140 kg E 16%
250

200 175
D 11%
150
105
130 128 C 10%
96
100 70 B 9%
50

0
A 8%
A A/B B C D E Full
Frame 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%
No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
 Main development 2006-2012
2006 - 2012 EU Aluminum (kg)
Content Increase
The total increase in EU light
Wheels with Spares 6.7 vehicle aluminium content from
2006 to 2012 is estimated at
Chassis & Suspension 5.6
19.2 kg or 16%
Engines with Mounts 2.2

Transmission & Driveline 0.9 The increase in aluminium content

Plus in North American cars for the
Wheels with Spares 32%
Bumper Beams & Crash Boxes 0.7 same period is estimated at 13 kg
Chassis & Suspension 54%
Transmission & or 9%
Heat Shields 0.3 Driveline 5%
Engines with Mounts 5%
0.7
Body & IP Beams
Bumper Beams & CB 25% 40% of the aluminium growth in
Heat Shields 21%
Closures 1 the sample results from structural
Body & IP Beams 25%
Closures 29% components in car body and
Brakes 0.2 Brakes 4% suspension. Currently, the EU
Heat Exchangers 6% leads the world in the use of high-
Heat Exchangers 0.7 All other Components
including Trim & Sun tech aluminum automotive
All other Components including
Trim & Sun Roofs 0.2 Roofs 5% components
0 1 2 3 4 5 6 7 8
Increase (kg)
No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
 Aluminium product forms

Total EU 2012 140 kg/vehicle Aluminium extruded and rolled products

are expected to represent 40-45% of the
mix in the longer term
Forged
Extruded 4%
10% Rolled aluminium products are mainly used
for heat exchangers and closures.
Rolled
13% 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

Cast
73%
in crash management systems (CMS).
Nearly 40% of front CMS produced today
are made of aluminium.

No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
 What is driving further aluminium penetration
Tough CO2 emission standards all across the world
Source: www.theicct.org

US-LDV
270 Solid dots and lines: historical performance
Solid dots and dashed lines: enacted targets California-
Grams CO2 per kilometer, normalized to NEDC

Solid dots and dotted lines: proposed targets LDV

250 Hollow dots and dotted lines: unannounced proposal Canada-
LDV
EU
230
Japan

210 China

S. Korea
190
Australia

170

150

130

China 2020: 117 US 2025:107

110
Japan 2020: 105
EU 2020: 95
90
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.

No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
 Further aluminium penetration

200
2012 Forecast 2015 - 2020 180 Ducker forecasts that the
180
average aluminium content could
160 150 rise to 180 kg/car in 2020 if
140
134
140 lightweighting was encouraged
121
120

100
This assumes that the aluminium
80
penetration into small and
60 medium cars follows the
40 evolution recorded in the upper
20 segments
0

No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
 Further aluminium penetration
Required increase of aluminum content to reach an average of 180 kg / car

350 A, B and C segment are

key to continued growth
300 15
Kilograms per Vehicle

250 Added by 2020

2012
200
35

55 40
150 290
15
34
100
175
130 128 140
50 96

0
A/B C D E Full Frame Total

No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
 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.

No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide