AMU Summit: Automotive aluminum demand shifts across key product groups

Panelists discussed aluminum content by product form and application. The discussion covered castings, extrusions, sheet and forgings, as well as changes in vehicle and powertrain mix.

Ducker Carlisle said aluminum content per vehicle continues to increase even as North American vehicle production remains relatively flat. Speakers then pointed to several product groups and applications that could contribute to further content gains.

Extrusions gain in structural applications

John L’Esperance, engagement manager at Ducker Carlisle, said the firm sees growth across several product forms. He singled out extrusions for the highest growth and pointed to structural applications.

“Extrusions, we’re really seeing the highest growth in that area in pillars, longitudinals, different parts like that,” L’Esperance said.

He also noted extrusion growth extends into commercial vehicles and trailers.

The comments refer to additional extrusion use in vehicle structures. Earlier automotive aluminum use centered heavily on cast components such as wheels and engine blocks.

Sheet moves into more demanding applications

Sheet also featured prominently in the discussion of vehicle aluminum demand. Scott Ulnick, managing principal at Ducker Carlisle, said sheet has made inroads in body-in-white and closures.

Ducker Carlisle tied sheet growth from increased closure demand to vehicle weight targets and a product mix that leans towards larger vehicles.

Arconic Vice President of Commercial Automotive Hervé Gehanno said automakers are also asking suppliers for greater formability.

He tied demand partly to vehicle styling. Automakers want aluminum that can accommodate tighter radii and more demanding shapes, he said.

Higher strength represents another area of customer interest.

“The OEMs also are considering switching some of the steel to high-strength aluminum of the structure of the car,” Gehanno said.

Gehanno also discussed aluminum alloys for hoods designed around pedestrian safety. He said the material can deform and absorb energy during impact.

Castings retain the largest share by weight

Castings remain the largest automotive aluminum product grouping by weight, according to Ducker Carlisle. The firm cited engine blocks, heads and wheels among the established applications.

The firm expects newer EV components and structural body-in-white castings to offset changes in traditional powertrain and transmission applications. Structural castings also ranked among Ducker Carlisle’s highest-growth automotive aluminum applications.

L’Esperance described the casting segment as mature, then turned to large and megacastings as another potential application.

“Castings is, they’re pretty mature right now,” L’Esperance said. “We’ve talked about megacastings in some prior presentations, and large castings as well, to consolidate many parts into one.”

OEMs continue to examine where megacastings can work, he said. As a result, the speakers presented large castings as a developing application rather than an established source of additional aluminum consumption.

The panel also discussed repair considerations. Part consolidation can increase the scope of replacement after relatively minor damage.

“On the consumer side, if you get in a small fender bender, you may have to replace the entire part or scrap the vehicle,” said L’Esperance.