aluminium penetration in cars · aluminium penetration in cars b.gilmont, ... • the eaa has...
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No part of this presentation can be quoted or reproduced without prior written approval from the European Aluminium Association or Ducker Worldwide
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
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
Aluminium content in specific models*
0
100
200
300
400
500
600
Fia
t 5
00
(312
)
Fia
t P
and
a(1
39
)
Vo
lksw
ag
en U
p
Ren
au
lt C
lio(X
98
)
Ren
au
lt M
ega
ne(X
95
)
Lan
cia
Yp
silo
n(8
46
)
To
yo
ta Y
ari
s(8
50
L)
Op
el M
eri
va(G
M S
447
0)
Citro
en
C3(A
51
)
Citro
en
C3 P
icasso
(A5
8)
Vo
lksw
ag
en P
olo
(VW
25
0)
Op
el Z
afira
(GM
A33
70)
Vo
lksw
ag
en G
olf(V
W37
0)
Pe
ug
eo
t 2
08(A
9)
Op
el A
str
a(G
M P
340
0)
Pe
ug
eo
t 5
008
(T8
7)
Au
di A
1(A
U210
)
Alfa R
om
eo
Gulie
tta
Fo
rd C
-Max(C
344
)
Citro
en
C4(B
7)
BM
W 1
(F
20
)
Fo
rd F
ocu
s(C
34
6)
Vo
lksw
ag
en T
ou
ran
(VW
36
8)
Fo
rd K
ug
a(C
39
4)
Vo
lksw
ag
en P
assa
t(V
W4
71)
Min
i C
ou
ntr
ym
an
(R60)
Pe
ug
eo
t 5
08(W
2)
Hon
da
Civ
ic(2
HC
)
Vo
lvo
C30
(Y2
79
)
Au
di A
4(A
U481
)
Op
el In
sig
nia
(GM
G37
00
)
Me
rced
es-B
en
z B
-Cla
ss(W
24
6)
Au
di A
3(A
U370
)
Vo
lvo
XC
60
(Y4
13)
Au
di Q
3(A
U3
16)
Vo
lvo
S60
(Y2
83
)
Me
rced
es-B
en
z C
-Cla
ss(W
20
4)
BM
W 3
(F
30
)
Lan
d R
ove
r R
an
ge
Rover
Evo
qu
e(L
53
8)
Au
di Q
5(A
U4
16)
Vo
lksw
ag
en T
ou
are
g(V
W5
26
)
Jag
uar
XF
(X2
50
)
Me
rced
es-B
en
z E
-Cla
ss(W
21
2)
Au
di Q
7(A
U7
16)
Po
rsche
Ca
ye
nne
(E2
)
Au
di A
6(A
U571
)
BM
W 5
(F
10
)
Au
di T
T(A
U3
24
)
Po
rsche
Pa
na
mera
(970
)
Au
di A
7(A
U573
)
Me
rced
es-B
en
z S
-Cla
ss(W
22
1)
BM
W 7
(F
01
/F02
)
Me
rced
es-B
en
z S
-Cla
ss(W
22
2)
Jag
uar
XK
(X1
50)
Jag
uar
XJ(X
35
1)
Au
di A
8(A
U641
)
Lan
d R
ove
r R
an
ge
Rover(
L4
05)
Kil
og
ram
s p
er
Sam
ple
Veh
icle
Aluminum Intense (Doors and/or partial body
and suspensions)
Complete
Bodies and
Suspensions
Aluminum hoods
and suspensions Below average aluminum content
*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
Total aluminium use for specific models*
0 20000 40000 60000 80000
Audi Q5(AU416)
Mercedes-Benz B-Class(W246)
BMW 1 (F20)
Audi A4(AU481)
Peugeot 208(A9)
Volkswagen Passat(VW471)
Mercedes-Benz C-Class(W204)
Volkswagen Polo(VW250)
Opel Astra(GM P3400)
Audi A6(AU571)
Ford Focus(C346)
BMW 5 (F10)
Mercedes-Benz E-Class(W212)
BMW 3 (F30)
Yearly tonnage per model
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
*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*
342.7
292.1 275.9
226.3 218.4 218.2
181.6
140.1 130.3 126.8 125.5 119.6
96 91.1 82.6
0
50
100
150
200
250
300
350
400
Kilo
gra
ms p
er
Veh
icle
Weighted Average 2012 Aluminum Content by OEM for the Sample Vehicles
*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
8%
9%
10%
11%
16%
0% 5% 10% 15% 20%
A
B
C
D
E
2012 Aluminum Share of Curb Weight per segment
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%
70 96 105
130
175
290
128
0
50
100
150
200
250
300
350
A A/B B C D E FullFrame
2012 EU Total Average of 140 kg
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
• 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 high-
tech aluminum automotive
components
Increase (kg)
0.2
0.7
0.2
1
0.7
0.3
0.7
0.9
2.2
5.6
6.7
0 1 2 3 4 5 6 7 8
All other Components includingTrim & Sun Roofs
Heat Exchangers
Brakes
Closures
Body & IP Beams
Heat Shields
Bumper Beams & Crash Boxes
Transmission & Driveline
Engines with Mounts
Chassis & Suspension
Wheels with Spares
2006 - 2012 EU Aluminum (kg) Content Increase
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%
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
Cast 73%
Rolled 13%
Extruded 10%
Forged 4%
Total EU 2012 140 kg/vehicle • 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.
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
US 2025:107
EU 2020: 95
Japan 2020: 105
China 2020: 117
90
110
130
150
170
190
210
230
250
270
2000 2005 2010 2015 2020 2025
Gra
ms
CO
2 p
er
kil
om
ete
r, n
orm
ali
ze
d t
o N
ED
C
US-LDV
California-LDVCanada-LDVEU
Japan
China
S. Korea
Australia
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
[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.
Tough CO2 emission standards all across the world Source: www.theicct.org
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
121
134 140
150
180
0
20
40
60
80
100
120
140
160
180
200 2012 Forecast 2015 - 2020 • Ducker forecasts that the
average aluminium content could
rise to 180 kg/car in 2020 if
lightweighting was encouraged
• This assumes that the aluminium
penetration into small and
medium cars follows the
evolution recorded in the upper
segments
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
96
130
175
290
128 140
34
55
35
15
15
40
0
50
100
150
200
250
300
350
A/B C D E Full Frame Total
Kilo
gra
ms
per
Ve
hic
le
Added by 2020
2012
Required increase of aluminum content to reach an average of 180 kg / car
A, B and C segment are
key to continued growth
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.