Body covering parts: doors, bonnets, boot lids, etc. are made of 6-series aluminium alloy (Al-Mg-Si), which has a density of only 1/3 of steel, with a weight reduction of 40%-60%, and corrosion resistance is enhanced through anodic oxidation (e.g. aluminium alloy doors of Tesla Model 3).
Chassis and structural components: Suspension systems, subframes, etc. are made of 7-series aluminium alloys (Al-Zn-Mg-Cu), which are close to high-strength steels (with tensile strengths of more than 500MPa), and can be die-cast to achieve one-shot forming of complex structures (e.g., aluminium alloy chassis for the Azera ET5).
Wheels and power components: the wheels are made of A356 cast aluminium alloy, and the elongation is improved by T6 heat treatment (≥8%), which combines lightweight and impact resistance; the battery pack shell is made of 5-series aluminium alloy (Al-Mg), which has excellent corrosion resistance and meets IP67 waterproofing standards.
Material composite trend: Aluminium alloy is composited with carbon fibre and engineering plastics (e.g. aluminium silicon carbide composites), which is used in motor shells and bearing parts, with a 30% increase in heat dissipation efficiency, and is suitable for the needs of high-power electric drive systems.
Recycling of recycled aluminium: about 75% of aluminium alloys used in automobiles come from recycled aluminium, and the energy consumption per tonne of recycled aluminium is only 5% of that of primary aluminium, which is in line with the goal of ‘double carbon’.
Increasing penetration rate:In 2024, the volume of aluminium alloy used in automobiles in China will reach 14 million tons, a year-on-year growth of 12%, of which the volume of aluminium used in new energy vehicles will reach 180kg (about 140kg for traditional fuel vehicles), and it is expected that it will break through 200kg/vehicle in 2025 (Source: China Nonferrous Metals Industry Association).
Cost advantage: the comprehensive cost of aluminium alloy parts is 15%-20% lower than that of steel parts (considering processing energy consumption and recycling value).
Green manufacturing: Promote ‘renewable power + carbon capture’ primary aluminium production process (e.g. Hydro’s zero-carbon aluminium technology), with the goal of achieving a 50% reduction in carbon emissions over the entire life cycle of aluminium used in automobiles by 2030.
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