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
Kilograms per Sample Vehicle 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 kg has not been validated by each OEM 100 200 300 400 500 600 0 Aluminium content in specific models* Fiat 500(312) Fiat Panda(139) Below average aluminum content 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) and suspensions Aluminum hoods 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) (Doors and/or partial body Aluminum Intense Audi Q5(AU416) Volkswagen Touareg(VW526) Jaguar XF(X250) Mercedes-Benz E-Class(W212) Audi Q7(AU716) Porsche Cayenne(E2) Audi A6(AU571) Suspensions Bodies and BMW 5 (F10) Complete 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)
Total aluminium use for specific models* BMW 3 (F30) Mercedes-Benz E-Class(W212) Top 15 vehicles compared with BMW 5 (F10) total automotive aluminium use Ford Focus(C346) Audi A6(AU571) per year in EU 27: Opel Astra(GM P3400) • BMW 3-series, Mercedes E-class Volkswagen Polo(VW250) and BMW 5 series represent ~9 % Mercedes-Benz C-Class(W204) of the total Volkswagen Passat(VW471) Peugeot 208(A9) • The 15 top vehicles represent ~25% Audi A4(AU481) of the total BMW 1 (F20) 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 Weighted Average 2012 Aluminum Content by OEM 342.7 350 for the Sample Vehicles 292.1 300 275.9 Kilograms per Vehicle 250 226.3 218.4 218.2 200 181.6 140.1 130.3 126.8 125.5 119.6 150 96 91.1 100 82.6 50 0 *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 2012 EU Total 290 300 E 16% Average of 140 kg 250 D 11% 200 175 C 10% 130 128 150 105 96 100 70 B 9% 50 A 8% 0 A A/B B C D E Full 0% 5% 10% 15% 20% Frame 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 5.6 Chassis & Suspension 19.2 kg or 16% 2.2 Engines with Mounts • The increase in aluminium content 0.9 Transmission & Driveline in North American cars for the Plus Wheels with Spares 32% 0.7 Bumper Beams & Crash Boxes same period is estimated at 13 kg Chassis & Suspension 54% or 9% Transmission & 0.3 Heat Shields Driveline 5% Engines with Mounts 5% 0.7 Body & IP Beams • 40% of the aluminium growth in Bumper Beams & CB 25% Heat Shields 21% the sample results from structural 1 Closures Body & IP Beams 25% components in car body and Closures 29% 0.2 Brakes suspension. Currently, the EU Brakes 4% Heat Exchangers 6% leads the world in the use of high- 0.7 Heat Exchangers All other Components tech aluminum automotive including Trim & Sun All other Components including 0.2 Roofs 5% components Trim & Sun Roofs 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 • Aluminium extruded and rolled products Total EU 2012 140 kg/vehicle are expected to represent 40-45% of the mix in the longer term Forged Extruded 4% • Rolled aluminium products are mainly used 10% for heat exchangers and closures. Rolled • Aluminium bonnets and fenders are now 13% “state of the art”. 21% of the cars produced today in Europe have an aluminium bonnet • Aluminium extrusions are particularly used Cast in crash management systems (CMS). 73% 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 CO 2 per kilometer, normalized to NEDC Solid dots and dotted lines: proposed targets LDV 250 Canada- Hollow dots and dotted lines: unannounced proposal LDV EU 230 Japan 210 China S. Korea 190 Australia 170 150 130 US 2025:107 China 2020: 117 110 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 • Ducker forecasts that the 180 180 average aluminium content could 150 160 rise to 180 kg/car in 2020 if 140 134 lightweighting was encouraged 140 121 120 100 • This assumes that the aluminium 80 penetration into small and medium cars follows the 60 evolution recorded in the upper 40 segments 20 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 Added by 2020 250 2012 200 35 40 55 150 290 15 34 100 175 140 130 128 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
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