Aluminium penetration in cars B.Gilmont, P.Ragnarsson & C.Leroy - - PowerPoint PPT Presentation

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*

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) 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) 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) 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) 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)

Kilograms per Sample Vehicle

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*

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 %

• f the total
• The 15 top vehicles represent ~25%
• f 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

50 100 150 200 250 300 350 400

Kilograms per Vehicle

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

• f 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 50 100 150 200 250 300 350 A A/B B C D E Full Frame

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

• r 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

1 2 3 4 5 6 7 8

All other Components including Trim & 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

Grams CO2 per kilometer, normalized to NEDC

US-LDV California- LDV Canada- LDV EU 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

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Further aluminium penetration

121 134 140

150 180

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 50 100 150 200 250 300 350 A/B C D E Full Frame Total Kilograms per Vehicle 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.