Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Global Aluminium Applications In Electric Vehicles And Charging
Infrastructure
Authors: Jost Gärtner, AluMag Automotive Marketing GmbH, Germany
Jesper Larsen, AluMag Scandinavia
Roberto Boeker, AluMag Automotive LLC
Abstract
The following paper is an abstract of an analysis performed by AluMag ® Automotive Marketing
GmbH in 2012 called “Global Aluminium Applications In Electric Vehicles And Charging
Infrastructure”. First step was, to provide producers of light weight materials, system integrators
and OEMs an overview of future material applications needed for electric vehicles and for the
buildup of the electric vehicle infrastructure.
The survey with 640 PPT pages is primarily focused on the three regions NAFTA, EU and East
Asia, but also other foreign market players, solutions and projects have been considered in the
analysis. At this time about 230 companies, all with a confirmed or potential demand for light
weight materials, have been obtained in the study. The study is continuously being updated and
expanded.
Aluminium 2010
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Electric Cars – The Future Has Arrived
Moving green is now a must and not any longer a nice to have or an option. Drivers like China,
Europe and USA have taken a decision for electromobility and flatten the way with R&D state
supported programs as well as for plug-in infrastructur and buyer incentives.
Electric cars have come to stay. Several OEMs have already launched or are planning to launch
electric cars within the next 2-3 years. It is not a matter of if but when electric cars will enter the
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mass market. No OEM can afford to ignore this segment as it represents the future.
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Most Important Proclaimed Plug-Ins Worldwide
North America:
Coda SOP 2012 (EV)
Cadillac ELR SOP 2013 (PHEV)
Chevrolet Spark SOP 2013 (EV)
Chevrolet Volt (PHEV)
Chrysler 500 based EV SOP 2012 (EV)
Fisker Karma (PHEV)
Fisker Atlantic SOP 2012 (PHEV)
Fisker Surf SOP 2012 (PHEV)
Fisker SUV SOP 2013 (PHEV)
Ford C-Max SOP 2012 (PHEV)
Ford F-Series SOP 2013 (PHEV)
Ford Focus (EV)
Ford Fusion Sedan SOP 2012 (PHEV)
Ford Transit Connect (EV)
Ford Fuel Cell SOP 2015 (Fuel Cell)
GM Fuel Cell SOP 2015 (Fuel Cell)
GM Urban Commuter SOP 2015 (EV)
Tesla Roadster (EV)
Tesla Model X SOP 2013 (EV)
T l Model
Tesla
M d l S SOP 2012 (EV)
ASIA:
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BAIC C30DB (EV)
BAIC M30RB (EV)
BAICC50 SOP 2013 (EV)
BAIC C70 SOP 2012 or later (EV)
BAIC C80 SOP 2013 (EV)
BAIC C60FB /Q60FB SOP 2013 (EV)
BAIC C60FS /Q60FS SOP 2013 (PHEV)
Brilliance / BMW SOP 2013 (EV)
BYD F3DM (PHEV)
BYD E6 SOP 2012 (EV)
BYD/ Mercedes Denza SOP 2013 (EV)
Chery S18 (EV)
Honda Accord SOP 2013 (PHEV)
Honda FIT / Jazz SOP 2012 (PHEV)
Honda Fuel Cell SOP 2018 (Fuel Cell)
Hyundai I30 SOP 2013 (PHEV)
Hyundai Sonata SOP 2013 (PHEV)
Infiniti Luxury Electric Car SOP 2014 (EV)
KIA Fuel Cell SOP 2014 (Fuel Cell)
KIA TAM (Picanto) SOP 2013 (EV)
Lexus CT 200h SOP 2012 (PHEV)
Mahindra Reva (EV)
M d 2 SOP 2012 (EV)
Mazda2
Mazda First PHEV SOP 2013 (PHEV)
Mitsubishi Mirage SOP 2012 (EV)
Mitsubishi iMiEV (EV)
Mitsubishi SUV SOP 2013 (PHEV)
Nissan Leaf (EV)
Proton EMAS SOP 2012 (PHEV)
Samsung SM3 SOP 2013 (EV)
SAIC Roewe E50 (EV)
SAIC Roewe 550 (PHEV)
Scion SOP 2012 (EV)
Suzuki Swift SOP 2013 (PHEV)
Tata Indica Vista (EV)
Tata Nano SOP 2013 (EV)
Toyota Fuel Cell Car SOP 2015 (FC)
Toyota IQ SOP 2012 (EV)
Toyota Prius (PHEV)
Toyota RAV4 SOP 2012 (EV)
Toyota Vios SOP 2012 (PHEV)
Europe:
Aston Martin Cygnet SOP 2013 (EV)
Audi A1 E-Tron SOP 2013 (EV)
Audi A2 E-Tron SOP 2015 (EV)
Audi A3 E-Tron
E Tron SOP 2014 (PHEV)
Audi A4 E-Tron SOP 2014 (PHEV)
Audi Q7 E-Tron SOP 2014 (PHEV)
BMW I3 SOP 2013 (EV)
BMW I3 SOP 2014 (PHEV)
BMW I8 SOP 2014 (PHEV)
BMW 5-Series SOP 2012 China (PHEV)
BMW X5 SOP 2014 (PHEV)
BMW X6 SOP 2014 (PHEV)
MIA Electric (EV)
Citroen Berlingo (EV)
Citroen C-Zero (iMiev) (EV)
Fiat 500 SOP 2012 (EV)
Jaguar C-X75 SOP 2013 (PHEV)
R
Range
R
Rover SOP 2014 (PHEV)
Mercedes A-Class SOP 2014 (PHEV)
Mercedes B-Class SOP 2014 (PHEV)
Mercedes A-Class SOP 2014 (Fuel Cell)
Mercedes B-Class SOP 2014 (Fuel Cell)
Mercedes S-Class SOP 2013 (PHEV)
Mercedes SLS SOP 2013 (EV)
Smart (EV)
Opel Ampera (PHEV)
Peugeot Ion (iMiev) (EV)
Peugeot BB1 SOP 2013 (EV)
Peugeot Partner (EV)
Pininfarina Bluecar (EV)
Porsche 918 Spyder SOP 2013 (PHEV)
Renault Fluence (EV)
Renault Kangoo Rapide (EV)
Renault Twingo SOP 2014 (EV)
Renault Twizy Z.E (EV)
Renault Zoe Z.E SOP 2012 (EV)
Seat first plug-in vehicle SOP 2015 (PHEV)
Seat first EV vehicle SOP 2016 (EV)
Skoda UP SOP 2013 (EV)
Volvo V40 SOP 2012 (PHEV)
Volvo V60 SOP 2012 (PHEV)
Volvo XC60 SOP 2012 (PHEV)
VW Golf
G lf VII SOP 2015 (PHEV)
VW Passat SOP 2015 (PHEV)
VW UP SOP 2013 (EV)
VW XL1 SOP 2013 (EV)
Yo Auto City Car SOP 2013 (PHEV)
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Plug-In Share Of Worldwide Light Weight Vehicle Market By 2020
12 00%
12,00%
10,00%
8,00%
6,00%
4,00%
2,00%
0,00%
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Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Millions
s of units
Global Electric Vehicle Forecast By Region In 2020
Source: Ford Motor Company, 03.2010
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BEV =
PHEV =
HEV =
Battery Electric Vehicle
Plug-In Hybrid (with Range Extender)
Hybrid EV (without Plug-In)
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Use Of Aluminium In Spaceframes & Structures In Plug-In Vehicles
BMW I3
Fisker Karma
Think City
Electric and Hybrid vehicle structures will without doubt be a major area of use for aluminium
i the
in
h ffuture. Th
The fifirst market-ready
k
d electric
l
i vehicles
hi l h
have shown
h
that
h aluminium
l i i
h
has very hi
high
h
growth possibilities within this segment.
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Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
EVs With An
E
n Aluminium BIW
Use Of Aluminium In Spaceframes & Structures In Plug-In Vehicles
Audi A8
Audi
A
di R8
BMW I3
BMW I8
E-Mobile Motors TW4XP
EcoCraft EcoCarrier
QBEAK
Ecomove Q
E-Wolf Alfa II
Giugiaro Namir
Jaguar C-X75
Jaguar XJ
Koenigsegg Quant
Lightning Car Company GT
Pininfarina Bluecar & Nido
Tazzari Zero
Think City (Upper frame)
Valmet Eva
Venturi Fetish
Yarovit-Motors Citycar
Production Vehicle With Alu-Frame
Production Vehicle With Hybrid-Frame
Concept Vehicle With Alu-Frame
ATT R&D Parade
CT&T E
E-Zone
Zone
Kia Borrego (FC)
Leo Motors LZ-1
Mitsubishi Imiev Sport
Mitsubishi MEEV-II
y
Proton Citycar
Sim-Drive Eliica
E
Europe
A i
Asia
Bright Automotive Idea
Dodge
g ZEO
Chrysler ecoVoyager
Jeep Renegade
Fisker karma, Sunset, Surf &
Nina
Saba Motors Zero Roadster
Tesla Roadster & Model S & R
A
America
i
European OEMs have taken a leading position when it comes to the use of aluminium within BIW,
followed by the Americans. Asian OEM Proton has recently announced plans for Asia’s first plug-in
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electric car with an aluminium spaceframe.
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Kg Car Weig
K
ght Per M2
Use Of Aluminium In Spaceframes & Structures In Plug-In Vehicles
Fisker Karma
Kg weight per m2: 209
Chevrolet Volt:
KM range: 80
Mitsubishi I-Miev:
Kg weight per m2: 202
Kg weight per m2: 203
KM range: 64
KM range: 144
Nissan Leaf:
Kg weight per m2: 196
KM range: 160
*** Expected values
BMW Megacity***:
Kg weight per M2: 157
KM range: 185
Kil
Kilometer
t Range
R
By using lightweight materials like aluminium and carbon fibre in the frame of the Megacity vehicle,
BMW has gained an advantage over competing electric vehicles. The BMW Megacity weight per m2
is only about 157 kg and the expected electric range will be somewhere between 160 – 210 km.
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Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Use Of Aluminium Within Electric Vehicle Powertrain Applications
Saving one kg in car body mass
saves between 10 and 20 € on
the cost of the battery pack.
Source: Ricardo
Reduce the mass of the
vehicle 20 percent and go 20
percent farther.
farther
Source: Aluminium Assoziation
The range of electric vehicles is a major hurdle towards becoming a real alternative to combustion
engine vehicles.
vehicles To optimize the battery range of electric vehicles
vehicles, light weight materials like
aluminium plays an important role for the OEMs and system suppliers. Lower weight equals longer
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range and lower weight saves cost of the battery pack.
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Use Of Aluminium Within Electric Vehicle Powertrain Applications
Extrusion
Battery housing:
E-Drive:
Inverter housing:
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Casting
Sheet
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Who Buys A Car With No Range And Not Always Ready For Use?
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Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
The Buildup Of An Electric Vehicle Infrastructure
Charging Stations
Battery Swap
Inductive Charging
In the short to middle run charging of most electric vehicles will take place at home or through
public charging stations. An alternative is battery swap through “Better Place”. This method
though, has not been given many chances by some industry experts. When several million electric
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vehicles hit the roads more simple and inexpensive charging possibilities will be developed.
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Worldwide Sales Of Electric Vehicle Charging Stations
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Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Comparison Of Incentive Programs
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Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Use Of Aluminium For The Buildup Of An Electric Vehicle Infrastructure
Aluminium
55%
Coulomb Technologies, Inc.
Other Materials
45%
Elektromotive Ltd.
Aluminium is often used as housing material for electric charging stations. AluMag roughly estimate
about
b t 45 percentt off allll charging
h i station
t ti producers
d
are using
i aluminium
l i i
ffor th
the h
housing.
i
(M
(Mainly
i l
aluminium extrusions.)
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Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Use Of Aluminium For The Buildup Of An Electric Vehicle Infrastructure
Toyota Industries Corporation
Envision Solar International
Parking lots of the future could be covered by solar panels to charge electric vehicles. Several
companies like Toyota Industries Corporation (Japan) CleanPower GmbH (Germany) and Envision
Solar International (USA) have installed or are planning to install solar powered parking lots. An
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intensive use of aluminium can be expected for the buildup of solar powered charging stations.
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Summary
Car producers and suppliers are reengineering many applications these days to save a few
grams or kilos. A lower car weight will not only increase the battery range but also indirectly
decrease the costs for the expensive battery pack.
Aluminium, with its properties, is bound to play a dominant role in order to bring the weight
of electrical vehicles down.
Regardless of the process aluminium has been detected in various areas of electric vehicles
and for the build up of its infrastructure. Mentionable are applications like battery housings, EE
drives, inverters, BIW, and charging stations.
For more information please contact AluMag Automotive Marketing GmbH
GmbH.
Aluminium 2010
Global Aluminium Applications In Electric Vehicles
And Charging Infrastructure
Authors
AluMag Automotive GmbH
AluMag Automotive Scandinavia
AluMag Automotive LLC
Mr Jost Gaertner
Mr Jesper Ove Larsen
Mr Roberto Boeker
Fon: +49 2373 929492
Email: j.gaertner@alumag.de
g
www.alumag.de
Fon: +45 5810 6454
Email: j.larsen@alumag.de
www.alumag.de
g
Fon: +1 248 9244072
Email: r.boeker@alumag.de
www.alumag.de
g
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