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 Aluminium 2010 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: Aluminium 2010 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% Aluminium 2010 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 Aluminium 2010 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. Aluminium 2010 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 Aluminium 2010 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. Aluminium 2010 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 Aluminium 2010 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: Aluminium 2010 Casting Sheet Global Aluminium Applications In Electric Vehicles And Charging Infrastructure Who Buys A Car With No Range And Not Always Ready For Use? Aluminium 2010 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 Aluminium 2010 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 Aluminium 2010 Global Aluminium Applications In Electric Vehicles And Charging Infrastructure Comparison Of Incentive Programs Aluminium 2010 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.) Aluminium 2010 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 Aluminium 2010 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 THE MARKET DEVELOPER AluMag is a global market developing company that will help you penetrate new markets and find new business. We access new markets and open doors for your business – regardless of Aluminium 2010 application, material, process or product. AluMag makes you successful worldwide!