The role of aluminium in the electric vehicle (EV) industry

Aluminium is incredibly important to the development of sustainable and energy-efficient transportation solutions. From EV batteries to body construction, this versatile metal plays a critical role in the development of EVs, thanks to its lightweight, high-strength, and low-cost properties.

Sayan Dey from Bhoruka Fabcons, a downstream aluminium company that manufactures EV battery casings, highlights some of the prominent applications of aluminium in the EV ecosystem.

The Global EV Outlook 2023 by IEA forecasts ~ 14 million electric car sales this year, accounting for 18% of total car sales in CY2023. The demand for EVs is growing worldwide across vehicle segments, and aluminium is becoming increasingly important in the production of these vehicles.

As per CRU, the combined requirement of aluminium extrusion and sheet metal for EVs worldwide will be almost 10M tonnes by 2030 and extrusion demand will be around 2M tonnes.

Aluminium is a cost-effective and environmentally friendly material, making it an ideal choice for EV manufacturers. Unlike traditional internal combustion engine vehicles, which rely on heavy steel frames, EVs require lightweight materials to maximize efficiency and range. Aluminium meets these requirements by providing strength and durability while minimizing weight. One of the most significant advantages of using aluminium in EVs is that it is a highly recyclable material. In fact, up to 90% of aluminium can be recycled, making it one of the most sustainable materials in the automotive industry. This recyclability feature allows automakers to reduce their carbon footprint and help to conserve natural resources.

Some prominent applications of aluminium in the EV ecosystem are as below:

Battery pack enclosures

One of the most significant ways aluminium is used in EVs is in battery pack enclosures. Aluminium is lightweight, durable, and has excellent thermal conductivity, making it an ideal material for battery casings. It is crucial to ensure that the batteries are well-protected at all times. Regulations such as AIS-156 Amendment 3 demand the utmost safety of these battery packs. According to BNEF, aluminium demand for batteries (including battery enclosures) will reach about 1.9 million tonnes/ year by 2030. For the 4W segment, the battery assembly makes up 25% of the vehicle weight. For instance, a 60kWh to 100kWh battery unit can weigh from 350kg to 600kg. Therefore, lightweighting becomes a major driver for choosing Aluminium.

Most swappable batteries use aluminium extrusion technique to manufacture the battery casings. Other techniques would be sheet metal processing, pressure die casting and gravity die casting. In addition, aluminium is also used in battery conductors, crash structures, housing trays,
cooling systems and terminals. Furthermore, the use of aluminium in battery technology is also essential for reducing the overall weight of the vehicle and making it more range efficient.

Body construction

Another crucial area where aluminium is used in the electric vehicle industry is body construction. EVs need to be lightweight to reduce energy consumption. Aluminium is nearly as strong as steel but significantly lighter, making it an ideal material for constructing EV bodies. In addition to weight reduction, aluminium is also highly durable and resistant to corrosion, making it an ideal material for use in harsh environments.

The use of aluminium in EV body construction is driving innovation in the industry, with manufacturers designing vehicles that are both lightweight and strong. According to BNEF, the average aluminium extrusion content will increase from the current ~65kg/BEV to ~80kg/BEV by 2030. BEV stands for Battery Electric Vehicle.

Charging infrastructure

For the success of EV adoption, having a robust charging structure is critical. BAAS (battery as a service) companies, charge point operators and vehicle manufacturers are investing in building charging and swapping stations. It is reported that around 20 lakh charging stations are required to cater to 5 crore electric vehicles by 2030. According to AluMag, around 45% of charging station producers use aluminium for housing. The use of aluminium will further accelerate with changing price sensitivity in the market, especially the Indian market.

Leading aluminium companies around the world, such as Hydro, use aluminium extrusion housing solutions for charging stations. The extrusion-based design is not only strong and durable but also cost-effective as it integrates components such as heat sinks, screw ports and other profiles, thereby eliminating post-process activities such as milling and welding.

Conclusion

India has a net zero target of 2070, while some countries have this target set to as early as 2045. Aluminium application in EVs can be a significant contributor to this journey. Aluminium is a highly recyclable material, with over 75% of all aluminium ever produced still in use today. Furthermore, the lightweight and durable nature of aluminium means that EVs made with this material require fewer resources to manufacture, resulting in a lower carbon footprint. As the demand for sustainable and environmentally friendly EVs continues to grow, the use of aluminium in their production will only become more critical.

In conclusion, aluminium is an essential material in the EV market, playing a vital role in battery technology, body construction, infrastructure and driving sustainability. As the demand for sustainable and efficient EVs continues to increase, the use of aluminium in their production will only become more critical.

We must also note that the opportunities for extrusion in the EV space are immense. But limitations exist within Indian extruders in terms of die development and press sizes. China’s prices are nearly 8% lower than India, with added benefits of export subsidy by China. For these reasons, localization of products becomes a challenge for companies. It is important for Indian extruders to invest in technology, form consortiums, and develop collaborations with research institutes to improve on technology and cater to the burgeoning market.

This article was first published in EVreporter May 2023 magazine, which can be accessed here.