Global Aluminium Applications In Electric ... · Global Aluminium Applications In Electric...

Global Aluminium Applications In Electric VehiclesGlobal 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

AbstractThe following paper is an abstract of an analysis performed by AluMag ® Automotive MarketingThe 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

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expanded.


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

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electric cars within the next 2-3 years. It is not a matter of if but when electric cars will enter the

mass market. No OEM can afford to ignore this segment as it represents the future.


Most Important Proclaimed Plug-Ins Worldwide

North America:Coda SOP 2012 (EV)

Honda Fuel Cell SOP 2018 (Fuel Cell)Hyundai I30 SOP 2013 (PHEV)

BMW 5-Series SOP 2012 China (PHEV)BMW X5 SOP 2014 (PHEV)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)

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)

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 R SOP 2014 (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)

Mazda2 SOP 2012 (EV)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)

Range 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)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 M d l S SOP 2012 (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)

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)Tesla Model S SOP 2012 (EV)

ASIA: BAIC C30DB (EV)BAIC M30RB (EV)BAICC50 SOP 2013 (EV)

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)

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)

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)

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 SOP 2014 (PHEV)

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 G lf VII SOP 2015 (PHEV)

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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)

Audi A3 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)

VW Golf 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)


Plug-In Share Of Worldwide Light Weight Vehicle Market By 2020

12 00%

10,00%

12,00%

8,00%

4,00%

6,00%

2,00%

0,00%

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Global Electric Vehicle Forecast By Region In 2020

s of

uni

tsM

illio

ns

Source: Ford Motor Company, 03.2010

BEV = Battery Electric Vehicle

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BEV Battery Electric VehiclePHEV = Plug-In Hybrid (with Range Extender)HEV = Hybrid EV (without Plug-In)


Use Of Aluminium In Spaceframes & Structures In Plug-In Vehicles

Fisker KarmaBMW I3 Think City

Electric and Hybrid vehicle structures will without doubt be a major area of use for aluminium

i h f Th fi k d l i hi l h h h l i i h hi h

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in the future. The first market-ready electric vehicles have shown that aluminium has very high

growth possibilities within this segment.



Audi A8A di R8

mB

IW

Production Vehicle With Alu-FrameProduction Vehicle With Hybrid-Frame

Concept Vehicle With Alu-Frame

Audi R8BMW I3BMW I8

E-Mobile Motors TW4XPEcoCraft EcoCarrierEcomove QBEAK

n A

lum

iniu

Bright Automotive IdeaDodge ZEOATT R&D Parade

CT&T E Zone

QE-Wolf Alfa II

Giugiaro NamirJaguar C-X75

Jaguar XJKoenigsegg Quant

Lightning Car Company GT

EVs

With

An g

Chrysler ecoVoyagerJeep Renegade

Fisker karma, Sunset, Surf & Nina

Saba Motors Zero RoadsterTesla Roadster & Model S & R

CT&T E-ZoneKia Borrego (FC)Leo Motors LZ-1

Mitsubishi Imiev SportMitsubishi MEEV-II

Proton Citycar

Lightning Car Company GTPininfarina Bluecar & Nido

Tazzari ZeroThink City (Upper frame)

Valmet EvaVenturi FetishE

E A iA i

Tesla Roadster & Model S & RySim-Drive EliicaYarovit-Motors Citycar

European OEMs have taken a leading position when it comes to the use of aluminium within BIW,

Europe AmericaAsia

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followed by the Americans. Asian OEM Proton has recently announced plans for Asia’s first plug-in

electric car with an aluminium spaceframe.



*** Expected values

Chevrolet Volt:Kg weight per m2: 202

Fisker KarmaKg weight per m2: 209

KM range: 80 Mitsubishi I-Miev:Kg weight per m2: 203

ght P

er M

2

Nissan Leaf:Kg weight per m2: 196

KM range: 160

Kg weight per m : 202KM range: 64

Kg weight per m2: 203KM range: 144

Kg

Car

Wei

g

BMW Megacity***:Kg weight per M2: 157K

Kil t R

Kg weight per M2: 157KM range: 185

By using lightweight materials like aluminium and carbon fibre in the frame of the Megacity vehicle,

Kilometer Range

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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.


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 fartherpercent farther.Source: Aluminium Assoziation

The range of electric vehicles is a major hurdle towards becoming a real alternative to combustion

engine vehicles To optimize the battery range of electric vehicles light weight materials like

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engine vehicles. To optimize the battery range of electric vehicles, light weight materials like

aluminium plays an important role for the OEMs and system suppliers. Lower weight equals longer

range and lower weight saves cost of the battery pack.


Use Of Aluminium Within Electric Vehicle Powertrain Applications

Extrusion Casting Sheet

Battery housing:

E-Drive:

Inverter housing:

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Who Buys A Car With No Range And Not Always Ready For Use?

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The Buildup Of An Electric Vehicle Infrastructure

Charging Stations Inductive ChargingBattery Swap

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

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though, has not been given many chances by some industry experts. When several million electric

vehicles hit the roads more simple and inexpensive charging possibilities will be developed.


Worldwide Sales Of Electric Vehicle Charging Stations

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Comparison Of Incentive Programs

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Use Of Aluminium For The Buildup Of An Electric Vehicle Infrastructure

Aluminium55% 45%

Other Materials55% 45%

Elektromotive Ltd.Coulomb Technologies, Inc.

Aluminium is often used as housing material for electric charging stations. AluMag roughly estimate

b t 45 t f ll h i t ti d i l i i f th h i (M i l

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about 45 percent of all charging station producers are using aluminium for the housing. (Mainly

aluminium extrusions.)


Use Of Aluminium For The Buildup Of An Electric Vehicle Infrastructure

Envision Solar InternationalToyota Industries Corporation

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

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Solar International (USA) have installed or are planning to install solar powered parking lots. An

intensive use of aluminium can be expected for the buildup of solar powered charging stations.


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, E-and for the build up of its infrastructure. Mentionable are applications like battery housings, E

drives, inverters, BIW, and charging stations.

For more information please contact AluMag Automotive Marketing GmbHFor more information please contact AluMag Automotive Marketing GmbH.

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Authors

AluMag Automotive GmbH

Mr Jost Gaertner

AluMag Automotive Scandinavia

Mr Jesper Ove Larsen

AluMag Automotive LLC

Mr Roberto Boeker

Fon: +49 2373 929492Email: [email protected]

Fon: +45 5810 6454Email: [email protected]

Fon: +1 248 9244072Email: [email protected] g g

THE MARKET DEVELOPER

AluMag is a global market developing company that will help you penetrate new markets and find

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new business. We access new markets and open doors for your business – regardless of

application, material, process or product. AluMag makes you successful worldwide!

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