Aluminium takes the wheel: Towards greener mobility

The automotive industry is shifting gears towards lighter, more fuel-efficient vehicles. Aluminium, with its impressive strength-to-weight ratio and endless recyclability, is at the forefront of this revolution. Leading the charge is Aditya Birla Group's Novelis, a global leader in aluminium rolling and recycling. Novelis helps carmakers meet stricter emission regulations and consumer demands for eco-friendly cars by capitalising on aluminium’s unique properties. Because it is lightweight and infinitely recyclable, aluminium has become crucial in minimising waste and reducing the environmental impact of car production.

In a move significant for the automotive industry, Alumobility and Porsche released the findings of a collaborative effort – a groundbreaking study on the potential of aluminium for lightweight car design. Titled "Aluminium Lightweight Study : A Conversion of the Porsche Taycan Top Hat from Mixed Material to an Aluminium Design," the study explores the advantages of utilising aluminium in vehicle construction.  The non-profit association Alumobility was founded to focus on studies to explore the feasibility of using aluminium in the automotive industry to create lighter, more efficient, safer, and sustainable vehicles for the future.

An impetus for a sustainable future

The study cements Novelis’ position as a leader in supplying innovative aluminium solutions for the automotive industry. Aluminium sheets from Novelis are the first choice for the automotive industry due to its unbeatable manufacturing footprint and consistent product quality. Novelis is invested in finding and offering the best solutions to adopt aluminium and achieve the lightweight, performance, and design goals of the automotive industry.

The Novelis product portfolio which includes Advanz and Fusion – two high-performing alloys are primary choices for more than 315 models. Novelis leverages aluminium’s unique properties to create sustainable solutions for carmakers so they can meet government regulations all while meeting consumer demands. Novelis’ partnership with Porsche is an example of their commitment to developing and promoting aluminium's potential for lightweight car design.

This study paves the way for further exploration of aluminium's role in sustainable car manufacturing. With its focus on weight reduction and potential performance benefits, aluminium can play a key role in the future of automobiles.

Aluminium: Moving forward, lightly

The study focuses on the Porsche Taycan's top hat, a crucial structural component. By replacing the current mixed-material design with aluminium, the research investigates the weight reduction possibilities and performance enhancements achievable.

This shift towards aluminium has the potential to revolutionise car manufacturing because it could result in saving around 40% less in weight against the steel reference parts while still maintaining the same parameters for safety, body stiffness and performance The move to aluminium would also elevate manufacturing efficiency by reducing the number of parts, joint types, and total joint count.

This move would also be a nod to sustainability efforts as recycled aluminium would lower lifetime emissions. Lighter vehicles require less energy to operate, translating to improved fuel economy or greater range for electric vehicles like the Taycan. Weight reduction from using lightweight aluminium can improve handling and overall vehicle dynamics.

With their commitment to research and development, Novelis is not only supplying the industry with innovative aluminium solutions but also paving the way for a lighter, greener future. As car manufacturers prioritise efficiency and eco-friendliness, Novelis' leadership in aluminium technology positions them perfectly to steer the automotive industry towards a sustainable future.