Automotive Lightweight Application Database

Jost GAERTNER

Managing Partner

Contact Details
Tel: +49 172 6000569
j.gaertner@alumag.com

Ying ZHOU

Lead Of Japan & China Projects

Contact Details
Tel: +49 172 6415876
y.zhou@alumag.com

DATABASE DESCRIPTION:

The database contains details regarding around 10.000 automotive aluminium, magnesium, steel & CFRP applications by car body variants (Supplier – Material – Process – Weight – Demand By Bodyvariant)

TREND ANALYSIS:

The Automotive Application Database is connected with AluMag in-house automotive production forecast. Accurate material demand analyses by model variant are generated by multiplying an application weight with yearly model variant production.

The direct connection with our automotive production forecast makes it possible to generate several data enquires:

  • Demand by material [aluminum, magnesium, steel, composite, carbon]
  • Demand by core processes [cast, extruded, rolled, forged, …]
  • Demand by OEM
  • Supplier market shares
  • Demand by application

APPLICATION FOCUS AREAS:

  • Exterior: Hood & bonnet, lid & tailgate, roof railing, door inner & outer structures, bumper beams, sunroofs …
  • Suspension / Steering / Braking: Suspension link-arms, knuckles/wheel carrier, sub frames/cradles/cross members, calipers,
  • BIW: Front & rear longitudinal carriers, suspension domes, A- / B- / C- pillars, cross members, …
  • Power train: (Limited focus)

Aluminum Extrusion Customer Database

Jost GAERTNER

Managing Partner

Contact Details
Tel: +49 172 6000569
j.gaertner@alumag.com

Ying ZHOU

Lead Of Japan & China Projects

Contact Details
Tel: +49 172 6415876
y.zhou@alumag.com

DATABASE INTRODUCTION:

The AluMag® Aluminium Extrusion Customer Database is an acquisition tool containing about 3,000 companies, situated on the European market, and all with a demand for aluminium extrusion profiles/ tubes. The combined demand for the 3000 potential customer companies is about 755,000 tons aluminium extrusion profiles/tubes yearly.

All market segments have been analysed including automotive, truck & trailer and non-automotive segments like building & construction, furnitures, general engineering etc.

For more information please download the presentation and/or contact AluMag Automotive GmbH.

INFORMATION AVAILABLE FOR EACH COMPANY:

  • Full company address
  • Purchase contact details
  • Demand split in semi-finished / machined
  • Demand allocated by EAA segment

Consumption of CFRP in Automotive BIW Applications

Jost GAERTNER

Managing Partner

Contact Details
Tel: +49 172 6000569
j.gaertner@alumag.com

Ying ZHOU

Lead Of Japan & China Projects

Contact Details
Tel: +49 172 6415876
y.zhou@alumag.com

SCOPE & METHOD DESCRIPTION:
For a Chinese producer of electronic equipment AluMag® executed a global snapshot study of the automotive CFRP market.

CFRP DEMAND & MARKET SHARES:
AluMag® has analyzed the consumption of CFRP in automotive BIW applications worldwide. Furthermore supplier market shares for each application group were determined.

CFRP SUPPLY CHAIN:
A comprehensive carbon fiber supply chain chart were researched for six premium OEMs. In total 110 companies were detected as being part of the six OEMs carbon fiber supply chain. For each company a qualified contact is listed

CFRP APPLICATION TECHNOLOGY OVERVIEW:
As part of the analysis several CFRP BIW applications have been thoroughly described in regards to material, process steps, equipment and assembly.

Carbon / Composite Threat against Cast Aluminum

Jost GAERTNER

Managing Partner

Contact Details
Tel: +49 172 6000569
j.gaertner@alumag.com

Ying ZHOU

Lead Of Japan & China Projects

Contact Details
Tel: +49 172 6415876
y.zhou@alumag.com

SCOPE & METHOD DESCRIPTION

AluMag® has analyzed the composite / carbon fiber threat against cast aluminum within suspension and BIW applications.

The main goal was to provide the client [European aluminum foundry] with an application overview outlining the composite / carbon fiber threat by means of a timeline “What to expect when”.

The timeline was based on existing AluMag® market information as well as on 20 interviews with industry experts representing OEMs, carbon fiber producers and tool makers.

Global Non Ferro Casting Industry Analysis

Jost GAERTNER

Managing Partner

Contact Details
Tel: +49 172 6000569
j.gaertner@alumag.com

Ying ZHOU

Lead Of Japan & China Projects

Contact Details
Tel: +49 172 6415876
y.zhou@alumag.com

SNAP SHOT SUMMARY EXTRACTION:

Cast aluminum is primarily used in power train applications, such as cylinder heads, engine blocks and transmission housings. In NA about 85% of all vehicles are equipped with an aluminum engine block. In Europe, this figure is 55%, 60% in China and 45% in Brazil [2015]. For 2020, a penetration rate of 89% in NA is expected.

Another important application is cast aluminum wheels, currently around 45% of all vehicles sold are equipped with original cast aluminum wheels world wide. In NA, the OE incorporation rate is of 77% [2015]. For 2025 OE penetration rate of 50% is expected worldwide.

When it comes to BIW structures, especially sports cars are equipped with cast aluminum [vacuum HPDC] since the 90s. Audi initiated the turn with the introduction of an aluminum frame for medium to high Volume vehicles [A8 and A2] beginning of this millennium. The Audi “space frame“ Was made of cast-, extruded- and sheet aluminum processed parts. With a very high growth rate of applications in the automotive structure, aluminum is no longer a rarity. New generations of models of high-end car manufacturers such as  MB [C,E, and S-Class], BMW [X5, X6, 5 & 7-Series], JLR [Range Rover, Range Rover Sport, XJ, F-Type, XE] Cadillac [ATS, CTS, CT6], Audi [Q7, A4, TT, A8, A6] have ..

KEY FINDINGS – ALUMINUM ENGINE BLOCK PENETRATION:

  • N. America 85%
  • China 60%
  • Europe 55%
  • Brazil 45%

Global Cast and Forged Alloy Wheel Market

Jost GAERTNER

Managing Partner

Contact Details
Tel: +49 172 6000569
j.gaertner@alumag.com

Ying ZHOU

Lead Of Japan & China Projects

Contact Details
Tel: +49 172 6415876
y.zhou@alumag.com

SUMMARY EXTRACTION:

Worldwide the market for OE aluminum wheels is expected to grow with 0,91% in the period 2014-2015 within light weight vehicles.  From 44% in 2014 to 45% in 2015. In the period 2014-2029 a growth rate of 7% points is expected which will bring the worldwide penetration of OE aluminum wheels up to 51% in 2029. The Highest growth rates in the period 2014-2029 are expected in China [14% points], Japan [13,5% points] and Central Europe [15% points]. 

Cast wheels will remain the preferred alloy wheel for light weight vehicles while the penetration of forged wheels is expected to grow moderate over the coming years.

Today forged wheels are primarily used on high end vehicles and sports cars, but the booming electric vehicle segment Could boost the penetration of forging wheels in the near future. On the other hand new hybrid wheels to be launched by Maxion / Thyssen could become a threat to forging wheels manufacturers.

The penetration of forged wheels within commercial vehicles [Medium – heavy duty trucks, trailers and buses] is 13% on average in the analyzed regions.  Again Nafta is the market with the highest penetration rate of forged wheels with 40%. Trailers and trucks in Nafta has in general more axles compared to other regions,..

Study was executed in year 2016/2017.

KEY FINDINGS – GROWTH RATES:

  • World – 7 points
  • China – 14 points
  • Japan – 13.5 points
  • Central Europe – 15 points

Eu28 Top 15 GDC & LPDC Foundries

Jost GAERTNER

Managing Partner

Contact Details
Tel: +49 172 6000569
j.gaertner@alumag.com

Ying ZHOU

Lead Of Japan & China Projects

Contact Details
Tel: +49 172 6415876
y.zhou@alumag.com

BASE & BACKGROUND:

  • Within an overseeing period of time, client will run-out of orders for exciting process lines in the location XXX with casting cells in line and round tables
  • Client will get an entire overview about the market players and applications
  • Cylinder heads are not really in the clients focus. But, GDC & LPDC machines which are processing Cylinder heads today, could be used in future for any other products too. Means, this capacity / company will be looked at too
  • The research will consider entire Europe
  • The machines / area, which will run out of production, could be use with:
    • existing machines for new products
    • refurnished / modified existing machines for new products
    • new machines for new products

SCOPE:

  • GDC and LPDC including hollow cast and counter pressure in Europe 28
  • Market player and their products / applications
  • Proposed application by AluMag®

HPDC Automotive Aluminum Applications In Nafta

Jost GAERTNER

Managing Partner

Contact Details
Tel: +49 172 6000569
j.gaertner@alumag.com

Ying ZHOU

Lead Of Japan & China Projects

Contact Details
Tel: +49 172 6415876
y.zhou@alumag.com

SHORT SCOPE EXTRACTION:

The client is a Japan based aluminum processing company and a leader in the industry. The client would like to get a sustainable understanding and benchmark of the global industry leaders like; Nemak which specializes in the production of cast aluminum powertrain components such as cylinder heads, engine blocks and transmission parts for light vehicles. Since the cast structural “body in white” [BIW] will be applied for areas where strong part integration is feasible, Nemak is going to target new components / areas like thin-wall, ductile and weldable castings. This is a target market for the client too.

THE CLIEN REQUESTED SUPPORT FROM ALUMAG® TO EXECUTE THE FOLLOWING SERVICES & ANALYSIS:

  • Leading cast aluminum structures supplier for body and chassis parts
  • Selected car manufacturer in NA with their in-house casting, future strategy and make or buy decision as well as decision maker
  • Body and chassis segment NA, strategy, locations, expansions, supplier selection process and risks at selected car manufacturers
  • ……..