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Which Vehicles Use A Lot of Aluminum

Driven by both fluctuating oil prices and range anxiety surrounding new energy vehicles, "lightweight" has become a core issue in the automotive industry. Aluminum alloys, with their density being only one-third that of steel and a 100% recycling rate, have become a "star material" for achieving lightweight. Which cars on the market today are most willing to use aluminum? And where are these aluminum alloys hidden in the car body?

The amount of aluminum used in a car is directly linked to its model positioning and powertrain. Generally speaking, new energy vehicles (especially pure electric vehicles) and luxury brand gasoline vehicles are the absolute "aluminum giants," the former for weight reduction and increased range, and the latter for improved handling and quality.

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In the new energy vehicle sector, the Tesla Model Y is considered a "benchmark for aluminum use." Its integrated die-cast rear panel integrates 70 steel parts into a single aluminum component, with the body structure alone using 70-90 kilograms of aluminum.

In the luxury gasoline vehicle camp, Audi and Jaguar have always been staunch supporters of all-aluminum car bodies. The Audi A8L boasts over 80% aluminum in its body panels, with components like the hood and doors made of aluminum alloy. The Jaguar XJ, through its all-aluminum body structure, reduces weight by nearly 300 kg compared to comparable steel models.

Applications of aluminum alloys in cars

1. Battery and thermal management systems

For new energy vehicles, the battery system is the core area using aluminum, and 3003 aluminum alloy, with its excellent rust resistance and thermal conductivity, has become the "main force" here. In the battery pack, 3003 aluminum alloy is used both for the casing of the square battery cells (utilizing its good deep-drawing performance for sealing) and in the manufacture of battery cooling plates.

Furthermore, the ultra-thin aluminum foil in automotive air conditioning condensers and the radiators in electronic control systems also largely use aluminum alloy 3003, whose thermal conductivity is more than three times that of steel, significantly improving heat exchange efficiency.

2. Body panels and structural components

If 3003 aluminum sheet is the "functional player," then 5754 aluminum alloy is the "all-rounder" of body components. As an Al-Mg series rust-resistant aluminum alloy, 5754 aluminum sheet, with a magnesium content of 2.6%-3.6%, achieves a perfect balance between strength, formability, and corrosion resistance. Its strength is higher than 3-series alloys such as 3003, while its formability is superior to high-strength 6-series and 7-series alloys.

In automobiles, 5754 alloy is mainly used for door panels, trunk panels, and other covering parts, as well as structural components such as seat frames and chassis support components. These parts must withstand certain loads, undergo complex stamping and bending processes, and resist daily rain corrosion. 5754aluminum 's excellent weldability (weld strength comparable to the base material) and resistance to marine atmospheric corrosion perfectly meet these requirements.

While 5754 aluminum plate is excellent, in specific scenarios (such as cost control or performance upgrade requirements), suitable alternative alloys are needed. When structural components require higher strength, 5182 and 5083 alloys, aluminium 5754 equivalent, are better solutions.

Original Source:https://www.autoaluminumsheet.com/a/which-vehicles-use-a-lot-of-aluminum.html

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