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Aluminum Value in Battery Electric Vehicles (BEVs)

New research by FEV North America confirms aluminum’s value in battery electric vehicles (BEVs). The study includes an analysis of three vehicle segments and finds aluminum is an economically attractive mass reduction tool to improve performance and efficiency in BEVs.

Research Highlights

  • Improvements in energy density, range, and overall weight reduction expected for all specified BEVs thru 2030
  • Current materials composition was estimated for three BEV segments using benchmark data from four BEV examples
  • From FEV benchmark data, aluminum content is observed to increase with performance and size, and is higher in BEV vs. ICE equivalents
  • Sensitivity analysis to show the impact on BEV weight with increased aluminum in a “substitution scenario”
  • Objective is to recommend optimal point in each BEV segment with best balance between cost and average efficiency (MPG / MPGe)
  • All three BEVs yield a net savings for both 2025 and 2030 up to a certain point of aluminum share in the vehicle and within a specific $/lb weight saved

Related Resources

2023 North American Light Vehicle Aluminum Content and Outlook
Processing for Aluminum Auto Body Sheet
Aluminum Galling and Lubrication for Automotive Applications