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Auto Aluminum - Automotive Lightweight Solutions

Auto Aluminum - Automotive Lightweight Solutions

Aluminum's lightweight and high strength make it essential in passenger and commercial vehicles, enhancing performance, fuel economy, and safety.

Aluminum is widely used in the passenger car and commercial vehicle industries due to its lightweight and high-strength properties. Aluminum not only significantly improves vehicle performance and fuel economy; it also improves overall vehicle performance without compromising safety.

Comprehensive application of automotive aluminum: in-depth analysis from body structure to interior and exterior decoration

MASTAR designs and manufactures aluminum products for all vehicles, covering all vehicle systems such as passenger cars, commercial vehicles, racing cars, new energy vehicles, etc.

Aluminum plate for automobile body

  • Aluminum for automobile
    • Automobile shells typically use 5000 and 6000 series aluminum alloy sheets for doors, hoods, roofs, and tailgates, offering excellent deep drawing, hot forming, dent resistance, baking hardening, gloss hardening, and lightweight benefits.
    • Surface treatment: anodizing
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Automobile body sheet alloy and part comparison table
Location Alloys and products Material properties
Inner and outer coverings (shell plates) 2008, 2010, 2036 3004(External Covering) 5052, 5182(inner hull), 5754(inner hull) 6022(Inner and outer shell), 6016, 6A16, 6014 Aluminum alloy honeycomb panel These alloys combine excellent formability, strength and corrosion resistance for automotive interior and exterior panels. They ensure that body parts maintain structural strength while providing durability and good appearance, adapting to a variety of complex shapes and environmental conditions.
Door inner panel, skylight panel, fence inner panel 6010, 6009, 6016 Aluminum alloy honeycomb panel Good stamping and forming properties, suitable for parts with complex shapes.
Front gate 6010 Aluminum alloy honeycomb panel Good strength and flatness, suitable for key parts such as front gate.
Siding 6010, 6111 High strength, good formability, excellent corrosion resistance and weldability, suitable for wall panels subject to greater stress.
Wings (front wing, sliding wing, outer wing) 6010, 6016 Suitable for complex shaped wings, with good formability and strength.
fender 5182, 5754 Excellent corrosion resistance and formability, suitable for fenders exposed to external environment for a long time.

Aluminum profiles for use in body in white (BIW)

  • Aluminum for automobile
    • Vehicles require a strong body structure to support weight and pressure, and to firmly connect various components. Aluminum, with its high tensile strength and lightweight characteristics, is an ideal and sustainable choice. MASTAR offers a variety of aluminum materials for automotive body-in-white (BIW), from simple extruded profiles to complex sections, as well as complete aluminum chassis, with products, systems, expertise and solutions.
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Automobile body structural alloy and part comparison table
Location Alloy Material properties
Automobile profiles/body frames 6082, 6061 High strength, good processability and weldability, suitable for vehicle body frames subject to heavy loads.
Roof rails 6063, 6005 Good corrosion resistance and formability, suitable for roof rails with complex cross-sections.
Body parts/structural reinforcements 6082, 7075 6082: High strength and fatigue resistance; 7075: Extremely high strength and hardness, suitable for high stress areas.
Automobile beam 6061, 6082 High strength and good corrosion resistance, suitable for structural parts subject to pressure and stress.
Anti-collision beam/anti-collision frame/anti-collision frame energy absorption box 6063, 6061, 6082, 7003 7003: Excellent strength and impact resistance; 6061,6082: High strength and fatigue resistance, suitable for energy absorption and protective structures.
bumper 6061, 7075, 7003, 7046 6061: high strength and good durability; 7075: extremely high hardness and impact resistance, suitable for safety protection purposes.

Aluminum sheets and profiles for automotive chassis systems

  • Aluminum for automobile
    • Chassis components such as suspension systems, subframes, control arms, etc. usually use aluminum profiles and aluminum castings. The alloy types are usually 6061, 6082, etc., which have high strength and fatigue resistance.
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Automobile chassis alloy and part comparison table
Location Alloy Material properties
Subframe 6061, 6082, 7003 High strength, fatigue resistance and corrosion resistance, suitable for carrying and supporting the weight of the vehicle body.
Chassis frame and power tray 6009, 6061, 7021 Strong and durable, with a balance of strength and lightness, suitable for bearing the weight of the vehicle body and power system.
Suspension Suspension Link 6082, 5154 It has excellent mechanical properties, fatigue resistance and durability and is suitable for highly loaded suspension components.
Shock absorber/shock mount 5052, 6061, 6009, 7003, 7021, 7029
Control Arm 6061, 6082, 7075
Steering system Front and rear steering knuckle 6082, 7075 High strength and durability ensure the stability and precision of the steering system.
Steering linkage 6061, 6082, 7075
Drive system Transmission/Differential 6061, 6082 Excellent processing performance and fatigue resistance, suitable for drive and transmission components subject to rotation and torque.
Drive shaft 6061
transmission shaft 6063, 6463, 6262, 6151
Braking system Brake box parts 6082, 6262 High strength, corrosion resistance and wear resistance ensure the long-term stability and reliability of the braking system.
Vacuum booster pump 5754, 5182
Brake series products 6061, 6082, 7075
ABS valve 6061, 6082, 7075
Wheel hub 6061, 6082, 6063, 5454, 6010, 6151 High strength and impact resistance, suitable for wheel hub parts that bear vehicle loads and road impacts.

Aluminum sheet and aluminum profile for automobile power system

  • Aluminum for automobile
    • Using aluminum in powertrain and engine systems can improve efficiency, reduce weight and lower vehicle production costs. MASTAR's aluminum engine parts have excellent machinability and mechanical properties.
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Automobile power system alloy and part comparison table
Location Alloy Material properties
Engine systems and components Engine cover inner and outer panels 6010, 6016, 6111 It has good formability and corrosion resistance, is lightweight and provides appropriate strength.
Engine auxiliary bracket and engine mount 5454, 6061, 5083, 6082 High strength and fatigue resistance, suitable for supporting and fixing engines under high stress conditions.
Engine Parts 6063, 6082 Excellent processing performance and corrosion resistance, suitable for complex shape engine components.
piston 4032, 2618, 6262 High strength, high temperature resistance and wear resistance ensure stability and durability when the engine runs efficiently.
Turbocharger housing 2618 Extremely high heat resistance and strength, able to maintain stable performance under high temperature and high pressure conditions.
Motor Generator housing 6061 Good corrosion resistance and strength, suitable for the protective shell of the generator, ensuring stability during long-term use.
Generator bracket 6061 High strength and good processability can effectively support and fix the generator to ensure its normal operation.

Aluminum foil and profiles for automotive interiors decorative

  • Aluminum for automobile
    • Aluminum trim and interior reduce weight and support sustainability, promoting a green automotive future. MASTAR offers high-spec aluminum extrusions for trim parts like decorative strips, door handles, grooves, and instrument panels. Further processing services: matte or shiny, embossed or embossed
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Comparison table of aluminum alloys and parts for automotive interior
Parts used Alloy
Loading floor 2036, 5182, 5754, 6009
Various brackets 6151
Seat frame 2036, 6010, 6009
Seat Track 7003, 7129, 6010
Door and window frames 6063, 6463
Sealing strip 5754-H24, 3105-H28
Car B-pillar decoration 3005-H22, 5754-O
Body sheet metal 6009, 6111, 6016
Decoration/Inlays/Nameplates 1100, 3002, 5005, 5252, 5457, 5657
Audio 5052-H32
Air cleaner tray and hood 5182, 5754

Aluminum alloy brazing materials for automotive heat exchange systems

In modern cars, brazed aluminum sheets, strips, foils, tubes and other materials are widely used in heat exchange systems such as engine radiators, oil radiators, intercoolers, air conditioning condensers and evaporators. Aluminum is an ideal choice for automotive thermal management due to its strength, corrosion resistance, weight reduction, excellent thermal conductivity and sustainability, effectively managing vehicle temperature and improving environmental credentials.

MASTAR focuses on providing high-quality aluminum products to customers around the world, covering various specifications of plates, strips, foils, composite strips (foils), extruded round tubes, flat tubes, porous flat tubes and welded tubes. We are committed to helping customers manufacture automotive parts that can maintain optimal temperatures under any conditions and promote the future development of the automotive industry.

Aluminum for automobile

Reference table of various aluminum heat exchanger and intercooler structures and main materials used
Structural form Heat sink Cooling water pipe
Tube and belt vacuum brazing 1100, 3003, 3005, 6063, 5005, 6951 Double-sided composite tape is welded into a flat tube by high-frequency seam welding 4045/3003/7072/4045/3005/7072 4A17/3003/7A01, 4A17/3005/7A01
Gas shielded brazing of pipes 3003, 3003+Zn, 3203+Zn, 7072 Double-sided composite tape is welded into a flat tube by high-frequency seam welding 4043+Zn/3003/7072, 4045+Zn/3003/7072, 4043+Zn/3003/7 A01, 4045+Zn/3003/7 A01
The pipe segment is a structure 1050, 1100, 1145, 3A21, 3003, 7072, 7A01, 8006, 8007 Extruded or high frequency seam welded round tube 1050, 1100, 3003, 3A21, 1050
Corrugated welding 1100, 3003 Extruded flat tube or porous flat tube 1050, 3003, 3A21
Plate fin welding 1100, 3003 Stamped plate fin 3003, 3A21
  • Aluminum for automobile
    Heat Exchanger

    6591, 6051, 6061

    3003 (Brazed Heat Exchanger Tubes)

  • Aluminum for automobile
    Heat sink

    3003 (Radiator)

    3005 (Brazing Radiator Tubes)

    7072 (Radiator fin)

    5182-O (Engine Radiator)

  • Aluminum for automobile
    Heater

    3003 (heater fins and inner and outer tubes)

    3005 (heater and edge support)

  • Aluminum for automobile
    Intercooler

    3003, 4045, 6061

  • Aluminum for automobile
    Oil Cooler

    3003

  • Aluminum for automobile
    Condenser/(Extrusion) Condenser Tube

    1200, 7072

  • Aluminum for automobile
    Evaporator

    3005

  • Aluminum for automobile
    Heat transfer fins

    1200

  • Aluminum for automobile
    Air conditioning pipe

    3003

Aluminum alloy breakthrough in new energy vehicles: innovative applications from battery trays to vehicle frames

  • Aluminum for automobile
    • Aluminum plays an important role in the lightweighting of electric and hybrid vehicles. MASTAR aluminum electric vehicle components include battery packs and housing frame solutions for all electric vehicles. Other products include aluminum battery cables, radiator systems, motor housings, cabin heaters and structural body parts.
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  • Battery cooling system: Battery thermal management requires an efficient cooling system. Aluminum brazing composite materials are widely used in battery liquid cooling plates to improve cooling effects and ensure battery safety and performance.
  • Lightweight design: In order to extend the driving range, electric vehicles rely more on lightweight materials. Aluminum is an ideal choice for body structure, chassis and other key components due to its lightness and strength.
  • Electric motors and electronic control systems: Aluminum's good electrical conductivity and heat dissipation properties make it the preferred material for components such as motor housings and electronic control module heat sinks, helping to improve system stability and efficiency.
  • Thermal management system: New energy vehicles require a more complex thermal management system. Aluminum materials are widely used in radiators, condensers, air-conditioning systems and other components to ensure temperature control of the vehicle under various operating conditions.
Comparison table of aluminum alloys and parts for electric vehicles
Application area Application and Gold Product form
Power battery shell 1050,3003,3005 Aluminum Coil
Power battery cover 3003,5182 Aluminum Plate
Power battery side panel 5083 Aluminum Plate
Battery Tray 6063,6016,6061,6082,5083 Aluminum sheet, aluminum alloy extrusion
Power battery water cooling plate 3003 3003/43443 Brazed composite plate
Aluminum foil for power battery soft connection 1060 Aluminum foil
Electric vehicle line Electric vehicle internal wiring 8000 Series Aluminum wire
Aluminum wire and cable for charging infrastructure ACSR, AAAC Aluminum alloy stranded wire, cable

The Green Case——How Aluminum Reduces Vehicle Weight and Carbon Emissions

  • Aluminum is strong, efficient, safe, recyclable, and abundant. For every 0.45 kg (1 pound) of aluminum used in a car instead of steel, the vehicle loses 0.45 kg of weight. This metal keeps vehicles on the road safer and more efficient. Aluminum has become increasingly popular in the automotive industry over the years. It is used to produce engines, transmissions, suspensions, wheels, brake parts, frames, magnets for tachometers and speedometers, wiring, air conditioning components, and even body parts.
  • Here is a formula that makes it easier to understand the importance of reducing the weight of a car. Assume that a car has traveled 200,000 kilometers, which is about 125,000 miles. Assume that the secondary weight is reduced by 20%. On average, 1 kilogram of weight is saved for every kilogram of aluminum, because steel weighs twice as much as aluminum.
  • Every kilogram of aluminum used in a car saves 19 kilograms of CO2 over the car's lifetime. If we also take into account the production and distribution of fuel (wheel-to-wheel), we can say that a 100 kilogram reduction in vehicle weight means 10 grams of CO2 per kilometer, or 2,000 kilograms over the car's lifetime.

Mastar——Your professional automotive aluminum supplier and technical service expert

  • Comprehensive aluminum product supply: We provide a full range of aluminum products from aluminum alloy sheets, strips, foils to aluminum tubes, profiles, brazing materials, etc. to meet the needs of different components in automobile manufacturing.
  • Technical support and customization services: Our professional team provides technical support and material customization services for the automotive industry to ensure the best application effect of aluminum and help customers improve product performance.
  • High quality and strict quality control: We adhere to the highest quality standards. All aluminum products undergo rigorous testing and certification to ensure that we provide customers with reliable aluminum that meets the requirements of the automotive industry.
  • Fast delivery and global supply chain: With a complete supply chain network, we can respond quickly to customer needs and provide efficient logistics services around the world to ensure on-time delivery of aluminum.
  • Sustainability and environmental commitment: We are committed to providing aluminum materials with sustainable and environmental advantages to help customers reduce carbon emissions and promote green automobile manufacturing.

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