Is Lightweighting the Key to the Electric Car Revolution?

Electric Vehicle Lightweighting: Who Will Be the Ultimate Winner?

As winter descends, the performance of electric vehicles (EVs), particularly their batteries, faces significant challenges. It is common to see the range of electric cars drop by 30% to 50% in cold weather. Additionally, charging times can increase by up to 70% in lower temperatures. Despite the penetration of new energy cars approaching 20%, range anxiety continues to be a persistent concern for many electric car owners.

Research indicates that reducing the weight of a pure electric vehicle by 10 kg can extend its range by 2.5 km. This correlation between weight reduction and increased range has made lightweighting a mandatory pursuit for new energy car manufacturers.

The Quest for Lightweight Electric Cars

Weight has always been a significant hurdle for electric vehicles in China. The shift to electrification, with battery, motor, and electronic controls replacing traditional powertrains, has ironically led to heavier vehicles. For instance, Geely's electric sedan model, the Emgrand GS, weighs 220 kg more than its fuel-powered counterpart. The integration of advanced technologies like chips, radars, and high-resolution cameras further adds to this weight increase.

China's lightweighting efforts lag behind those in Europe and America. Data shows that Chinese electric sedans and pickups are generally 10-30% heavier than their Western counterparts, and this weight hampers their range.

Recognizing lightweighting as a critical advancement axis, policies are now emphasizing it. The "Made in China 2025" initiative identifies lightweighting as a focal area for automobile advancements. The "Energy Saving and New Energy Vehicle Technology Roadmap" sets specific targets: reducing electric car weights by 20% from 2015 levels by 2025, and by 35% by 2030. For the EVauto industry, achieving these reductions is paramount.

Lighter electric cars not only improve range, thereby alleviating range anxiety, but also contribute to reduced carbon emissions. Lightweighting technologies help decrease braking distance, conserve kinetic energy, and minimize noise.

Estimates from Xiamen Fengyuan Machinery suggest the market for lightweight materials in the automotive sector will surge to 35 billion yuan over the next three years, driven by the rapid growth of new energy vehicles.

Three Pillars of Lightweighting

Aluminum alloys, the prime material choice, are pivotal in the quest for lighter electric vehicles. Due to their maturity and cost-effectiveness, aluminum and high-strength steel are the leading materials for automobile lightweighting, together accounting for over 85% of the market share. Aluminum alone constitutes nearly 65%. Major automakers like Tesla and Nio utilize extensive aluminum components to lighten their vehicles. For instance, Nio's ES8 sedan, with a 95.8% aluminum body, weighs only 335 kg, approximately 40% less than traditional steel-bodied cars.

The advantages of aluminum alloys are evident, with increased use in doors, hoods, and tailgates. As batteries are a critical component in the electric vehicle ecosystem, aluminum battery casings are favored for their cost and performance benefits.

Significantly, the lightweighting of EV chassis alone is projected to grow sixfold over six years, expanding the market from 4.6 billion yuan in 2019 to 32 billion yuan by 2025. Similarly, the markets for aluminum battery cases and subframes are poised for rapid growth, expected to reach 18 billion yuan and 7.5 billion yuan respectively, with compound annual growth rates of 31% and 55%. The use of aluminum per electric car is anticipated to rise from 190 kg in 2020 to 259 kg by 2025, and 350 kg by 2030.

This promising outlook has attracted many companies to the field. Among them, Lizhong Group stands out as a leading producer of intermediate alloys for EVs. Its diverse operations span alloy wheels, casting aluminum, and new material production.

While carbon fiber for automotive use is still on the cusp of widespread adoption, advancements in technology and processes could enable it to replicate its successful trajectory seen in wind energy and defense sectors.