Steel or Aluminium: Which is Better for Electric Vehicles Manufacturing

With the growing global shift towards electric vehicles (EVs), automakers are forced to rethink automotive designs. And one of the major debates is on the selection of steel or aluminium for vehicle crafting. Both the raw materials play a crucial role in EV manufacturing, and the choice of any of these metals depends on several factors, like cost, safety, weight, performance, sustainability, etc. Though steel and aluminium both are essential for automobile manufacturing, the selection gets more critical as every added kilogram has a direct impact on the performance of the vehicle. 

Read the blog to find out how these materials compare in EV manufacturing and the factors automakers need to consider while making the final choice. 

Why Metal Processing for EV Manufacturing is Different

EVs have a different functionality from internal combustion engine (ICE) vehicles, as the battery pack in these vehicles makes up 20-30% of the total weight. To maintain the range, efficiency and overall performance of the vehicle, it is essential to adjust/reduce weight elsewhere, like chassis, body and battery enclosures. Careful selection of the metal for these parts becomes a necessity as these have a direct impact on: 

• Energy efficiency and driving range
• Structural safety and crash resistance
• Manufacturing and repair costs
• Sustainability and recyclability

With distinct features, both steel and aluminium can help in addressing these issues and design a perfect electric vehicle. 

Steel for Electrical Vehicle Manufacturing

When it comes to metal processing for automobile manufacturing, steel has been leading the market for decades. But what about its role in electrical manufacturing? Get your answers below.

Key Applications of Steel in EVs

• Vehicle body and chassis, including safety cages
• Battery enclosures using advanced coatings for protection
• Supporting the design of electric motors with speciality steels
•  Safety-critical areas like the passenger cell and crash zones

Advantages of Steel in Electrical Vehicle Manufacturing

Strength and Safety: Heavy battery packs make modern vehicles heavier than regular vehicles. Steel enhances crashworthiness and passenger safety by absorbing and dissipating impact energy during collisions.

Thermal and Magnetic Shielding: Steel provides enhanced protection against electromagnetic interference (EMI) in sensitive electronic systems in EVs.

Cost Benefits: When it comes to steel price as compared to aluminium, steel always wins, helping OEMs design affordable vehicles for the segment looking for budget-friendly vehicles. 

Ease of Manufacturing: As steel has been in use for decades, the processes for stamping, welding, and recycling are well established. Further, the mature and cost-efficient supply chain eases the manufacturing process. 

Recyclability and Sustainability: Steel is a highly recyclable raw material, making it possible to align manufacturing processes with sustainability goals. Moreover, galvanised steel offers enhanced corrosion resistance, supporting longer lifecycle components.

Downsides of Steel in Electrical Vehicle Manufacturing

Heavy Weight: Irrespective of the type of steel, the density always adds extra weight to the vehicle. This reduces the efficiency of the EV.

Corrosion Risk: Though galvanised steel reduces this issue to a high level, chances of rust are always there in harsh environments.

Aluminium for Electrical Vehicle Manufacturing

In modern vehicles, aluminium is taking the lead as a preferred raw material due to innovation and its lightweight. Find out more reasons below. 

Key Applications of Steel in Electrical Vehicle Manufacturing

• Chassis and internal panels
• Battery enclosures and motor housings
• Shock towers and modular structural components
• Doors, hoods, and outer panels

Advantages of Aluminium in Electrical Vehicle Manufacturing

Lightweight: When it comes to weight, aluminium is just one-third of steel per cubic foot, helping OEMs reduce a substantial mass in vehicles. This has a direct impact on the improved range and energy efficiency of an EV.

Flexible Design: Easy forming and better heat conductivity make aluminium an ideal choice for the manufacturing of battery cases, body panels and parts where better thermal management is needed.

Heat Dissipation: Aluminium perfectly disperses heat and prevents the battery from overheating. It boosts the safety, making it ideal for EV battery housings and enclosures.

Recyclability: Aluminium supports low-carbon initiatives and sustainability mandates as it is recyclable up to 90%. Further, the recycled aluminium retains its original properties, reducing the efforts on energy consumption in reuse. 

Corrosion Resistance: Aluminium’s natural oxide layer provides excellent protection against corrosion, enhancing vehicle lifespan with minimal maintenance.

Downsides of Aluminium in Electrical Vehicle Manufacturing

High Material Cost: Aluminium price is comparatively higher than steel. It can be 2-3 times more expensive than steel per kg.

Specialised Processing Requirements: Advanced extrusion and forming methods are required, increasing complexity and investment in new equipment.

Cost vs Performance Analysis of Steel and Aluminium for EV Manufacturing

Cost vs Performance Analysis of Steel and Aluminium in EV Manufacturing

Steel or Aluminium: Which is Better for Electric Vehicle Manufacturing

There is no one-size-fits-all answer for steel or aluminium selection for EV manufacturing. For electric vehicle manufacturers and their supply chain partners, the choice depends on multiple factors, such as:

• Desired vehicle weight and range
• Safety and crash performance requirements
• Cost targets and scalability
• Sustainability goals

Steel and aluminium each offer unique technological, economic, and environmental advantages. The EV industry’s leaders are creating hybrid vehicles that combine both materials to meet evolving consumer demands and regulatory requirements.