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ALUMINUM  Smart Developments

              Case Study                                                                                                           Case Study

              04 04         The Audi e-tron EV platform                                                                            05 05         MX-5 with lightweight properties

                                                                                                                                                 Mazda MX-5
                            EV Platform

                                                                               Audi e-tron Sport concept                         Aluminum alloy front bumper

                                                                                                                                 The Mazda MX-5 (ND)  front
                                                                               The large-capacity lithium-ion battery            bumper reinforcement uses         Front bumper
                                                                               loaded on the Audi e-tron is made up of           a 7000 series high-strength       reinforcement: 4.2kg
                                                                               aluminum alloy modules, each containing           aluminum alloy newly                                       Aluminum alloy power plant frame
                                                                               12 ‘pouch’ cells. To produce the battery          developed by UACJ.                                         The power plant frames used for the MX-5 are press-formed
                                                                               pack, the modules are placed in an                                                                           products made of 6000 series high-strength aluminum alloy
                                                                               aluminum alloy housing.                                                                                      plate for structural purposes produced by UACJ.

                                                                                                                                                        Strength    7003
                                                                                                                                                         5 5         New
                                                                                                                                                         4 4
                                                                                                                                                         3 3
                                                                                                                                              Weldability  2 2  Corrosion
                                                                                                                                                         1 1
                                                                                                                                                         0 0
                                                                                                                                                 Bending      Hollow extrusion                                                             Motor Fan illustrated
                                                                                                                                                 workability  performance
    Motor Fan illustrated

                                                            Front electric motor
                                                                                                                                                                                     Among the aluminum components used for the Mazda MX-5,
                                                                                    Rear electric motors                           Previous model                  Aluminum                                                               ALUMINUM  Smart Developments
                                                                                                                                                                   Ultra-high tensile steel
                                                                                                                                                                   1,180MPa          the bumper reinforcement is of special interest. In order to
                                                                                                                                                                   980MPa            meet the increasingly strict collision safety standards, the
                                                                                                                                                                   590MPa            performance required for front bumpers is becoming very high.
                                                                                                                                                                   270MPa            Regarding the MX-5, further weight reduction was achieved
    ALUMINUM  Smart Developments
                                                                                                                                                                                     while at the same time securing a safety performance of the
                                                                                                                                                                                     highest level. Reducing the weight of the components which
    08                                                                                                                             Mazda MX-5                                        are the furthest from the vehicle’s center of gravity is effective   09
                                                                                                                                   4th Generation                                    not only for improving fuel efficiency but also for increasing
                                                                                                                                                                                     Further weight reduction has been gained by using the 7000
                                                                                                                                                            0%  20%  40%  60%  80%  100%
                                                                                                                                                                                     series high-strength aluminum alloy extruded shapes newly
                                                                                                                                                                                     developed by UACJ.
                                                                                                                                 Aluminum alloys have been widely used in the MAZDA MX-5 to create a
                     Charging point                                                                                              lightweight but highly rigid body.

                                                 Liquid cooled
                                               lithium-ion battery

             Regarding the structure of vehicles which are rapidly making   weight becomes. That is why the use of lightweight aluminum
             their way to being electric-powered, it is now becoming   alloys is favored. For example, the Audi e-tron’s battery
             standard to lay out the lithium-ion batteries in an aluminum   housing consists of 47% aluminum extruded shapes, 36%
             frame positioned under the floor as part of the body structure.   aluminum sheets, and 17% aluminum cast products. Despite
             Tesla took the initiative and the BMW i3 was the pioneering   being made of aluminum, the total weight of the system         TESLA MODEL-S                    JAGUAR I-PACE                   Range Rover Sport
             model for this. Audi’s e-tron has adopted a similar structure   reaches up to 700kg. Considering the structure in terms of   The chassis of the Tesla Model-S has an   The I-PACE is the SUV model of Jaguar’s first   Based on knowhow accumulated through the
             and Jaguar’s I-PACE displays the same concept. The mileage   shock being dispersed during a side collision, thermal   all-aluminum frame structure. The battery   all-electric vehicle. From its aluminum alloy   development of the Jaguar XJ, this is the first
             of an EV depends on battery capacity, but the greater the   management, and other factors, an aluminum frame can now   cells are arranged beneath the flat floor.   platform to its body panels, the I-PACE   SUV to feature an all-aluminum monocoque
             capacity of the loaded batteries, the heavier the total vehicle   be regarded as the standard for an EV platform.   Aluminum is also used for all the body panels.  features aluminum construction.  body design.

                                                                                                                                                                                                        PHOTO: AUDI/MAZDA/JAGUAR/LAND ROVER/MFi
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