Automakers around the world are employing aluminum to lower the weight of their vehicles, and aluminum manufacturers are readying new products to meet their needs. Alcoa has announced the new Micromill process, which gives automotive-grade aluminum more strength and better formability for car design.

One of the most difficult parts of using aluminum in car designs is the ability to form the metal into desired shapes. Alcoa’s Micromill process increases formability by some 40%, allowing for far more leeway in the shape of individual panels. The new aluminum is also 30% stronger, making it more resistant to dents, dings, and scratches than the current grade of automotive aluminum, and the manufacturing process is faster too. This is accomplished by tweaking the microstructure of the aluminum itself, which is explained in more detail in the video below.

Though more expensive than traditional steel, aluminum can shave hundreds of pounds in weight off of larger vehicles. The 2015 Ford F-150 for example shed as much as 700 pounds by switching to aluminum, and aluminum helps keep the weight of the Tesla Model S under the 5,000 pound threshold (albeit barely in certain trims). But aluminum isn’t the only weight-saving contender on the market.

BMW has invested hundreds of millions into carbon fiber for the i3 and i8 plug-in vehicles, and has machinations of reducing production costs by some 90%. The steel industry is also scrambling to introduce newer, lighter, and stronger alloys that can still undercut the cost of aluminum while providing weight savings. There’s also the spectre of 3D printing looming over the entire manufacturing industry, which could change everything we know about automotive manufacturing.

For the immediate future though the prospects for aluminum are looking good, and Alcoa’s new Micromill process should only increase the appeal of aluminum to the auto industry.

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Tags: 2015 Ford F-150, Alcoa, aluminum, BMW, BMW i3, bmw i8, Micromill

About the Author

Christopher DeMorro A writer and gearhead who loves all things automotive, from hybrids to HEMIs, Chris can be found wrenching or writing- or esle, he’s running, because he’s one of those crazy people who gets enjoyment from running insane distances.

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