Novelis, in collaboration with Sourced Economics, published a working paper via the Social Science Research Network (SSRN) on lightweighting vehicles with aluminum. Novelis’ Mario Greco, Global Technology Director, Automotive, and Kashif Solaija, Senior Manager, Sustainability and Commercial Excellence, Global Automotive, teamed up with Sourced Economics CEO John Frechette, and Head of Research Yifei Xu, to rigorously investigate and ultimately contribute to key academic and scientific literature on the economics of vehicle lightweighting. 

The working paper describes the characteristics of prevailing life cycle assessments (LCAs), which mainly forecast select life cycle costs associated with a change in a vehicle’s materials or design, and reviews notable examples. The goal of the paper is to introduce a richer framework for analyzing these decisions that emphasizes quantifying not only cost-based but also value-based considerations, such as improvements in vehicle performance. 

In its conclusion, the paper calls for a paradigm shift in automotive product planning focused on better analyzing and improving customer experiences – enabled by new and rapidly emerging data on customer preferences and demand. 

Read the full paper here: Link 

Please reach out to Kashif Solaija with any questions. 

A thought leadership piece by Daniel Kern, Vice President, Global Automotive Development, Novelis  

Traditionally, aluminum was reserved for luxury and high-performance vehicles. However, advancements in material science, recycling capabilities, and design innovation have transformed aluminum into a cost-effective and sustainable choice for all vehicle categories—from compact cars to SUVs and trucks. 

Electric vehicles (EVs) are transforming the automotive industry, but their significantly heavier weight—up to 500kg more than comparable internal combustion engine (ICE) models—poses unique challenges. Reducing weight is critical for improving performance, safety, and sustainability while meeting the evolving demands of consumers and regulators. 

Novelis recently participated in an insightful panel discussion hosted by Automotive World, alongside industry experts from Ricardo and Cranfield University, on ways to address these challenges. Moderated by Megan Lampinen, Editor-at-Large for Automotive World, the webinar explored: 

Dr. Daniel Kern, Vice President of Global Automotive Development at Novelis, shared Novelis’ lightweighting strategies for EVs and insights into the future of sustainable mobility. 

The recording of this engaging webinar is now available! Watch it here. 

Join the conversation and discover how Novelis is driving the future of sustainable automotive solutions here: Automotive – Novelis. 

16th January 2025 | 4 PM CET | 7 AM PDT | 10 AM EDT

Electric vehicles (EVs) are the future of mobility, but their weight—up to 500kg more than comparable internal combustion engine (ICE) models—presents significant challenges for manufacturers, like the need for larger batteries, to achieve acceptable driving ranges, which further increases vehicle weight and cost.  

How can automakers address the critical weight issue while balancing cost, safety, and environmental impact? 

Join us for an engaging 60-minute webinar featuring leading experts in EV lightweighting as they explore innovative strategies to reduce vehicle weight and drive the development of more efficient and sustainable EVs. 

What You’ll Learn: 

Meet the Panelists: 

Don’t miss this opportunity to gain critical insights into the future of EV lightweighting! 

Register Now Microsoft Virtual Events Powered by Teams 

As the automotive industry navigates the crossroads of electrification, sustainability, and consumer preferences for vehicles that are more efficient, safer, and environmentally friendly, one thing is clear: the future of mobility requires a new approach to vehicle design. At Novelis, we believe that aluminum is the key to unlocking a lighter, greener, simpler, and safer future for automakers and their customers.

Novelis, in collaboration with Sourced Economics, is advancing the conversation on sustainability in the automotive industry. In a recent article published in Inbound Logistics, Novelis experts Mario Greco, Global Technology Director of Automotive, and Kashif Solaija, Senior Manager Sustainability and Commercial Excellence, Global Automotive, joined Sourced Economics CEO John Frechette to explore how businesses can pinpoint and quantify the commercial value of green initiatives. 

The article outlines innovative modeling techniques to integrate environmental performance into product design and business strategy. It highlights research on consumer willingness to pay for sustainable features and provides actionable insights into prioritizing sustainability investments for maximum impact. 

This collaboration underscores Novelis’ commitment to driving data-driven sustainability solutions and fulfilling our purpose of Shaping a Sustainable World Together. 

Read the full article in Inbound Logistics

When Li Auto set out to design its first fully electric, multi-purpose vehicle (MPV), the Li MEGA, the Beijing-based automotive start-up aimed to push the boundaries of technology to increase battery range and enhance the driver experience. To achieve this ambitious goal, Li Auto needed a partner with expertise in lightweight materials and advanced engineering solutions. Enter Novelis.

The Partnership Begins

Li Auto partnered with Novelis’ Customer Solution Center in Shanghai, marking the start of a dynamic collaboration. Together, the two teams set out to incorporate Novelis’ lightweight aluminum solutions into nine critical parts of Li Auto’s premium model.

Innovative Solutions

One of the standout features of the Li MEGA is its use of Novelis Advanz™ 6HS-s650, a custom-made alloy designed for structural applications that demand high in-service strength and superior crash performance. This innovative material contributed to an 11% weight reduction compared to the original aluminum design.

Technical Excellence in Production

Novelis’ involvement didn’t stop at the design phase. We provided extensive technical support during the production phase of the Li MEGA. Our expertise in mixed-material construction and joining technologies was invaluable in bringing the vehicle to life. Members of Novelis’ Customer Solution Center worked closely with the equipment supplier to determine the optimal process parameters for stud-welding s650 crash parts on the vehicle’s underbody.

Through numerous welding tests conducted both in the lab and on the production line, the teams from Li Auto and Novelis achieved high-quality stud welding, a crucial factor in the successful mass production of the Li MEGA.

A New Benchmark in Electric Vehicles

The collaboration between Novelis and Li Auto on the Li MEGA has set a new benchmark in the electric vehicle industry. By leveraging Novelis’ advanced aluminum solutions and technical expertise, Li Auto was able to develop a vehicle that not only delivers exceptional performance and safety but also enhances the overall driving experience through innovative design and lightweight construction.

This partnership showcases the power of collaboration and innovation in driving the future of sustainable mobility. The success of the Li MEGA is a testament to what can be achieved when industry leaders join forces to push the boundaries of what is possible in automotive design and engineering.

Learn more about how Novelis is shaping the future of sustainable transportation through groundbreaking partnerships and innovative solutions.

As the automotive industry increasingly shifts toward electric vehicles (EVs), the challenge of recapturing aluminum from end-of-life vehicles has become more critical. With aluminum’s lightweight, sustainable properties, the industry is searching for ways to efficiently recycle high-value alloys without downgrading their quality. Traditional methods often lead to downcycling, mixing various alloys together, and reducing their overall value.

In a new blog, Daniel Kern discusses industry-wide solutions, including innovative scrap sortation and segregation technologies that enable the recovery of specific alloys. These advancements, combined with new uni-alloy designs and collaboration across the supply chain, offer promising pathways to improve recycling processes and create a more sustainable future for automotive aluminum.

Read the full blog for insights on the industry’s path forward.

Aluminum, which is much less dense than steel, is rapidly becoming the material of choice for automakers looking to create smarter, lighter, safer, and more sustainable vehicles. Compared to steel, an aluminum vehicle body can be up to 45% lighter while maintaining equal stiffness and load-carrying capacity. This significant weight reduction offers numerous advantages, especially as the automotive industry shifts toward electrification. 

Alumobility , an organization dedicated to advancing the use of aluminum in the automotive industry, recently published a compelling white paper titled “When it Comes to Aluminum, Less is More” in Aluminum International Today. This article highlights eight major reasons why aluminum is the material of the future for automakers. The benefits detailed include improved efficiency and range, secondary weight and cost savings, enhanced safety, increased vehicle durability, reduced corrosion, greater payload and towing capacity, manufacturing efficiency, and better circularity through recycling.  To explore these advantages and understand how aluminum is revolutionizing the future of mobility, read the full Alumobility article here.

We are excited to announce that Novelis has been shortlisted for the prestigious World Sustainability Awards 2024 for our entry “Novelis Partners with OEMs for Closed-Loop Recycling” in the Sustainable Technology Provider Award category. This recognition celebrates our commitment to sustainability and innovation in the aluminum industry.

Overview of the Entry:

Novelis, the global leader in aluminum recycling and a key supplier to the automotive industry, has established groundbreaking, closed-loop-recycling partnerships with several major automakers. These partnerships allow us to reclaim and recycle aluminum scrap generated during OEMs’ manufacturing processes, turning it back into high-quality aluminum sheets for new vehicle production.

The Challenge:

The automotive market presents unique challenges in recycling. Traditionally, automakers sold their aluminum scrap to recyclers, leading to inefficiencies and unnecessary costs. This process often downgraded the high-value aluminum scrap, preventing it from being reused in new automotive parts.

Our Approach:

Recognizing these inefficiencies, Novelis develops innovative closed-loop recycling systems in collaboration with automakers. These systems ensure the highest value use of aluminum scrap, maintaining the integrity of high-value aluminum sheets and reducing carbon emissions.

Outcome:

As the world’s largest recycler of aluminum, Novelis leverages the infinite recyclability of aluminum to deliver sustainable solutions. Recycling aluminum uses only 5% of the energy required to produce primary aluminum, reducing carbon emissions by up to 95%. Our closed-loop-recycling partnerships help automakers reduce their environmental impact, meet regulatory requirements, and appeal to eco-conscious consumers.

About Novelis:

Novelis is the leading producer of flat-rolled aluminum products and the world’s largest recycler of aluminum. We partner with customers in the automotive, beverage packaging, aerospace and specialties industries to deliver sustainable solutions across North America, Europe, Asia, and South America. Headquartered in Atlanta, Georgia, Novelis operates 31 facilities in nine countries and employs approximately 13,190 people. Novelis is a subsidiary of Hindalco Industries Limited, the metals flagship company of the Aditya Birla Group.

Our Commitment to Sustainability:

At Novelis, sustainability is at the core of everything we do. We work closely with our customers to leverage aluminum’s unique properties, delivering solutions that meet their needs and create a more circular economy. Our expertise in closed-loop recycling and our ability to partner with industry leaders enable us to drive sustainability forward.

We are honored to be shortlisted for the World Sustainability Awards 2024 and look forward to continuing our journey toward a more sustainable future.

Read more about our sustainability efforts here.