Driving Innovation: Aluminum in Automotive Applications
As the automotive industry continues its push for lighter, more efficient, and environmentally responsible vehicles, aluminum has emerged as a material of choice. At Mill Steel Company, we supply high-quality aluminum solutions tailored to meet the evolving needs of OEMs, Tier 1 suppliers, and metal buyers across the automotive supply chain.
Why Aluminum?
Aluminum offers an exceptional strength-to-weight ratio, making it ideal for reducing vehicle mass without sacrificing structural integrity. In fact, according to the Aluminum Association, aluminum components can reduce vehicle weight by up to 50% compared to traditional steel parts. This directly contributes to improved fuel efficiency, better handling, and lower emissions.
Key Automotive Applications for Aluminum
Aluminum is now a staple across nearly every vehicle segment, from internal combustion engine models to electric vehicles (EVs). Here are some of its most common uses:
Body-in-White (BIW) Structures
OEMs are increasingly incorporating aluminum into the body-in-white structure to reduce curb weight while maintaining crashworthiness. Aluminum sheet and extrusion products are used in doors, hoods, trunk lids, and body panels.
Chassis and Suspension Components
Aluminum castings and extrusions provide lightweight yet durable options for suspension arms, crossmembers, knuckles, and subframes. This not only reduces unsprung weight but also improves ride performance and braking.
Powertrain & Drivetrain
Aluminum alloys are widely used for engine blocks, cylinder heads, transmission housings, and differential covers, providing both weight reduction and efficient thermal conductivity.
Electric Vehicle (EV) Platforms
Aluminum is crucial in EV development due to its heat dissipation properties and light weight. It's commonly used in battery enclosures, structural floor pans, and motor housings to enhance performance and range.
Common Grades & Tempers for Automotive Aluminum
At Mill Steel, we offer a broad range of aluminum alloys and tempers ideal for automotive manufacturing. Popular options include:
- 5000 Series (e.g., 5052, 5754) – Known for corrosion resistance and formability; often used in structural components and panels.
- 6000 Series (e.g., 6061, 6016) – Offers a strong balance of strength, corrosion resistance, and weldability; widely used in body and chassis applications.
- 7000 Series (e.g., 7075) – Extremely strong; used in high-performance or niche applications where strength is critical.
Each alloy is available in various tempers depending on your forming, welding, and finishing needs. Our experts can help you choose the right solution for your application.
What Metal Buyers Should Consider
When sourcing aluminum for automotive use, keep the following in mind:
- Application-specific requirements: Weight savings are important, but not at the expense of performance. Match alloy and temper to the specific part function.
- Surface quality: For exterior panels, surface finish and paintability matter. Mill Steel provides aluminum with tight surface controls for class-A finishes.
- Corrosion resistance: Especially important in structural and underbody components—choose alloys with proven resistance to road salts and moisture.
- Supply chain reliability: Work with a supplier who understands the demands of automotive timelines and can provide consistent, just-in-time delivery.
- Job size flexibility: Whether you're working on a major platform program or a low-volume specialty part, Mill Steel is committed to quoting the job. Even if your item isn’t forecasted to be a high-runner, we’ll review the specs and help you move forward with confidence.
Partner with Mill Steel for Automotive Aluminum
With expertise in aluminum processing, a nationwide distribution network, and a customer-first approach, Mill Steel is your trusted metal supplier. Whether you're producing EVs, commercial vehicles, or traditional passenger cars, we’ll help you find the right aluminum products to meet your design, budget, and production goals.
Let’s move the industry forward, together. Contact our aluminum specialists today to learn how we can support your next automotive program.
