Currently, India’s foundry market for automotive components is small (only 10 percent of total foundry market — 10 million of cast iron + aluminium) in comparison to USA’s foundry market, which is at 14 million tonnes per annum, of which 3.3 million is aluminium (24 percent). With an increasing focus on higher performance with better safety and lower emission, this gap is going to shrink in the coming years, anticipates Ajay Kapur, CEO – Aluminium & Power Business, Vedanta Aluminium.

“There is immense scope for Indian aluminium producers to tap into the emerging market in the automotive sector,” said Kapur. Vedanta Aluminium was the first in India to supply PFA (primary foundry alloy) to the domestic auto sector. Before, the launch of PFA by the company, India’s entire PFA demand was being met through imports, even though the country has the world’s second-largest aluminium production capacity. Looking at the potential of the auto market and its import dependency, the company decided to tap into the opportunity and develop indigenous capabilities at its state-of-the-art facilities in Jharsuguda and BALCO to meet that demand. Currently, the company has a PFA casting capacity of 240KT spread across its plants in Odisha and Chhattisgarh.

“Primary aluminium producers develop PFAs which are customised to suit the exact needs of automakers in terms of performance, strength, durability, etc. Significant R&D and technical expertise go into developing PFAs, resulting in excellent metal quality and outstanding castability, which makes these alloys the preferred choice for the automotive industry,” explained Kapur. PFAs are ideal for aluminium alloy wheels, cylinder heads and brakes. The company also anticipates that with an increased focus on reduction of vehicle weight with higher safety performance, automotive parts critical to safety will be made from PFA instead of cast iron to offer higher strength and nearly double absorption of crash energy. “Besides, aluminium PFAs will always have the added advantage of cost-saving on fuel and maintenance,” added Kapur.

Vedanta Aluminium has started steadily supplying PFAs to OEMs and ancillaries in wheel manufacturing in India. “Our proactive move to expand business on this front helped us on-board some of the most reputed equipment manufacturers and auto ancillaries as our clients, and we have received a very positive response from them. Encouraged by that, we will soon look to expand our alloy portfolio for supporting manufacturing of cylinder heads, ABS brakes and certain key applications where traditional materials can easily get substituted with aluminium alloy. We are also exploring prospects of long-term investments by auto ancillaries near our aluminium smelters so that they may leverage cost savings in terms of freight, re-melting and electricity,” said Kapur.

The company, according to him, is well-positioned to cater to the current and emerging needs of the Indian auto sector, offering a broad range of products that find usage across the automotive value chain – from casting to extrusion. “When choosing suppliers for alloys, automotive players should look for companies having high-quality casting facilities, sophisticated R&D facilities and technological prowess for developing customised high-performance alloys for their specific needs, and finally, having robust after-sales technical support; USPs that have earned us the trust of our clients,” he added.

Aluminium is the second most used metal in the world after steel, today, and, according to Kapur, it has the potential to become the most important commercial metal in the future. “Most developed countries have already designated aluminium as a core industry. Aluminium holds strategic importance for the economy as the metal of choice for all kinds of transportation, power, aerospace, defence, building and construction needs. So, given the role it plays in supporting the core sectors meet the Government’s ‘Make in India’ initiative, we expect its application to only expand with time,” said Kapur.

The metal’s usage in the transportation sector has been rapidly increasing as it offers an environment-friendly and cost-effective way to increase performance, boost fuel economy and reduce emissions while maintaining or improving safety and durability. Aluminium is substantially lighter than its counterparts, offering a significant reduction in weight, which has a direct impact on fuel consumption and carbon emissions.

The metal also has a higher strength-to-weight ratio compared to traditional materials that enable it to absorb twice the crash energy of mild steel, ensuring that vehicular performance enhancements do not come at the cost of safety. “Further, nearly 90 percent of all the aluminium used in a vehicle is recycled at the end of its lifecycle. The energy required to recycle aluminium is only five percent of the energy required to produce the metal. With all these advantages, aluminium can play a pivotal role in the changing face of the automotive sector,” said Kapur.

Aluminium alloys are used by the Indian auto industry majorly as alloy wheels. Around 95 percent of two-wheelers include aluminium, averaging at 7kg per bike, taking total consumption of aluminium alloy in this segment to 115KTPA (kilo tons per annum). Whereas, only 20 percent of four-wheelers use aluminium, majorly in high-end models, which max out at 40kg per car. “The crux of the matter is, in India, we are yet to explore more applications of aluminium in the automotive industry akin to our global peers. For example, in developed countries, around 21 PFAs are used in the automotive segment to achieve light-weighting in the form of various auto parts and components. In India, we majorly use PFAs only for manufacturing alloy wheels and to some extent, for cylinder heads. So, there is immense potential for usage of aluminium in other auto parts like engine, suspension, front end carrier, instrument panel support, rear frame, chassis and many more,” said Kapur.

Shortly, the company expands its alloy portfolio for supporting manufacturing of cylinder heads, ABS brakes and certain other applications where currently steel or iron is being used but can be substituted by suitable aluminium alloys to provide additional benefits. As the market for aluminium alloys in automotive segment expands with inclusion of newer applications, Vedanta Aluminium will look for opportunities to leverage its technological expertise and R&D capabilities to develop products customised to the needs of the market. Vedanta Aluminium is also open to collaborating with the downstream industry, to unlock the entire potential of aluminium used in the auto sector and cater to the rapidly evolving aluminium requirements of the Indian automotive industry.

In the Indian automotive market, one of the biggest challenges faced today is the increasing imports of auto components from China and other countries. The size of the auto components imports was USD 17.6 billion in FY19. Asia, the largest source of imports for Indian auto-components, had a share of 61 percent followed by Europe at 29 percent; North America at eight percent; Latin America and Africa at one percent each in FY19. China, with 27 percent, enjoyed the status of the largest exporter in the Indian automotive market.

“The potential of the aluminium industry should be acknowledged and recognised as a core sector with a National Aluminium Policy that will encourage, protect and boost the domestic aluminium industry. The domestic capability needs to be harnessed for critical sectors of national importance like defence, aerospace, aviation, transportation, infrastructure, electrification, housing, etc. We must make the vision of ‘Make in India’ a ground reality in these sectors, leveraging the potential of the entire aluminium value chain, from mining to end usage. Besides enhancing domestic capacity and reducing import dependency and subsequently trade deficit, it will also generate huge employment opportunities in our country which has a deep talent pool that needs to be capitalised for the realisation of our vision of a USD5 trillion economy. We are on the right path, but there is still a long way to go,” said Kapur.

The global economy is swiftly moving towards a cleaner, greener and more sustainable lifestyle. For more than a decade now, concerns about fuel efficiency have encouraged OEMs to replace steel with aluminium in vehicle bodies, doors, trunks, hoods, bumpers, crash boxes, brakes and wheels. With the advent of electric vehicles (EV), OEMs worldwide are focusing on exploring and applying new uses of aluminium. The need for lightweight battery casings and heat exchangers in electric vehicles, combined with autonomous vehicles’ demands for high visibility and structural integrity, is expected to exponentially increase the use of aluminium in cars, trucks and buses from now on. “Using aluminium in EVs has several advantages, foremost amongst which is the distance travelled per charge. Lighter the vehicle, the longer its range. Coming to better battery life, thanks to the metal’s thermal and anticorrosion properties, aluminium is ideal for battery frames. Demand for aluminium will also rise on account of infrastructure for serving EVs since the metal is commonly used as a housing material for EVs charging stations as well. While India is waking up to this future of automobiles, partnerships between different automotive industry bodies/institutions and auto companies for sharing knowledge and expertise will help fast-track development of electric vehicles in the country,” said Kapur. MT

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Marquardt, a supplier of mechatronic systems, has launched a concept vehicle, ‘The Centum’, to demonstrate the integration of functional controls into automotive surfaces. The project involved a collaboration with E Ink and Covestro to develop a door interior panel that embeds a responsive display within synthetic materials.

The project aimed to maintain the tactile properties of polyurethane (PU)-coated textiles while enabling a colour-changing display to remain invisible until activated. This supports industry trends toward backlit surfaces and integrated control elements.

The display technology uses E Ink, which provides a low-energy, durable electronic paper display designed for automotive environments. For coating, Covestro has developed a transparent film using INSQIN waterborne PU technology. The coating uses Impranil DLC-F, a waterborne polyurethane dispersion used in automotive topcoats.

The resulting material retains the texture of standard automotive textiles while allowing the underlying display colors to remain visible through the coating.

Felix Hake, Head of Innovation, Marquardt, said, “With The Centum, we wanted to demonstrate how intelligent functions can be integrated into interior surfaces without compromising design or quality. Working with E Ink and Covestro allowed us to create a material solution that combines a premium tactile experience with responsive visual effects.”

Dr Torsten Pohl, Global Head of Textile Coatings, Covestro, added, “This project highlights the versatility of INSQIN PU technology and Impranil DLC-F. By developing a transparent, automotive-grade PU coated synthetic compatible with E Ink displays, we were able to support Marquardt in integrating dynamic functionality into familiar surface materials.”

Pete Valianatos, Senior Director, E Ink, said, “Our e-paper display technology is designed to deliver dynamic visual experiences with low power consumption, while maintaining the robustness required for demanding applications. Collaborating with Marquardt and Covestro has enabled us to demonstrate how E Ink displays can be integrated behind coated interior surfaces, allowing automotive designers to introduce adaptive colour features without changing the established look and feel of premium materials.

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Yazaki Innovations Inc (YII), the technology subsidiary of Yazaki Corporation, has announced the appointment of Manish Mehta as its new CEO and President.

Mehta has been a long-time associate of Yazaki Corporation and has spent over two and half decades with the organisation. He had joined the company as an Engineer Manager in 2001, and grew to the ranks of Vice-President Corporate Planning and Strategy in 2021.

He joined the company’s board of directors in 2023, and is now responsible for leading YII, which focusses on the integration of the parent company’s global product portfolio, manufacturing assets and product development with an approach to innovation.

The subsidiary is tasked with developing technologies across several industrial and transport segments. Its remit includes the engineering and development of solutions for the following areas:

• Mobility: Electric vehicles, autonomous vehicles, and Electric Vertical Take-off & Landing (eVTOL) aircraft.
• Industrial & Infrastructure: Aerospace, construction and agriculture equipment and PreFab Home Wiring.
• Specialised Engineering: Off-road and specialty vehicles, alongside advanced manufacturing processes.

The organisation aims to combine Yazaki Corporation’s business assets with a methodology designed to address trending technologies in these sectors.

"I am pleased to announce my new role as CEO & President of Yazaki Innovations Inc (YII). Yazaki Innovations is the disruptive technology subsidiary of Yazaki Corporation, integrating the best attributes and strengths of the company’s global product portfolio, product development, manufacturing, and business assets with a quick, agile approach to innovation. This is an exciting opportunity, and I look forward to collaborating with internal and external partners to contribute to the future growth of Yazaki," said Mehta.

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TSUYO Manufacturing Pvt Ltd has appointed Naveen Kumar Amar as Senior Vice President of Finance, effective 1 April 2026. Recognised as a global finance power leader, Amar brings over 20 years of expertise in financial strategy, corporate governance and operational efficiency within capital-intensive industries. His arrival marks a strategic move as the company accelerates growth in the EV powertrain sector.

Before joining TSUYO, Amar was CFO at SpiceXpress, where he led financial restructuring, cost optimisation and drove digitisation projects. He also managed international and domestic fundraising across equity and debt. At TSUYO, he will oversee financial planning, capital allocation, and governance as the company scales manufacturing and deepens EV powertrain investments.

The company recently secured Single Window Clearance from Karnataka Government for a proposed 20-acre EV Powertrain Campus in the Dharwad–Hubli region, a hub for design, testing and production. Last month, TSUYO launched next generation electric motor technologies for India’s light commercial vehicle market, emphasising modular design, deep engineering and Make in India innovation.

The leadership team welcomed Amar, stating his appointment strengthens alignment of capital strategy with long term objectives. TSUYO is also investing in advanced manufacturing infrastructure and localisation of key EV components to reduce import reliance and bolster the domestic EV ecosystem.

Amar said, “I am excited to join Tsuyo at a crucial moment in its growth journey, as the company scales its manufacturing capabilities and strengthens its position in India’s evolving electric mobility ecosystem. With experience across diverse, capital-intensive sectors, I see immense opportunity in building a financially disciplined, execution-focused organisation that can sustain high growth over the long term. The company’s focus on the convergence of deep technology, localisation and large-scale manufacturing presents a unique platform for creating enduring value. I look forward to partnering with the leadership team to enable Tsuyo’s ambition of becoming a globally acclaimed EV powertrain company."

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German automotive luxury brand Audi has launched the new RS 5, featuring a high-performance plug-in hybrid system and a rear transaxle equipped with electromechanical torque vectoring. Marketed as quattro with Dynamic Torque Control, this system manages transverse torque distribution between the rear wheels within 15 milliseconds.

The system enables torque shifts between the rear wheels regardless of the power applied. Unlike mechanical equivalents, it operates during throttle application, off-throttle states and under braking.

It features a High-Voltage Actuator that uses a water-cooled permanent-magnet 400-volt electric motor providing 8 kW and 40 Nm of output. Overdrive Gears components use actuator torque to transfer differences of up to 2,000 Nm to the driveshafts.

The differential consists of a conventional unit with a low lock percentage that distributes applied torque to the left and right shafts.

The technology is designed to reduce understeer and oversteer by directing torque to the wheel with the most grip. If the vehicle begins to oversteer in a bend, the system increases torque at the inside wheel to provide stability. Conversely, it reduces torque at the inner wheel to prevent understeer, redirecting power to the outer wheel for traction.

Control is centralised via the HCP1 (High-Performance Computing Platform), which harmonises driver inputs with environmental data. This platform interprets steering intentions to provide unfiltered transfer to the wheels.

• Electromechanical torque vectoring at the rear axle works in conjunction with front-axle supports:
• Electronic Differential Lock: Enhances front-axle traction via the brakes.
• Brake Torque Vectoring: Provides additional front-end assistance.
• Adaptive Shock Absorbers: The twin-valve units are calibrated with the rear transaxle to improve throttle response and corner entry.

The system allows for customisable driving characteristics through various drive select modes, ranging from a balanced setup to a rear-biased configuration. Audi states the ‘fixed coupling’ of this electromechanical solution ensures torque distribution remains independent of drive torque, a distinction from clutch-based torque splitters.

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