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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Maruti Suzuki India, the country’s largest passenger vehicle manufacturer, has announced the second phase expansion of its Integrated Traffic Management System (ITMS) in Gurugram under its corporate social responsibility initiative, allocating approximately INR 750 million to the project.

The expansion will see the installation of 1,000 additional radar-integrated cameras across 70 junctions and nine road stretches covering 65 kilometres in the city. Combined with the initial phase, which deployed 400 cameras across 23 junctions, the completed network will encompass 1,400 cameras across 93 junctions and 13 road corridors.

Implemented in partnership with the Gurugram Metropolitan Development Authority and the Gurugram Police, the automated system detects traffic offences including speed limit violations, red-light jumping, helmetless riding, triple riding and wrong-side driving. The camera units record registration plate details and transmit data directly to the Integrated Command and Control Centre for enforcement processing.

Sibash Kabiraj, Commissioner of Police, Gurugram, said, "We appreciate Maruti Suzuki’s continued support in strengthening Gurugram’s traffic management infrastructure through its CSR initiative. The expansion of the Integrated Traffic Management System will further strengthen our ability to monitor traffic violations, enable timely enforcement, and encourage greater compliance with traffic regulations."

P C Meena, CEO of the Gurugram Metropolitan Development Authority, said, "GMDA is committed to building a robust, technology-driven surveillance network to strengthen traffic management and road safety across Gurugram. The expansion of CCTV coverage in collaboration with Maruti Suzuki India Limited and Gurugram Police will enable more effective traffic monitoring, strengthen enforcement of traffic rules and promote greater road discipline. Connecting the CCTV network with GMDA’s Integrated Command and Control Centre will further enhance real-time surveillance, improve coordination among enforcement agencies and facilitate quicker action against traffic violations, contributing to safer roads for all commuters."

Rahul Bharti, Senior Executive Officer of Corporate Affairs, Maruti Suzuki India, said, "We are pleased to further strengthen our partnership with GMDA and the Gurugram Traffic Police in advancing road safety through technology-driven interventions. This advanced tracking system addresses issues like riding without helmets, triple riding, red-light violations, over-speeding, and wrong-side driving. These violations highlight a critical road-safety challenge, as human error continues to be the leading cause of road accidents in India. The findings reinforce the need for sustained, collaborative efforts to improve compliance with traffic regulations and foster safe road behaviour. Improving road safety requires a combination of responsible driving, robust driving license testing and effective traffic enforcement. We are committed to working alongside authorities in these areas to build a safer mobility ecosystem."

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Swedish automotive company Volvo Cars has expanded its technology partnership with NVIDIA to integrate the computing firm's Hyperion sensor and compute architecture into its next-generation vehicle platform.

The system combines Volvo's vehicle safety architecture with NVIDIA's hardware, Halos operating system and Alpamayo Stack driving software. The technology is designed to navigate highway environments, urban traffic and parking scenarios, laying the foundation for the gradual introduction of eyes-off and mind-off driving capabilities. The system will make its commercial debut in an upcoming production model as part of Volvo Cars' vehicle development roadmap.

Hakan Samuelsson, President and CEO, Volvo Cars, said, "Volvo has been synonymous with car safety for almost 100 years. By working with NVIDIA, we bring together two distinct strengths: industry-leading safety knowledge and world-class AI technology. That combination gives us a unique opportunity to create safer and more attractive cars for our customers."

Jensen Huang, Founder and CEO, NVIDIA, said, "Accelerated computing has transformed the car into an intelligent machine that can understand the world around it. Volvo has spent nearly a century protecting people on the road. Together, we’re combining Volvo’s extraordinary vehicle safety systems with NVIDIA Hyperion and Halos to build a new generation of cars that make driving safer and more effortless."

The agreement marks a continuation of the collaboration between the two companies, which established their initial development partnership in 2017. The deployment of NVIDIA's computing stack will support Volvo's transition toward software-defined electric vehicles across its global product lineup.

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French tier 1 supplier Valeo and open science research lab KE:SAI have launched a joint research collaboration to develop a generalist artificial intelligence (AI) driving system for autonomous vehicles. The partnership plans to publish models, code, weights and datasets as open-source resources.

The initiative brings together artificial intelligence teams from valeo.ai in Paris and the KE:SAI founding team in Tübingen, Germany. The collaboration focuses on training a unified AI model capable of operating across different vehicle platforms, sensor configurations and geographic environments. Initial development will utilise large-scale real-world driving data before integrating reinforcement learning within simulated environments to address rare driving scenarios.

KE:SAI was co-founded by research organisation Kyutai and the ELLIS Institute Tübingen. By making the underlying code, benchmarks and model weights accessible, the initiative aims to provide automakers, component suppliers and academic laboratories with a standardised reference system for autonomous driving research and development.

Marc Vrecko, CEO, Valeo Brain, said, "This open-science collaboration with KE:SAI marks a strategic milestone for Valeo and the broader European automotive ecosystem. By combining our deep industrial and technological expertise in autonomous driving with world-class open-source research, we are establishing a shared foundation to accelerate the development of physical AI and democratize next-generation self-driving technologies."

Andreas Geiger, CEO, KE:SAI, said, "For language models, open source compressed years of progress into months, yet frontier physical AI is still largely closed. Valeo shares our belief that open foundations create more innovation than any closed system ever could. Everything we develop will be open. Every step forward is a step forward for everyone."

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Researchers at Chalmers University of Technology, in collaboration with industry partners, have published a study in Nature Communications demonstrating that reconfigurable battery pack architectures can extend electric vehicle battery operational life by more than 20 percent under specific conditions.

In conventional electric vehicle battery packs, cells are wired in a fixed series configuration, meaning the weakest cell dictates the overall capacity, performance and lifespan of the entire pack. The architecture evaluated by the Chalmers engineering team uses integrated electronic switches and a centralised battery management system to monitor individual cells or cell groups. When a cell experiences accelerated degradation or reduced capacity, the system bypasses the degraded unit while electric current continues to flow through the remaining functional cells.

Albert Skegro, a PhD student at the Department of Electrical Engineering at Chalmers University of Technology, said, "They must all move at the pace of the slowest person and stop when that person stops, regardless of how much energy the others have left. With the architecture we have modelled, the battery can instead bypass the cell that is causing problems and continue using the remaining cells."

Changfu Zou, Professor at the Department of Electrical Engineering at Chalmers, said, "Reconfiguration is not an on-or-off choice. It is a spectrum. Where a manufacturer chooses to position itself on that spectrum determines how much of the potential benefit can be realised."

In a representative modelling scenario featuring an 80 kWh battery pack driven 12,000 kilometres annually over an 18.8-year vehicle lifespan, the reconfigurable system deferred battery replacement by approximately 14 months. The researchers noted that the technology yields the highest performance gains in high-voltage vehicles, including 400-volt and 800-volt electric passenger cars and commercial trucks, where higher cell counts in series increase the statistical probability of individual cell variance.

A techno-economic analysis included in the study determined that implementing cell-level switching hardware increases initial pack production costs by approximately nine per cent based on prototype-scale volumes of 1,000 units. The researchers identified an economic break-even threshold at a 12 percent cost increase, noting that volume manufacturing would lower component costs and increase financial viability for fleet operators and private owners. While prototype applications such as Volvo Cars' SmartCell concept and experimental road vehicles exist, mass-production vehicles using reconfigurable battery packs are yet to enter the commercial market.

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