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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Chinese technology company InfiMotion presented its latest electric drive technologies at the 5th International Forum on Automotive Power Systems held in Songjiang. The event gathered industry experts to discuss the theme of ‘dual carbon drive, diversified win-win.’

The company showcased a dual motor assembly featuring a magnesium aluminium alloy shell, which it identifies as a world first for mass production. The assembly uses a patented 360-degree bidirectional, full oil cooling technology for heat dissipation. According to the organisation, the magnesium aluminium alloy housing reduces weight by 25 percent compared to traditional aluminium versions while maintaining hardness, aiding vehicle range and energy consumption.

InfiMotion also showcased magnetic field adjustable motors, which is intended to reduce no-load drag losses and optimise power consumption.

Furthermore, it also displayed ultra-high speed motors capable of 36,000rpm for high-performance applications and 9-in-1 electronic control units designed to integrate power domain control and reduce drive weight.

During the forum, Xu Zhe, a technology expert at InfiMotion, delivered a speech titled ‘The Era Wave of Cross Integration of Electric Drive Calibration and Data Science.’

The presentation addressed the integration of product technology with data science during the research and development process.

The exhibition resulted in exchanges between InfiMotion and several domestic and international enterprises regarding the production and application of future power systems.

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Bengaluru-headquartered AI fleet safety and performance solutions company Netradyne has announced the acquisition of Moove Connected Mobility, a European fleet intelligence and mobility company with presence across European markets.

The acquisition is part of Netradyne’s expansion and its strategy for the European region. By combining Netradyne’s platform with Moove’s presence, customer relationships and experience, the company aims to serve customers across the continent.

Moove will join Netradyne Europe, serving as a hub for regional sales, customer engagement, partnerships and market development. This structure allows Netradyne to increase growth in Europe while remaining close to customers, regulators, and partners.

Avneesh Agrawal, CEO and Co‑Founder, Netradyne, said, “Europe is a critical pillar of our global strategy. This acquisition reflects a clear commitment to building long‑term presence, leadership, and trust in the region. By bringing together Moove’s local expertise and relationships with Netradyne’s AI platform, we are uniquely positioned to support European fleets at scale while staying deeply anchored in the region.”

Moove’s leadership team has experience in the European regulatory and operational landscape for mobility. Jeroen Bruinooge, Former CEO of Moove Connected Mobility, will become SVP & GM, Europe at Netradyne. He will lead the European strategy, partnerships and customer success.

The teams will focus on solutions to help fleet operators with safety outcomes, driver performance, and operational insights. The acquisition also increases Netradyne’s ability to support customers seeking a platform across North America, Europe, and Asia. This move is part of Netradyne’s mission to build an AI company with investment in the markets it serves.

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Italian technology company Brembo has announced that its intelligent braking platform, Sensify, has entered commercial production for a major global vehicle manufacturer. The system is being fitted as standard across the entirety of the vehicles in the initial programme, representing the platform's first full industrial deployment.

Sensify is designed as a fluid-free architecture that replaces centralised hydraulic circuits with distributed intelligence at the wheel level. This design allows for the precision control, wherein the system enables continuous and accurate modulation of braking forces to maintain vehicle stability in variable driving conditions. The platform integrates with software-defined vehicle architectures, allowing manufacturers to deploy advanced functions across different vehicle segments. It is engineered to be adaptable with the technology supporting a range of applications from driver assistance systems to fully autonomous vehicles.

Following this production milestone, Brembo has secured additional contracts with new customers for the Sensify platform. The company expects to equip hundreds of thousands of vehicles annually, moving toward large-scale deployment of by-wire braking systems.

Daniele Schillaci, CEO, Brembo, said, “Sensify translates our vision of an intelligent, integrated braking platform into industrial reality. Designed to orchestrate the entire corner ecosystem, it supports safer mobility, while paving the way for the next generation of software-defined vehicles, reflecting our long-term purpose of shaping a Zero Accident Future”.

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Bengaluru-based technology company Tsuyo Manufacturing has been granted two patents for electric vehicle motor designs, increasing its portfolio to 29 innovations.

The company claims it has supplied 300,000 powertrains to 25 manufacturers across the commercial vehicle, agriculture and industrial sectors.

The first patent covers a bridge design for synchronous reluctance motors. This architecture increases torque density and efficiency whilst reducing energy losses and the requirement for rare-earth materials. The second patent focuses on a five-phase permanent magnet motor using a dual inverter system. This technology allows the motor to switch between modes for startup and torque demands and maintains operation if a phase failure occurs.

These technologies were developed through research and collaboration with the Visvesvaraya National Institute of Technology, Nagpur. The company recently received approval from the Government of Karnataka for a manufacturing expansion to increase powertrain production.

Vijay Kumar, Founder and CEO, Tsuyo Manufacturing, said, "These patents mark a significant milestone and recognition in our mission to develop and promote Design-In-India technology for both domestic and global EV markets. At Tsuyo, we are not merely creating components; we are engineering a comprehensive design approach, crafting fundamental technology to drive sustainable and impactful innovation. Our goal is to offer a resilient powertrain system that addresses real-world performance challenges in electric mobility. Our commitment to deep-tech innovation, supported by a strong in-house R&D team and robust academic collaborations, enables us to challenge conventional construction and topology in hardware. This approach allows us to create niche, modular designs that are manufacturable and scalable, delivering solutions that enhance efficiency, reliability, and cost-effectiveness for OEMs. We take pride in being India's fastest research and engineering startup, consistently advancing our research from TRL1 to TRL9 levels. As India moves towards electrification, we are proud to contribute to the 'Design in India, for the world' vision while expanding our IP portfolio with numerous innovations in the pipeline."

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