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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Renault India has entered a partnership with the Indian Institute of Technology (IIT) Kanpur to conduct vehicle research and development. The collaboration will see Renault India use the National Wind Tunnel Facility (NWTF) at the institute for aerodynamic and wind-noise testing of its vehicles.

The NWTF is equipped with a test section measuring 3.0 m x 2.25 m, capable of speeds between 80 kmph and 280 kmph. It is currently being upgraded to support speeds above 400 kmph.

Dr. Vikraman V, Chief of Engineering, Renault Group India, said, "This partnership marks an important step in strengthening Renault's engineering capabilities in India. By collaborating with IIT Kanpur and leveraging the National Wind Tunnel Facility, we are bringing together world-class research infrastructure and Renault's global engineering expertise to develop futuREady vehicles. This collaboration also reflects India's growing importance within Renault's global innovation and engineering ecosystem."

Prof. Dr. Alakesh Chandra Mandal, Department of Aerospace Engineering & Co-Ordinator, NWTF, said, "We are pleased to partner with Renault India in advancing automotive research and development. This collaboration highlights the versatility of the National Wind Tunnel Facility and represents an important opportunity to extend our expertise beyond aerospace applications to support innovation in the automotive sector."

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Sun Mobility has introduced a modular multi-battery swappable solution for heavy electric vehicles, showcased on the Tata Starbus 12m EV platform at the Prawaas 5.0 exhibition in Gandhinagar.

The system aims to address barriers to fleet electrification, such as charging downtime and upfront vehicle costs. It enables the simultaneous swapping of two batteries in under five minutes. The architecture supports 50 kWh and 100 kWh configurations and is compatible with vehicles ranging from 3T to 55T gross vehicle weight. Through a Battery-as-a-Service (BaaS) model, operators pay for energy consumption rather than purchasing the battery pack.

Chetan Maini, Co-Founder and Chairman, Sun Mobility, said, "When we founded Sun Mobility, our vision was to make electric mobility as convenient, scalable, and economically viable as conventional transport by reimagining energy infrastructure. The unveiling of the world's first Modular Multi-Battery Swappable Solution demonstrated with Tata Starbus EV at Prawaas 5.0 marks a defining milestone in that journey. We believe the modular multi-battery swapping solution has the potential to unlock large-scale electrification across the commercial vehicle ecosystem by delivering a cost-effective and operationally efficient energy solution for diverse applications. As India accelerates its transition to clean mobility, technologies designed and built here can not only transform commercial transportation at home but also position India as a global leader in next-generation electric mobility solutions."

Ashok Agarwal, CEO, Sun Mobility HEV, added, “The next phase of electrification will not be defined solely by vehicles, but by the energy ecosystems that power them. Our showcase of World’s first Modular Multi-Battery Swappable Solution on the Tata Starbus EV platform demonstrates how one battery swapping platform can serve staff, city transit, and intercity fleets alike, without compromising on affordability or operational reliability. We see this as a real step towards mass adoption of EVs in commercial transportation.”

The system operates on an intelligent network that tracks battery health, location and energy usage. It also utilises a digital twin platform to support predictive maintenance and fault diagnosis. The technology is developed in-house and is intended to be OEM-agnostic, supporting bus and truck segments from 7 to 13.5 metres and 3T to 55T gross vehicle weight.

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LICO Materials and Ather Energy have announced a partnership to establish a system for the collection and recycling of lithium-ion batteries.

Under this agreement, end-of-life batteries from Ather’s electric two-wheelers will be processed at LICO Materials' facility in Karnataka. The recovered materials will then be reintroduced into the battery supply chain for use by cell manufacturers and vehicle producers.

The initiative aims to address the recovery of materials including lithium, nickel, cobalt, graphite and copper. LICO Materials states that its facility can achieve recovery rates of up to 95 percent.

Gaurav Dolwani, CEO, LICO Materials, said, "India is building one of the world's largest EV fleets and it is doing without domestic reserves of the minerals that power it. That is a structural vulnerability, and battery circularity is the only answer. This partnership means those batteries can be recycled and recovered minerals can be fed into the battery supply chain. We believe this is how India can reduce its dependence on imported critical materials.”

This collaboration aligns with the Battery Waste Management Rules 2022, which require extended producer responsibility within the electric vehicle industry. By recycling battery materials, the companies intend to reduce reliance on imported minerals and support India’s commitment to reach net zero emissions by 2070.

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Bengaluru-based deeptech start-up Vimag Labs has been granted a patent in India for its Virtual Magnet Synchronous Motor (VMSM) platform titled ‘A Robust Rotating Transformer Excited Synchronous Motor and Its Control’, which protects the architecture of the motor that does not require magnets.

The VMSM platform uses power electronics and algorithms to control its magnetic field. Vimag Labs claims that the motor functions without the rare-earth magnets typically found in permanent magnet motors. This is the 5^th patent granted to the company, which also has ten patents pending and 15 trademarks filed.

The company is conducting pilot programmes with manufacturers of two-wheelers and passenger cars. Future expansion plans include light commercial vehicles, commercial vehicles and industrial systems.

Manish Seth, Co-Founder and CEO, Vimag Labs, said, “This patent is the outcome of over 87,600 engineering hours. It strengthens every dimension of our commercial roadmap- OEM partnerships, licensing, manufacturing scale-up, and future growth. Our long-term vision is to build scalable, software-driven, magnet-free motor systems for global electrification. This innovation strengthens India’s deep-tech base across electric mobility, power electronics, robotics, defence, and clean-energy systems.”

Vimag Labs recently raised USD 5 million in a Series A funding round led by Accel, with participation from Chakra Growth Fund and Thinkuvate. The company has also signed a manufacturing memorandum of understanding with Jendamark.

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