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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Aptiv has announced that Volvo Cars has awarded its Gen 8 radar platform for deployment in future vehicle programs, with production scheduled to begin in 2028.

The partnership centres on enhancing the perception capabilities of Volvo’s Advanced Driver Assistance Systems (ADAS) as both companies shift toward software-defined architectures.

The Gen 8 platform is Aptiv's latest advancement in high-resolution sensing, utilising proprietary antenna and silicon designs to support AI-powered and machine learning-powered safety functions.

Key Capabilities of the Gen 8 Radar Platform:

• High-Resolution Perception: Superior angular measurement and discrimination allow the system to resolve complex driving scenarios with high precision.
• Environmental Robustness: Engineered to maintain high performance in adverse weather and challenging urban environments where traditional sensors may struggle.
• Sensor Fusion Optimisation: Designed for seamless integration with cameras and other perception layers, providing a more reliable "world model" for the vehicle's computer.
• Scalability: A modular architecture that allows Volvo to deploy the technology across various vehicle lines and global markets efficiently.

Alwin Bakkenes, Head of Software Engineering at Volvo Cars, said, “Volvo Cars has always been guided by a belief that safety should be designed around people and real‑world driving conditions. Aptiv’s Gen 8 radar platform helps us deliver even more robust perception capabilities to our advanced driver assistance systems across increasingly complex environments and driving scenarios.”

Matthew Cole, Senior Vice President, Sensors & Compute at Aptiv, added: “Volvo Cars’ commitment to protecting people inside and outside the vehicle has set the benchmark for automotive safety. Aptiv’s Gen 8 radar was designed with that same purpose in mind: delivering dependable, high-resolution perception that performs in a wide range of use cases and environmental conditions. We’re proud to support Volvo Cars as they continue advancing their safety ambitions across future vehicle programs.”

The collaboration reinforces Volvo Cars' long-term safety mission – aiming for a future with zero accidents, while positioning Aptiv as a primary technology partner in the evolution of intelligent, software-led vehicle safety systems.

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Mercedes-Benz has announced a strategic partnership with the German low-code automation provider n8n to roll out a global platform for AI-powered workflows.

The initiative is designed to move AI beyond isolated pilot projects and integrate it into everyday operations across R&D, production, sales, HR and IT.

The partnership emphasises digital sovereignty, with Mercedes-Benz utilising n8n’s self-hosted, cloud-agnostic model to maintain strict control over its data and processes within a European technology ecosystem.

The strategy categorises employees into ‘Takers’ (users), ‘Makers’ (who design workflows via n8n) and ‘Builders’ (who develop advanced software). The goal is to empower ‘Makers’ to actively shape AI-driven processes without deep coding knowledge.

n8n will act as the ‘glue’ in the Mercedes-Benz technology stack, connecting existing systems and enabling the deployment of AI agents that can resolve issues and make data-driven decisions autonomously.

The rollout follows a massive company-wide hackathon involving over 1,500 participants. The most successful use cases from this event are currently being transitioned into full-scale operational implementation.

Katrin Lehmann, Chief Information Officer, Mercedes-Benz, said, “Scaling AI takes more than technology, it’s about putting it to work in our core business. Together with n8n, we make it easy for our teams at Mercedes-Benz to turn ideas into measurable impact across our value chain and to actively shape how we operate.”

Jan Oberhauser, Founder & CEO, n8n, added, “What we are building together with Mercedes-Benz answers the question of how to move AI from pilot to production at a scale few can achieve.”

By adopting a modular and flexible low-code architecture, Mercedes-Benz aims to increase its ‘innovation velocity.’ The n8n platform allows the company to rapidly iterate on automation ideas while ensuring that the resulting workflows are governed, scalable and integrated with the brand's broader AI ecosystem. This move reinforces Mercedes-Benz’s commitment to an open, software-defined architecture as a primary factor in industrial competitiveness.

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The OPEN Alliance, a leading industry consortium, has issued a call for greater strategic alignment across the automotive sector to unlock the full potential of ‘automotive ethernet’.

According to the newly released Automotive Ethernet – Architecture Change Drives Growth report from Tech Insights, vehicle Ethernet ports are projected to triple from approximately 962,000 sockets in 2025 to 3.42 million by 2032.

Despite this rapid growth, the analysis highlights a significant ‘adoption gap’. A small group of advanced Original Equipment Manufacturers (OEMs) currently installs 4.5 times more Ethernet ports per vehicle than the market average, leading to high variability in maturity levels across different regions and manufacturers.

The report predicts that the average number of Ethernet sockets per vehicle is forecasted to rise from 11 in 2025 to 27 by 2030. While 100BASE-T1 remains common, its share is declining, 1000BASE-T1 is expected to become the dominant speed grade by 2030 to support high-bandwidth backbones.

The demand for 10BASE-T1S is gaining traction in body and infotainment domains, while 2.5GBASE-T1 is being adopted for advanced sensors and cameras. Time Sensitive Networking (TSN) is projected to underpin nearly 50 percent of all Ethernet-equipped vehicles by 2030.

Suma Prabhakara, President, OPEN Alliance, said, “Automotive Ethernet is set for rapid yet uneven growth as new architectures, higher sensor bandwidth and emerging applications drive a near-tripling of Ethernet sockets in vehicles by 2032. As regions like China grow in overall socket share but remain internally fragmented, the OPEN Alliance’s role in reducing variability and accelerating consistent, standards‑based adoption becomes even more important. We encourage OEMs and suppliers to align with our work and share their implementation experience.”

The report warns that fragmented strategies – where different OEMs use divergent implementation methods – risk keeping the cost of developing autonomous driving and next-generation systems ‘unnecessarily high.’

The OPEN Alliance advocates for the use of its standardised test suites to ensure interoperability and prevent costly integration delays.

Additionally, the report identifies geopolitics as the top risk factor for market stability. It also notes that SERDES (Serialiser/Deserialiser) technology will continue to grow alongside Ethernet rather than being displaced by it, as vehicles require a mix of high-speed data protocols to support complex sensor suites.

Samuel Sigfridsson, OPEN Alliance Board Member, added, “The industry cannot afford fragmented approaches. Tested, standards-based implementation will prevent the costly divergence that slows innovation.”

Representational image courtesy: Pexels/AmmyK

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Bengaluru-headquartered L&T Technology Services (LTTS), a global leader in AI and Digital Engineering R&D, has entered into a strategic global partnership with Emerson, a global automation leader.

The strategic collaboration aims to accelerate system integration and product development across the industrial, transportation, semiconductor & aerospace and defence sectors.

Under the agreement, LTTS will act as a global System Integrator and technology development partner for Emerson’s NI (National Instruments) test and measurement platform. The partnership focuses on architecting software-defined, data-centric engineering environments that enhance system performance and sustainability.

As part of the understanding, LTTS will establish a dedicated CoE at its Mysuru campus in India. This hub will leverage NI hardware and software to drive applied innovation, test automation and validation workflows. The partners will co-develop solutions tailored for high-complexity sectors where resilience and engineering rigor are critical. The engagement also includes joint go-to-market initiatives and extended client support models to provide ‘lifecycle enablement’ for global enterprises.

Ritu Favre, President for Emerson’s Test and Measurement business, said, “Engineering environments are becoming increasingly software defined, data centric and interconnected. Our open, modular NI platform provides the architectural foundation organisations need to manage growing system complexity while accelerating validation and deployment cycles. Through our collaboration with LTTS as a global system integrator, we extend this platform into industry-specific implementations that help customers move from engineering uncertainty to operational confidence and leveraging the proven technology leadership of NI automated test and measurement solutions.”

Alind Saxena, Executive Director & President at LTTS, added, “Our clients in Mobility, Sustainability and Tech require engineering systems that are intelligent and future-ready. Our partnership with Emerson strengthens LTTS’ ability to architect and deploy such systems at scale.”

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