Wed, 11 June, 2025
The aluminium sector is growing due to the needs of the automotive, construction, and energy industries, while the aluminium recycling sector is also expected to continue growing at a rapid rate year-on-year.
However, there is also growth in innovative new areas as aluminium transitions from being a basic, lightweight structural material to one that is helping reshape manufacturing, industry and the world around us.
This includes three key areas where TWI demonstrates expertise and experience; additive manufacturing, aluminium coatings and composites, and electrification for the automotive and other industries.
Additive Manufacturing with Aluminium
Additive manufacturing using aluminium alloys has seen growth in high-end industries such as aerospace, where it is moving from a potential to a production process. Offering a more cost-effective method for manufacturing complex and bespoke parts, additive manufacturing also cuts down on material waste, which saves material costs and is better for the environment. In addition, additive manufacturing can deliver faster production rates when compared to traditional processes. TWI Industrial Member, BAE Systems reported that additive manufacturing cut the production time for large aircraft fuselage components from two years down to just two months. These types of efficiencies have led BAE to aim for 30% of the components for its new Tempest fighter jet to be additively manufactured.
It is not just the aerospace industry that is seeing the benefits of aluminium additive manufacturing as the automotive and space sectors are also investing in additive manufacturing technologies and knowledge. For the aluminium industry, this should also see an increase in the demand for aluminium powders and additive manufacturing alloy stock.
TWI helps some of the biggest names in industry with additive manufacturing, from adoption of the process and maximising efficiencies, to feasibility studies, materials and process selection, testing, standards, and more.
Aluminium Coatings and Composites
Smart coatings and aluminium composite materials are also having an impact on industry, offering improved properties such as increased toughness, lighter weights and more conduction, as required. By combining aluminium with other elements at a micro level, it is possible to deliver a range of performance improvements.
For example, infusing graphene into aluminium maintains the low weight that aluminium is known for, but also increases the strength and electrical conductivity compared to regular aluminium. This could replace the use of heavier and more expensive alloying materials like copper. The demand for these innovative new materials is to deliver a ‘double duty,’ offering more than one benefit.
TWI has experience in composite material properties as well as coating processes such as cold and thermal spraying. We are, for example, currently investigating how to improve the properties and efficiencies of composites used with thermal spray so as to allow its use in more applications.
Aluminium and Electrification
Aluminium is helping to drive electrification in industries including automotive, aerospace and space. The use of aluminium helps to offset the additional weight added by the battery cells themselves –so much so that, the average electric vehicle (EV) built in Europe contains around 283 kg of aluminium compared to the 169 kg used in petrol cars. Furthermore, the amount of aluminium used in EVs is expected to rise to around 310 kg by next year. Due to the light weight and strength of aluminium, it is also often used for housing the battery cells themselves. Wherever it is being used, the lighter weights provided by aluminium translate to longer driving ranges in EVs, lighter aircraft, and more fuel efficient space launches. New innovations into advanced aluminium alloys and extrusions will improve properties further to make EV vehicles safer, lighter, and more efficient.
TWI has been heavily involved in supporting the growth of battery technologies for some of the biggest names in industry, including investigating the ease of disassembly as well as assembly to make recycling easier.
With a great many potential uses in industries ranging from aerospace to power, and rail, understanding the parameters of aluminium use, including the properties of alloys and composite materials, will be vital to continued innovation in all of these areas. In addition, a knowledge of the processes involved will allow for them to be improved and advanced, while maintaining standards and safety.
You can find out more about TWI’s support in the following related areas, below: