Amid the global automotive industry's accelerated transition toward electrification and intelligence, the synergistic enhancement of lightweighting and safety has emerged as a core challenge. Aluminum-steel cladding materials leveraging their unique "aluminum-layer weight reduction + steel-layer strengthening" characteristics, have broken through the performance limitations of traditional single-material solutions and are reshaping automotive material technologies. This article systematically explores their key technological breakthroughs, typical application scenarios, and industry development trends.
Al-Steel cladding materials integrate aluminum alloys with high-strength steel through physical or chemical bonding processes (e.g., roll bonding, explosive welding), creating a unified structure with the following advantages:
1 Weight Optimization: 30–50% weight reduction compared to all-steel structures; 40% cost reduction versus all-aluminum bodies.
2 Synergistic Mechanical Properties: The aluminum layer absorbs impact energy, while the steel layer provides structural support, achieving an interfacial shear strength of up to 210 MPa.
3 Multifunctional Integration: Combines electromagnetic shielding (60 dB attenuation), corrosion resistance (exceeds 1,000 hours in salt spray tests), and other functionalities.
4 Process Compatibility: Supports traditional stamping and riveting processes, reducing production line modification costs by 60%.
Case Study: Tesla Model Y’s side panels use aluminum-steel cladding materials, reducing vehicle weight by 12% and increasing torsional stiffness by 15%.
Suspension Components: Composite control arms reduce weight by 28% compared to steel parts, with a 20% improvement in handling responsiveness due to reduced unsprung mass.
Battery Protection: Battery enclosures combining 0.8 mm stainless steel and 2 mm aluminum achieve 300 kN puncture resistance (exceeding the 150 kN national standard) while cutting weight by 40%.
Motor Housings: Cladding materials reduce thermal deformation by 50% compared to all-aluminum housings under 120°C operating conditions.
High-Voltage Connectors: Steel-layer electromagnetic shielding designs reduce radiation interference to below 30 dB.
1 Audi A8 Space Frame: Partial use of aluminum-steel cladding framework reduces body-in-white weight by 51 kg.
2 NIO ET7 Battery Pack: Cladding enclosure design increases energy density to 300 Wh/kg.
3 Heavy-Duty Truck Driveshafts: Cladding materials enable 30% weight reduction and 5% improvement in fuel efficiency.
Aluminum-steel cladding materials are pioneering a "third path" in automotive engineering: circumventing the high-cost barriers of all-aluminum bodies while overcoming the lightweighting limitations of traditional steel structures. With ongoing advancements in interface modification technologies and intelligent manufacturing systems, these materials are poised for large-scale adoption, emerging as a critical solution in the era of new energy vehicles. Their evolution promises to redefine automotive manufacturing paradigms and drive sustainable progress across the transportation industry.