Introduction
The environment surrounding the manufacturing industry in recent years has demanded greater efficiency and flexibility than ever before due to intensifying global competition and supply chain instability. Particularly in growth sectors such as automotive, semiconductors, and medical equipment, simultaneously solving the three challenges of weight reduction, high precision, and cost reduction has become a major factor influencing corporate competitiveness.
Against this backdrop, “aluminum processing technology” is gaining attention. While aluminum has a specific gravity approximately one-third that of iron, it demonstrates performance suitable for transportation equipment and precision instruments through high-strength alloying and surface treatments. Furthermore, its excellent recyclability is also important, as it has a high affinity with decarbonization management and sustainability strategies.
With the spread of EVs, the use of aluminum in battery cases and motor parts is rapidly expanding. According to a survey by the International Energy Agency (IEA), the amount of aluminum used per EV reaches an average of 250kg, an increase of over 30% compared to conventional gasoline vehicles. This means that know-how in aluminum processing is becoming a competitive factor in parts procurement and manufacturing processes.
In the fields of semiconductor manufacturing equipment and medical devices, aluminum alloys are also indispensable as precision parts that leverage their high thermal conductivity and corrosion resistance. In particular, general-purpose alloys such as A5052 and A6061 are used in the manufacturing of complex-shaped parts through machining and milling, supporting short-turnaround prototyping and mass production systems.
This article, based on these trends, will organize “application examples of aluminum processing technology” and examine how they should be utilized in new product development and procurement strategies. The goal is not merely to introduce processing know-how, but to derive insights useful for decision-making by management and procurement officers, incorporating both success and failure stories.
1. Foundation and Latest Trends in Aluminum Processing Technology
Achieving Both Light Weight and High Strength
Aluminum has a specific gravity of 2.7, about one-third that of iron (7.8), and its light weight directly contributes to improved fuel efficiency and operational performance. Furthermore, its strength can be dramatically increased by adding magnesium, silicon, or copper. For example, A6061 and A7075 achieve strength comparable to steel through heat treatment and are widely used in aircraft and structural components.
In the EV market, aluminum is extensively used for battery housings, motor cases, and lightweight wheels. There are estimates that a 10% reduction in vehicle weight can improve fuel efficiency by 6-8%, and the amount of aluminum used per EV has increased by over 30% compared to conventional cars.
Evolution of Processing Methods
Typical aluminum processing methods include cutting, casting, bending, pressing, polishing, and surface treatment. Cutting achieves complex shapes with high precision using machining and milling, while casting can efficiently produce large parts and mass-produced items using sand or permanent molds.
In recent years, design optimization using CAE and AI has advanced, making it possible to significantly reduce prototyping costs and lead times. Furthermore, the implementation of smart factories using IoT sensors has led to improvements in processing accuracy and defect rates.
Global Market Trends
Global aluminum demand is projected to grow at a compound annual growth rate of over 5% from 2023 to 2030. In Japan, there has been a shift in import procurement away from a high dependence on China towards ASEAN, with the share from Vietnam, Thailand, and Malaysia expanding to over 20%. This enables both risk diversification and the strengthening of cost competitiveness in procurement strategies.
2. Application Examples of Aluminum Processing and New Product Development
Case Study Comparison of A5052, A6061, and A7075
- A5052: Excellent balance of corrosion resistance and workability, used in semiconductor manufacturing equipment and precision machinery parts. Yield is improved through high-precision finishing with wet processing.
- A6061: Widely used in aerospace and EV parts. Good balance of strength and corrosion resistance, with numerous case studies of cost reduction through overseas mass production.
- A7075: One of the highest strength classes, used for aircraft and sports equipment. However, its adoption is limited due to high cost and processing difficulty.
Application Examples by Industry
- Automotive: Used for EV motor cases and lightweight wheels. Weight reduction directly contributes to extending driving range.
- Medical Equipment: Utilized as precision-cut parts and materials compatible with sterilization. Corrosion resistance is enhanced by alumite treatment.
- Architecture & Design: Achieves both weather resistance and aesthetic appeal through alumite treatment. Demand is growing for design-focused building materials like gates and fences.
Innovation Case Studies
- High-precision machining × surface treatment to achieve short-turnaround prototyping.
- Hybrid processing of 3D printed casting × cutting accelerates new product development for complex-shaped parts.
- Smart factory implementation achieves reduced defect rates and extended tool life.
3. Procurement Strategy and Cost Competitiveness
Trend of Overseas Procurement and Production Transfer
ASEAN, particularly Vietnam, is drawing attention as a destination for procurement diversification, offering an excellent balance of cost and stable supply. At Daiwa Light Alloy Vietnam, a 20% reduction in mass production costs was achieved while maintaining a quality control system equivalent to that in Japan. They also succeeded in achieving both supply stability and market access.
Methods for Reducing Processing Costs
- Extending Tool Life: Reducing the frequency of tool replacement by using DLC-coated tools and optimizing coolants.
- Improving Yield Rate: Lowering defect rates through AI-based optimization of processing conditions and real-time monitoring.
- Alloy Selection: Suppressing material costs by choosing the optimal alloy that meets the required strength.
Responding to Supply Chain Risks
As the move away from dependence on China progresses, procurement from multiple locations such as ASEAN and India is effective as a measure to disperse currency and geopolitical risks. One-stop procurement utilizing networks of partner factories is accelerating.
Data Box | Latest Indicators for Aluminum Processing and Procurement
- Global Aluminum Demand CAGR: +5.3% (2023-2030)
- Aluminum Usage per EV: Average 250kg (+30% vs. gasoline cars)
- Japan’s Aluminum Import Sources: Shifting from China 50% → ASEAN now over 20%
- Daiwa Light Alloy Vietnam: Track record of 20% reduction in mass production costs
- Distribution Ratio of Major Alloys: 5000 series 40%, 6000 series 30%, 7000 series 15%
(Source: Ministry of Economy, Trade and Industry; Japan Aluminium Association; IEA; Statista)
4. Learning from Success and Failure Case Studies
Success Stories
- Overseas Production Transfer of A6061 Parts: Achieved a 20% cost reduction and stabilized supply through mass production in Vietnam.
- Yield Improvement in A5052 Precision Processing: Reduced defect rates and shortened lead times by introducing DLC tools and wet processing.
Failure Stories
- Inadequate Cutting Heat Management: Insufficient cooling led to tool wear and rough processed surfaces, increasing the defect rate by over 10%.
- A7075 Selection Mistake: Adopting a material with excessive strength led to increased costs and reduced price competitiveness.
These cases show that the three elements of alloy selection, processing conditions, and procurement strategy significantly influence results.
Conclusion
Aluminum processing technology is a core technology for simultaneously achieving “weight reduction × high precision × cost reduction.” The key points for success can be summarized in three areas: ① alloy selection, ② optimization of processing conditions, and ③ procurement strategy.
What management and procurement officers should focus on is precisely the combination of “ASEAN procurement × new processing technologies.” By adopting this perspective, aluminum processing will evolve beyond merely supplying parts to become a foundation that supports a company’s growth strategy.