The cost of aluminium in the production of automotive components remains an issue. It is some 2-4 times more expensive than steel, according to estimates. OEMs are prepared to absorb some of this extra expense for the benefits aluminium provides, and aluminium producers are working hard to develop stronger alloys, allowing carmakers to do more with less material. However, as the strength of the material increases, so its formability tends to decrease. Now, a number of companies and research institutes are developing innovative routes for the conversion of the metal into automotive parts that counteract these issues.

One such process is Hot Form Quench (HFQ), which has been designed to enable the production of parts with deep-drawn and complex geometries from high- and ultra-high-strength aluminium. These parts can be used to replace those made of steel or cold-formed aluminium grades…