The evolution of engineered aluminium through the ages

By Staff Report December 13, 2024 4:16 pm IST

Aluminium’s outstanding characteristics—its strength, lightweight nature, resistance to corrosion, and recyclability—make it an important material in contemporary manufacturing and technology. Sathesh Kumar, Senior General Manager of Operations at Jindal Aluminium Limited, discusses the transformation of aluminium from a rare and precious metal to a crucial industrial material.

Aluminium, once a rare and precious metal in the 19th century, has transformed into a crucial industrial material due to technological advancements. Initially more valuable than gold, Aluminium’s status shifted as innovations in extraction and production significantly lowered its cost, making it widely accessible.

As production techniques improved, the creation of versatile and robust alloys revealed aluminium’s true capabilities. These developments have transformed industries like aerospace and automotive, providing stronger and durable materials. Engineered Aluminium remains a prominent player in various sectors, driven by innovation.

The Transformation of Aluminium: From Precious Metal to Industrial Essential

Aluminium was a scarce and expensive metal in its early days, sometimes even more costly than gold due to labour-intensive extraction methods. This began to change in 1825 when Danish chemist Hans Christian Ørsted devised a new extraction technique that significantly reduced production costs. Later, in 1854, French chemist Henri Etienne Sainte-Claire Deville introduced mass production techniques, making the metal more widely available.

Initially utilised for decorative purposes like fine jewellery and precision instruments, aluminium’s breakthrough occurred in 1886 with the Hall-Héroult process, an electrolysis-based production method independently discovered by Charles Martin Hall and Paul Héroult. This innovation enabled aluminium to be produced more efficiently and at a lower cost, paving the way for large-scale production. It also established the foundation for recycling, which further decreased production costs. The Bayer process, which refined bauxite into alumina, improved aluminium production efficiency and sustainability, while by-products like iron and titanium supported other industries.

The Expanding Role of Aluminium in the 19th and 20th Centuries

By the late 19th and early 20th centuries, aluminium began to be used in various applications, impacting many industries. In 1891, Alfred Nobel commissioned the first aluminium-hulled vessel, Le Migron, which transported passengers on Lake Geneva. Three years later, Yarrow & Co. built the Sokol, a torpedo boat for the Russian Navy, which set a record speed of 32 knots.

In the United States, the versatility of aluminium was recognised by Hartford Railroad under J.P. Morgan, which introduced lightweight passenger cars featuring aluminium seats in 1894. Karl Benz showcased the first aluminium-bodied sports car in 1899 at an exhibition in Berlin. However, aluminium’s most groundbreaking influence was in aviation. On December 17, 1903, Wilbur and Orville Wright’s Flyer-1 took to the skies, powered by an innovative aluminium engine.

The invention of Duralumin in 1909, an alloy made from copper, magnesium, and manganese, represented a significant advancement. Created by German engineer Alfred Wilm, Duralumin became essential in aviation due to its enhanced strength and durability. At the same time, aluminium began to appear in consumer products. In 1907, Robert Victor Neher pioneered continuous foil rolling, and in 1911, Toblerone started using aluminium foil for its chocolate packaging.

World War II increased aluminium’s strategic significance, especially in aircraft and automobile production, leading to alloy technology advancements. By the mid-20th century, engineered aluminium was vital for space exploration, and the USSR’s 1957 satellite featured an aluminium hull. The launch of the aluminium can in 1958 by Kaiser Aluminium and Coors marked a significant step forward in environmental sustainability and design innovation. By the 1970s, aluminium had established itself as a traded commodity on the London Metal Exchange, securing its role in the global market.

Current Applications of Aluminium and Its Impact Across Industries

Aluminium is essential in many industries because of its lightweight strength and versatility. In transportation, it is vital for aviation, comprising 75-80% of modern aircraft, which helps reduce weight by 50% and lowers fuel costs by 12-15%. In electric vehicles, aluminium can decrease vehicle weight by up to 30%, enhancing energy efficiency and extending battery life by 10-15%. A 10% reduction in weight can lead to an increase in EV range by 6-8%. The recyclability of aluminium, which requires 95% less energy than primary production, results in a 92% reduction in emissions, highlighting its sustainability.

In the marine industry, aluminium’s resistance to corrosion makes it perfect for ships and offshore structures, allowing vessels to be up to 20% lighter and 15-20% more fuel-efficient compared to steel alternatives. It can also cut maintenance costs by as much as 40%. In packaging, aluminium’s impermeability helps extend the shelf life of food by 25%, and each year, 180 billion beverage cans are produced, with 75% of all aluminium ever made still in circulation.

Aluminium is a durable and corrosion-resistant material suitable for windows, doors, and cladding in architecture, ensuring over 40 years of service without needing much maintenance. Its application in consumer electronics is also noteworthy, as its lightweight nature and conductivity—62% that of copper but only 30% of the weight—make it ideal for compact devices like smartphones and laptops.

Final Thoughts

Aluminium has transformed from a rare and costly metal into a fundamental component of modern industry, showcasing remarkable technological progress and innovation. The creation of alloys and advancements in production techniques have broadened its application in vital sectors such as aerospace, automotive, and marine. Its outstanding characteristics—strength, lightweight, resistance to corrosion, and recyclability—make aluminium an important material in contemporary manufacturing and technology. As new developments in aluminium engineering arise, this metal’s influence on the future of various industries will continue to grow, propelling progress and innovation.