Aluminium is working its way deeper into vehicle wiring as carmakers try to take weight and cost out of more complex electric and hybrid systems.
Ferrari and BMW are among the major carmakers widening its use in selected wiring applications, Reuters reported.
The reason is because aluminium is lighter than copper and costs much less. It is not a straight swap, however, because aluminium conducts electricity less efficiently. Cables, connectors and insulation have to be engineered around the material.
Ferrari used aluminium power cables in the 296 hybrid before extending the technology to newer models, including its Luce electric vehicle.
The Italian sports car maker said the change cuts wiring weight by 15% to 20%. It also said the move was driven mainly by performance and weight reduction, rather than raw material savings.
BMW has been working with the material for longer. Reuters said the German carmaker first used aluminium conductors in the 1 Series in 2011, before extending the approach to hybrid and electric models.
Its latest Gen6 eDrive system now uses aluminium in high-voltage and low-voltage wiring.
Tesla and several Chinese EV makers are already using aluminium wiring, with Chinese brands moving quickly as they push for lighter, lower-cost electric vehicles.
For EVs and hybrids, the gain is not only in the price of the metal. Lighter wiring also helps counter the extra mass of batteries, motors and power electronics.
