U.S. Aluminum Market Size & Share Analysis - Trends, Drivers, Competitive Landscape, and Forecasts (2025 - 2032)

U.S. Aluminum Market Growth Factors

Usage of Aluminum as an Alternative to Steel Is Trending

• With the U.S. automotive industry strengthening its focus on lightweight and fuel-efficient vehicles, OEMs are turning to aluminum as an alternative to conventional iron and steel.
• Aluminum imparts strength and durability to the vehicle without adding to its weight.
• In manufacturing airplanes and trains, aluminum is widely preferred because it is lighter, stronger, and resistant to rusting.
• The rapid urbanization leads to the increasing use of aluminum in the construction industry because of these properties.
• The emphasis on recycling in this industry results in more than 75% of the aluminum that is used being reclaimed from recyclable products.
• This enables compliance with sustainability standards and decreases the reliance on mining.
• Recycling decreases energy requirements to 5% of that used to produce aluminum from bauxite, making sustainable aluminum economical for manufacturers.

Increasing Demand in Renewable Energy and EVs Drives Market

• The current revolution in the use of solar, wind, and hydroelectricity boosts the use of aluminum strongly.
• It is used to make photovoltaic cells, wind turbines, and other structures and components intrinsic to the low-emission energy sector lightweight, corrosion-resistant, and durable.
• In the EV sector, aluminum keeps the weight of the vehicle low, thus increasing its energy efficiency.
• Aluminum–graphene Li-ion batteries run on the same voltage with a similar shape to conventional Li-ion batteries.
• Additionally, they are hybrid battery superconductors capable of storing three times more energy.
• They also require 30% of the time to recharge than that for a Li-ion battery.
• According to a report published by the Congressional Research Service (CRS), the demand for aluminum in North America is forecast to increase by 5.1 million metric tons between 2020 and 2030.
• Approximately 50% of this growth will be due to the transportation sector, as North America has become a major electric vehicle production hub.

Segmentation and Category Analysis

Product Insights

Shapes are the largest category, holding 35% share in 2024, primarily due to the high-volume use of different shapes made from this metal in construction, automobiles, and industrial machinery. Shapes are made strong to be used as support structures in various projects. Additionally, their flexibility for modification makes it possible for manufacturers to satisfy particular design requirements in the aerospace and automobile industries.

Pipes and tubes are the fastest-growing category, driven by the expanding energy industry, as well as the rising HVAC equipment demand for tunnels, where lightweight and corrosion-resistant material is preferred. Furthermore, the increasing use of aluminum pipes and tubes in renewable power segments, such as solar and wind power, drives this category. Efficient heat transfer characteristics and high resistance to environmental stress make aluminum pipes and tubes popular in many energy and industrial applications.

The products studied in this report are:

• Shapes (Largest Category)
• Rods and Bars
• Pipes and Tubes (Fastest-Growing Category)
• Sheets
• Plates
• Others

Application Insights

The building and construction category is the largest because aluminum offers hardness, corrosion resistance, and low weight to windows, doors, roofs, and facades. Further, the industry’s shift toward sustainable and environment-friendly building materials bolsters the demand for aluminum because it is highly recyclable. Essentially, the burgeoning construction activities with the steady flow of investments in urban infrastructure drive the market.

The automotive and transportation category is the fastest-growing, with 5.5% CAGR. This is credited to the rising need for lighter vehicles for higher mileage, resulting from the high fuel costs and stringent emission standards. Aluminum is also gaining popularity as an EV material, as its lightweight nature adds to range and performance. In addition, the usage of recycled aluminum fulfills the automotive industries’ environmental targets.

The applications covered in the report are:

• Automotive and Transportation (Fastest-Growing Category)
• Building and Construction (Largest Category)
• Electricals and Electronics
• Consumer Goods
• Packaging
• Industrial Machinery
• Others

Series Insights

Series 1 is the largest category, with around 30% of share in revenue in 2024. The main reason is that series 1 aluminum is widely used in electrical and electronic appliances because of its high electrical conductivity. This is of great importance in electrical conductors, wiring, and busbars, where resistive losses and inefficiency cannot be afforded. Furthermore, the strong corrosion resistance of series 1 aluminum alloys means that they are ideal for chemical processing equipment, food storage containers, and storage tanks.

The series studied during analysis are:

• Series 1 (Largest Category)
• Series 2
• Series 3
• Series 4
• Series 5
• Series 6 (Fastest-Growing Category)
• Series 7
• Series 8

Processing Method Insights

Flat-rolling is the largest category due to the widespread use of this technique in making products for the food packaging and automotive industries. Specific packaging products it is used for include cans and foil paper, while in the automotive sector, it is utilized for panels and structures. The malleable, durable, and lightweight properties of this metal make it appropriate for this process.

Extrusion is the fastest-growing category, with a rate of 5.3% during the forecast period. This is because extruded aluminum is used extensively in the construction, automotive, and aerospace industries. Extruded aluminum products are extensively used in window and door panels, curtain walls, and many other structural components due to their high strength-to-weight ratio. The growth of the construction industry drives the market in this category as the country becomes increasingly urbanized and people seek energy-efficient buildings.

The processing methods studied were:

• Flat-Rolling (Largest Category)
• Casting
• Extrusion (Fastest-Category Category)
• Forging
• Others

Alloy Type Insights

Wrought is the larger category, generating 65% share of revenue in 2024. Alloys of wrought Al are suitable for weight-bearing applications in industrial fields because they possess excellent strength combined with flexibility and corrosion resistance. Manufacturers in the automotive industry create fuel-efficient components, alongside body panels and frames, from wrought alloys. Similarly, fuselages, together with wing structures and durable frameworks, represent the essential aerospace components made from these products. Further, the construction sector employs them for architectural elements and frameworks.

The alloy types included in the study were:

• Cast (Faster-Growing Category)
• Wrought (Larger Category)

U.S. Aluminum Market Regional Market Performance

The South is the dominant region, with 40% value share in 2024, due to the region's well-established automotive, construction, and aerospace industries. The South's infrastructure and supply chain capabilities further solidify its position as the leading region in the aluminum market of the country. The substantial industrial base in this area drives aluminum consumption, especially in the automotive and aerospace sectors. Major production complexes operated by Nucor and Arconic within Alabama and Texas, along with Tennessee, have elevated aluminum usage throughout these states.

Regions covered:

• Northeast
• Midwest
• West (Fastest-Growing Category)
• South (Largest Category)

U.S. Aluminum Market Competitive Landscape

• The U.S. aluminum market is dominated by major global players, such as Alcoa, RUSAL, and Rio Tinto, leading to a consolidated structure.
• Other large companies, such as Norsk Hydro, Emirates Global Aluminum, and Arconic, intensify the competition by holding substantial shares and offering a wide range of aluminum products.
• While there are several players involved, the overall market remains controlled by a few dominant corporations that have considerable influence over production, pricing, and industry trends.

U.S. Aluminum Market News & Updates

• In August 2024, Alcoa Corporation completed a deal to acquire Australia’s Alumina Limited for USD 2.2 billion. This transaction improves Alcoa's strategic position as a bauxite and alumina company.
• In August 2023, Apollo Global Management Inc. finalized the acquisition of aluminum product manufacturer Arconic Corporation for USD 5.2 billion in cash, which included debt obligations.