Vedanta Aluminium Develops, Patents Breakthrough Alloy, Advancing Innovation in Sustainable Metallurgy
17th October 2025
- Pathbreaking lead- and tin-free bismuth-aluminium alloy reinforces Vedanta Aluminium’s commitment its Net Zero 2050 vision through sustainable, homegrown technology
- Lab tests show up to 30% smoother finish, 8% higher tensile strength, 21% higher yield strength, and 17% greater hardness compared to conventional alloys
- Engineered for automotive, electronics, and textile industries
New Delhi, October 17, 2025: Vedanta Aluminium, India’s largest producer of aluminium, has achieved a major milestone with the grant of its first new product development patent for a lead- and tin-free bismuth-aluminium alloy. This innovation addresses the global phaseout of hazardous elements like lead and tin, offering a sustainable, high-machinability solution for critical industrial applications.
This patent marks a breakthrough in sustainable material innovation, combining engineering excellence with environmental responsibility. Developed by Vedanta Aluminium’s in-house R&D team, this alloy represents a major step forward in sustainable metallurgy. By replacing hazardous elements such as lead and tin with bismuth, the alloy not only meets global environmental standards but also delivers exceptional machinability and mechanical strength.
The alloy is engineered for components used across automotive, electronics, and textile sectors, where machining operations are central to production. Applications include automotive parts such as ABS manifolds, hydraulic manifolds, valve blocks, transmission sleeves, air conditioning components, steering yokes, drive shafts, and electrical connectors, as well as electronic components like camera and clock parts and mobile phone housings.
Rajiv Kumar, CEO, Vedanta Aluminium, said, “Innovation and sustainability are at the heart of Vedanta Aluminium’s R&D efforts, driving us to create solutions that advance our environmental goals while delivering world-class breakthrough products. This patent validates our efforts at pushing the boundaries of material science, while embedding sustainability into every stage of our value chain. The bismuth-aluminium alloy represents the future of responsible manufacturing.”
The inspiration for this innovation stemmed from an increasing customer demand for sustainable, high-performance alternatives to traditional machinable alloys such as AA6262 and AA6020, which contain lead and tin. With these alloys under regulatory scrutiny, industries have been using standard grades like AA6061 and AA6082, which pose limitations such as poor surface finish, reduced tool life, higher cutting load, and longer operation times.
Vedanta Aluminium’s newly developed bismuth-aluminium alloy addresses these challenges by combining sustainability with performance, enabling industries to transition to cleaner, more efficient materials without compromise.
Lab trials of the new alloy demonstrate remarkable performance metrics:
- Higher Strength and Durability: 8% higher tensile strength, 21% higher yield strength, and 17% greater hardness compared to conventional grades.
- Superior Machinability: Smaller, easily breakable chip formation enhances cutting efficiency and reduces operational time.
- Improved Tool Life and Surface Finish: Up to 30% smoother surface finish and significantly extended tool lifespan, even under high-speed machining conditions.
The patented alloy underscores Vedanta Aluminium’s commitment to sustainable product development and supports national initiatives like ‘Make in India’ and ‘Atmanirbhar Bharat’ by fostering indigenous technological innovation. It also contributes to the company’s long-term ambition of achieving Net Zero Carbon Emissions by 2050.
Through innovations like this, Vedanta Aluminium continues to lead India’s transition toward sustainable industrial growth, setting new benchmarks in eco-conscious metallurgy and advanced manufacturing.
About Vedanta Limited:
Vedanta Limited, a subsidiary of Vedanta Resources Limited, is one of the world’s leading Oil & Gas and Metals company with significant operations in Oil & Gas, Zinc, Lead, Silver, Copper, Iron Ore, Steel, and Aluminium & Power across India, South Africa and Namibia. For two decades, Vedanta has been contributing significantly to nation building. Governance and sustainable development are at the core of Vedanta's strategy, with a strong focus on health, safety, and environment. Vedanta has put in place a comprehensive framework to be the ESG leader in the natural resources sector. Vedanta is committed to reducing carbon emissions to zero by 2050 or sooner and has pledged $5 billion over the next 10 years to accelerate the transition to net zero operations. Giving back is in the DNA of Vedanta, which is focused on enhancing the lives of local communities. The company’s flagship social impact program, Nand Ghars, have been set up as model anganwadis focused on eradicating child malnutrition, providing education, healthcare, and empowering women with skill development. Under the aegis of the Anil Agarwal Foundation, the umbrella entity for Vedanta’s social initiatives, the Vedanta group has pledged Rs 5000 crore over the next five years on social impact programmes with a thrust on nutrition, women & child development, healthcare, animal welfare, and grass-root level sports. Vedanta and the group companies have been featured in Dow Jones Sustainability Index, and was conferred Frost & Sullivan Sustainability Awards 2020, Golden Peacock Award for excellence in Corporate Governance 2022 and certified as a Great Place to Work 2022. Vedanta Limited is listed on the Bombay Stock Exchange and the National Stock Exchange.
For more information, please visit www.vedantalimited.com
About Vedanta Aluminium Business:
Vedanta Aluminium, a business of Vedanta Limited, is India’s largest producer of aluminium, manufacturing more than half of India’s aluminium i.e., 2.37 million tonnes in FY24. It is a leader in value-added aluminium products that find critical applications in core industries. Vedanta Aluminium ranks 1st in the S&P Global Corporate Sustainability Assessment 2023 world rankings for the aluminium industry, a reflection of its leading sustainable development practices. With its world-class aluminium smelters, alumina refinery and power plants in India, the company fulfils its mission of spurring emerging applications of aluminium as the ‘Metal of the Future’ for a greener tomorrow.
For more information, please log on to www.vedantaaluminium.com
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This press release contains “forward-looking statements” – that is, statements related to future, not past, events. In this context, forward-looking statements often address our expected future business and financial performance, and often contain words such as “expects,” “anticipates,” “intends,” “plans,” “believes,” “seeks,” “should” or “will.” Forward-looking statements by their nature address matters that are, to different degrees, uncertain. For us, uncertainties arise from the behaviour of financial and metals markets including the London Metal Exchange, fluctuations in interest and or exchange rates and metal prices; from future integration of acquired businesses; and from numerous other matters of national, regional, and global scale, including those of a political, economic, business, competitive or regulatory nature. These uncertainties may cause our actual future results to be materially different than those expressed in our forward-looking statements. We do not undertake to update our forward-looking statements.
