From presidential motorcade to production models: the evolution of Aurus materials

When they first showed it at the Victory Parade in 2018 Aurus Senat - a Russian limousine for the country's top leadership, Few people expected that in a few years the brand would become a symbol of the domestic automobile industry. But today Aurus - These are not only armored motorcades, but also serial sedans, SUVs and even electric cars. And the main question that worries potential buyers: What is this car made of?

The answer lies in the unique combination of domestic developments and foreign components. Construction Aurus - this is the result of work NAMI (National Automotive Institute), who spent more than 10 years creating the platform from scratch. At the same time, engineers were faced with a dilemma: use exclusively Russian materials (which would increase the cost and reduce reliability) or integrate imported components for competitiveness. As a result, a balance was found - and today we will look at what decisions formed the basis Senat, Arktika and other models.

It is important to understand: Aurus — this is not just a “Mercedes assembled in Russia.” This is a car designed with climatic features of the country (from −40°C to +40°C), road conditions and safety requirements exceeding the standard Euro NCAP. That is why the choice of materials here is fundamentally different from mass-produced foreign cars.

Body: steel, aluminum or carbon fiber?

Body base Aurus amounts to hybrid design, combining high-strength steel, aluminum and composite materials. In this case, the proportions depend on the model:

  • 🔹 Senat (sedan/limousine): up to 60% high-strength steel, 30% aluminum, 10% composites.
  • 🔹 Arktika (SUV): increased aluminum content (up to 40%) to reduce weight.
  • 🔹 Komendant (armored version): multi-layer steel with Kevlar inserts.

Used for load-bearing elements steel grade DP980 (two-phase, with a tensile strength of 980 MPa), which is used in Volvo and BMW. However, Russian engineers modified its composition by adding niobium and vanadium for better weldability in cold climates. Aluminum panels are made from alloy 6082-T6 - the same thing that is used in aviation (for example, in Sukhoi Superjet).

Interesting fact: body Aurus going together with laser welding (technology Remote Laser Welding), which reduces the number of connection points by 30% compared to traditional resistance welding. This not only improves rigidity, but also reduces the risk of corrosion in the seams.

📊 Which body material do you think is the most reliable?
High strength steel
Aluminum
Carbon fiber
Composites (Kevlar, carbon)
I don't know

Engine: Russian V8 or imported hybrid?

Heart Aurus Senat - this is 4.4 liter V8 petrol engine 600 hp, developed US together with Porsche Engineering. Structurally, it resembles motors BMW N63, but has key differences:

  • 🔧 Cylinder block cast from aluminum-silicon alloy (AlSi7Cu3Mg) with the addition zirconium to increase heat resistance.
  • 🔧 Crankshaft made from forged steel 42CrMo4 (analogous to German 42CrMoS4), but with additional nitrogen treatment to increase the resource.
  • 🔧 Pistons - forged, with ceramic coating on skirts (technology Mahle).

The peculiarity of this motor is dual charging system (mechanical compressor + turbine), which avoids “turbo lag” at low speeds. At the same time Aurus became the first Russian car to use cylinder deactivation system (turns off 4 of 8 cylinders when driving uniformly).

For hybrid versions (eg Aurus Senat Hybrid) is used electric motor from Siemens 180 kW power, integrated with 9-speed automatic transmission ZF 9HP. The battery is lithium-ion, with a capacity of 14 kWh, with a cooling system based on ethylene glycol.

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If you are choosing between petrol and hybrid Aurus, note: the hybrid version has a smaller trunk (420 liters versus 510 liters) due to the placement of the battery under the floor.

Salon: Russian luxury or imported chic?

Interior Aurus is a combination of traditional materials and high technology. Basic versions are covered genuine leather from Italian supplier Poltrona Frau, but for prestigious modifications (for example, Senat L700) is used Russian leather, made using special technology with the addition birch tar for resistance to changes in humidity.

Wooden inserts are made from Karelian birch (variety Betula pendula var. carelica), which undergoes a 12-step processing, including impregnation epoxy resins for protection against cracking. Alternative option - ebony (ebony), imported from Africa, but undergoing final processing in Russia.

Interior electronics include:

  • 📱 Multimedia system based on Android Automotive (developed Yandex and SberAutoTech).
  • 🔊 Audio system — 17 speakers Bowers & Wilkins with a 1400 W amplifier.
  • 🌡️ Climate control with ionic air purifier and sensor CO₂.
Material Supplier Features
Leather Nappa Poltrona Frau (Italy) / Russian leather (Tver) Thickness 1.2–1.4 mm, waxed for softness
Karelian birch KareliaDrevProm (Russia) 3D milling, 7 layers of varnish
Aluminum (decorative inserts) RUSAL (Russia) Anodizing with "soft touch" effect
Fabric Alcantara Alcantara S.p.A. (Italy) Used for ceiling and studs
Why in Aurus no vegan alternative to leather?

The Russian premium car market is not yet ready to completely abandon natural materials. According to Autostat, only 3% of class car buyers F considering vegan interiors. However, in 2026 Aurus plans to release a special version with lining from mushroom mycelium (biomaterial developed with MIT).

Suspension and chassis: German precision or Russian endurance?

Chassis Aurus built on the basis modular platform NAMI M12, which is adapted for different body types. key elements:

  • 🔩 Front suspension - multi-link, with aluminum levers (alloy AlSi10Mg).
  • 🔩 Rear suspension — pneumatic, with electronic stiffness control (MagneRide from BWI Group).
  • 🔩 Brakes — carbon-ceramic wheels (Brembo) with 6-piston calipers.

Feature Aurus — active damping system, which analyzes the road surface 50 meters ahead (thanks to a stereo camera) and adjusts the stiffness of the shock absorbers. This technology was developed jointly with Bosch, but adapted for Russian roads: for example, the algorithm recognizes “waves” of asphalt and holes with a depth of 3 cm.

Wheel rims are made from forged aluminum (alloy 6061-T6) at the factory KZLK (Kovrov Light Alloy Plant). Their feature is radial-angular rolling, which increases strength by 20% compared to cast wheels.

Knock when passing speed bumps|Uneven tire wear|Oil leaks on shock absorbers|Vibration of the steering wheel at speeds of 100+ km/h|Error "Suspension Fault" on the dashboard-->

Security: armor, electronics and secret technologies

Armored versions Aurus (for example, Komendant) correspond to the protection class VR7/VR9 (according to standard VPAM), which allows you to withstand fire from AK-74 and an explosion of 15 kg of TNT under the bottom. For this we use:

  • 🛡️ Multi-layer armor: steel AR500 (thickness 8–12 mm) + Kevlar plates Dyneema.
  • 🛡️ Armored glass: triplex with a polycarbonate layer (thickness 52 mm).
  • 🛡️ Mine protection: V-shaped bottom made of titanium alloy VT6.

In standard versions, security is provided by complex Aurus Safety Shield, including:

  • 🚨 8 airbags (including knee airbags for rear passengers).
  • 🚨 System PreSafe (analogue Mercedes): mutes the music, closes the windows and tightens the seat belts when there is a threat of an accident.
  • 🚨 Night vision with thermal imager (FLIR).
⚠️ Attention: In armored versions Aurus the vehicle's weight reaches 4.2 tons, which requires special studded tires Nokian Hakkapeliitta TR (load index 120). Using standard tires leads to premature wear of the suspension.

Comparison with foreign analogues: who is better?

To understand how competitive the materials are Aurus, let’s compare them with their closest analogues - Mercedes-Maybach S-Class and BMW 7 Series:

Parameter Aurus Senat Mercedes-Maybach S680 BMW 760i
Body material Steel (60%) + aluminum (30%) Aluminum (80%) + magnesium Carbon fiber reinforced plastic (CFRP) + aluminum
Engine (block material) Aluminum + zirconium Aluminum + silicon Aluminum + nickel
Armor protection (max. class) VR9 (optional) VR7 (optional) VR6 (optional)
Body warranty 12 years (from through corrosion) 6 years 12 years old

Main advantage Aurus — adaptation to Russian conditions:

  • 🌡️ Frost resistance: All rubber seals and plastics are tested at −45°C (at Mercedes - up to −30°C).
  • 🛣️ Ground clearance: 210 mm Arktika versus 150 mm BMW X7.
  • 🔧 Maintainability: 80% of components can be replaced without specialized equipment (with BMW — 60%).
⚠️ Attention: Upon purchase Aurus with mileage please note engine release date. Until 2022, engines used imported piston rings Mahle, which required replacement every 150 thousand km. Since 2023, domestically produced rings will be installed (plant TZA), the resource of which has been increased to 250 thousand km.

FAQ: answers to frequently asked questions about Aurus

🔹 Why Aurus so expensive if many parts are imported?

Cost Aurus is formed not so much because of the materials, but because of hand assembled (at the plant in Yelabuga) and small production volumes (about 1000 cars per year). For example, the body is welded by robots Kuka, but the final finishing is done manually - this increases the cost by 30%. In addition, 20% of components (e.g. electronics) undergo military quality control, which also affects the price.

🔹 Is it possible to install on Aurus gas equipment?

Technically possible, but not recommended for two reasons:

  1. Engine Aurus V8 optimized for gasoline AI-98 (98 octane). When using gas (methane/propane), the power drops by 10–15%.
  2. Engine and fuel system warranty canceled when installing HBO.

Alternative - hybrid version Senat Hybrid, which consumes 20% less fuel in the urban cycle.

🔹 Which tires are best to choose for Aurus Arktika?

Factory recommendation:

  • 🔄 Summer: Pirelli P Zero (size 275/40 R21) or Continental ContiSportContact 6.
  • ❄️ Winter: Nokian Hakkapeliitta R3 (studded) or Michelin Pilot Alpin 5 (friction).
  • 🏔️ Off-road: BFGoodrich All-Terrain T/A KO2 (size 275/50 R20).

Important: tire pressure must be 2.4 bar (front) and 2.6 bar (rear) for versions with air suspension.

🔹 Where are components for Aurus?

Distribution of suppliers (according to AvtoVAZ for 2026):

  • 🇷🇺 Russia (60%): engine (NAMI), body panels (Severstal), electronics (Rostec).
  • 🇩🇪 Germany (20%): gearbox (ZF), brakes (Brembo).
  • 🇮🇹 Italy (10%): skin (Poltrona Frau), audio system (Bowers & Wilkins).
  • 🇨🇳 China (5%): some sensors and wires.
  • 🇺🇸 USA (5%): thermal imagers (FLIR).

From 2026, the share of Russian components should increase to 75% due to the localization of electronics production.

🔹 How often does it need to be serviced? Aurus?

Maintenance regulations for Aurus Senat (petrol V8):

Mileage (km) Works Cost (≈)
10 000 Oil change (5W-40, 8 l), filters, diagnostics 25 000 ₽
30 000 + Replace the air filter, check the brake system 35 000 ₽
60 000 + Replacement of spark plugs, fuel filter, power steering fluid 50 000 ₽
100 000 + Replacing the timing belt, fluid in the air suspension 80 000 ₽

Important: Aurus requires mandatory adaptation of electronic systems after each maintenance (the procedure takes 1.5 hours).

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Aurus is not a copy of foreign cars, but a unique project with its own technologies. The main advantages: adaptation to Russian roads and climate, high maintainability and a combination of imported components with domestic developments.