A recent academic study examining long-term vehicle durability indicates differences in performance between electric vehicles and petrol cars over extended use. Based on a large dataset of vehicles in operation, the findings show that the failure rate of electric cars is lower.

These findings were published by the BK AUTO research group at Hanoi University of Science and Technology and presented at the International Conference on Manufacturing & Production Technology (ICMPT 2026), held in Malaysia.

At the International Conference on Manufacturing & Production Technology (ICMPT 2026), held in Malaysia from February 2nd to 5th, a research paper from Vietnam was presented to the international academic community. The research group outlined a study comparing the long-term durability of electric vehicles and internal combustion engine vehicles.

The research was conducted by Associate Professor Dr Dem Hoeng Phuc, Director of the Automotive Engineering Programme, together with his colleagues at Hanoi University of Science and Technology. The study employed three independent approaches: statistical reliability modelling, real-world maintenance data, and direct experimental testing on vehicles operating under Vietnamese traffic conditions.

During the conference presentation, Associate Professor Dr Dem Hoeng Phúc stated that, from a theoretical perspective, the research team applied the Weibull model, a commonly used tool in reliability analysis, to calculate the cumulative probability of failure for the two types of vehicles over time.

The study found that, during the early years of use, both electric and petrol cars exhibit low failure probabilities, with no statistically significant difference between them.

As the period of use extends, differences emerge. After approximately 12 years, the cumulative failure probability of petrol cars increases more rapidly than that of electric vehicles, with internal combustion engine cars exceeding 81%, while electric cars are close to 63%.

At the 15-year mark, internal combustion engine vehicles show a failure rate of more than 98%, whereas electric vehicles are just above 86%.

According to the research team, these differences are linked to the more complex mechanical structure of internal combustion engine vehicles, whereas electric drivetrains consist of fewer components subject to long-term wear.

The second layer of evidence is based on real-world maintenance data collected between 2020 and 2024, covering electric and internal combustion engine vehicles operating in Vietnam.

An analysis of fault frequency by mileage shows that, from approximately 40,000 km onwards, the failure rate of electric vehicles declines and remains lower than that of petrol cars for most of their service life.

In the 80,000-125,000 km range, electric vehicles recorded a lower average failure intensity than internal combustion engine vehicles. According to the researchers, this suggests that, over extended periods, electric drivetrains experience fewer mechanical faults and reduced physical wear.

Descending steep slopes

The third layer of evidence is derived from vehicle testing under real-world conditions. In continuous downhill braking tests, petrol cars recorded an increase in brake disc temperature, rising from 36.8 degrees Celsius to 147.6 degrees Celsius. Electric vehicles showed a smaller temperature change, increasing from 33.4 degrees Celsius to 38.4 degrees Celsius.

According to the research team, the temperature difference between the two vehicle types reflects the contribution of regenerative braking in electric SUVs, where a portion of kinetic energy is converted into electrical energy. This reduces reliance on conventional braking systems and affects braking system load during repeated deceleration.

In addition, data collected from service centres indicate that brake disc wear on electric vehicles is lower, at approximately 60-65% of that observed on petrol cars over the same mileage.

Beyond braking systems, the research team also evaluated the load-bearing capacity and durability of suspension systems under various operating conditions, including urban driving, emergency braking at 60 km/h, and cornering.

The results indicate that, although electric vehicles have higher overall mass, their suspension components experience lower internal material load intensity than those of petrol cars.

For example, during hard braking, the maximum stress on the front lower control arm of a petrol SUV reached up to 150 N/mm², while that of an electric SUV was approximately 65-70 N/mm². Under identical conditions, components on petrol vehicles are required to withstand higher loads.

This outcome indicates differences in load distribution and structural characteristics between the two vehicle types, which may contribute to variations in long-term durability and failure rates.

Based on the combined findings from all three analytical approaches, the research team concludes that differences in mechanical structure and braking systems influence long-term durability outcomes between electric vehicles and petrol cars.

In Vietnam, electric vehicles are recording increased adoption, consistent with broader changes in consumer preferences towards electrified mobility.