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Globalisation and innovation in the field of aluminium alloys
Vogel - CAR
December, 2014
本文档来自2014国际汽车技术年会 未经允许不得转载
Legislation trend worldwide
The need to reduce CO2 emissions is
the #1 driver globally for increased
adoption of Aluminum
Lightweight design is key to
sustainable mobility, globally
Weight reduction:
100 kg
Fuel reduction:
0.3 – 0.5 L/100 km
Reduction incl. 2nd-ary measures:
8 – 11 g CO2/ km
July 2011: New CAFE standards of 54.5 mpg for American vehicle fleets by 2025 - CO2 emissions reduced to 102 g/km
2025
USA
Apr 2012: China’s Energy Saving and New Energy Auto Industry Development Plan (2012-2020) by 2020 - CO2 emissions reduced to 112.5 g/km A
uto
CO
2 E
mis
sio
n T
ren
d (
in g
/km
)
本文档来自2014国际汽车技术年会 未经允许不得转载
Aluminum-based Mass Reduction Provides Cost Effectve Fuel Economy
6 Source: US Aluminum Association
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
$0
$200
$400
$600
$800
$1,000
$1,200
MP
G Im
pro
vem
en
t
Co
st
/ M
PG
National Academy of Science Fuel Economy Technology Assessment 2011
Cost / MPG
MPG Improvement
本文档来自2014国际汽车技术年会 未经允许不得转载
Moving to Aluminium – Range Rover case
All - Aluminum Range Rover (compared to steel predecessor)
Improvement
Weight
Aerodynamics
Fuel Efficiency
Performance & Driveability
Durability & Robustness
NVH & Sound level
Hours per Car
Part Count Reduction
0% 20% 40%
7 本文档来自2014国际汽车技术年会 未经允许不得转载
Existing Plant Existing Plant: Brownfield Expansion
New Plant: Greenfield Expansion
Novelis is the Global Industry Leader in Aluminum Sheet
9
GLOBAL
ALUMINUM
LEADER IN:
GLOBAL
OPERATIONS
本文档来自2014国际汽车技术年会 未经允许不得转载
via investment in
a unique global
production footprint
via investment in
Global Research
and Development
via investment in
breakthrough
recycled content
Global Automotive Strategy
10
Novelis is committed to extend our leadership position in:
本文档来自2014国际汽车技术年会 未经允许不得转载
11
Global Automotive Product Portfolio
Proprietary
Products
In-Production
Exterior Inner / Structure Strength Crash
Standard
Products
5754
5182
Advanz™ e170
Advanz™ s615
Advanz™ c300
Advanz™ e200
Advanz™ e600
Advanz™ s118
Advanz™ s200 RW
6111
Launch Ready RC5754
本文档来自2014国际汽车技术年会 未经允许不得转载
Specs Have Significant Impact on Cost
Harmonized specs enable optimization for the industry and customers
Harmonize and use “fit for service” specs
Use EDT surface where required for forming or appearance
12 本文档来自2014国际汽车技术年会 未经允许不得转载
Global Research & Technology
14
Kennesaw, GA
Global R&D
Global Engineering
Global Manufacturing
Excellence
Global Quality and Safety
Pilot Scale Development
Spokane, WA Global MMP
Global Plant Support
Goettingan, Germany Global R&T
NE Plant Support
Product Development
Mumbai, India ABSTC R&D
Technology Dev.
Modeling
Ulsan, Korea Global R&T
NA Tech. Support
NA Plant Support
Product Develop. Sierre, Switzerland Global R&T
NE Plant Support
Product Development
Pinda, Brazil
SA Tech Support
NSA Plant Support
Product Development
本文档来自2014国际汽车技术年会 未经允许不得转载
Future Direction for Aluminum Automotive Solutions
15
High Form and High Strength Monolithic
and Fusion™ Alloys
Tailored Multi-Material Solutions
Increased Recycled Content
Optimized Surface Texture and Treatment
Elevated Temperature Forming
本文档来自2014国际汽车技术年会 未经允许不得转载
ALLOY INNOVATION ENGINEERED SURFACES
Unified global pretreatment
Mixed body solutions
Optimized surface topography
Global Automotive R&D Program
16
APPLICATION TECHNOLOGY
Global technology & engineering
support
Tailored Aluminum Blank (FSW & LW)
Formability & crash characterization
Elevated temperature forming
characterization
Forming Advanz™ e200
Advanced Form Fusion™
Elevated Temperature
Joining Fusion™ for RLW
Multi-material Joining
Strength / Crash Advanz™ s615
6xHS: 330 MPa
7xHS: 500 MPa
7xHS: Phase 2
Recycling 6xxx skin and structural
5xxx structural
End of Life vehicle
本文档来自2014国际汽车技术年会 未经允许不得转载
Bodyside Evolution in Aluminum at JLR
XJ (X350) Bodyside NG5754
1.5mm
XJ (X351) Bodyside AA6111
1.2mm
Range Rover Bodyside
Advanz™ e170
1.1mm
17 Source: JLR presentation, Eurocarbody 2012, R. Lloyd, G. Moyce, S. Black, M. Rickards 本文档来自2014国际汽车技术年会 未经允许不得转载
Advanz™ c300 for Crash Energy Alloy
19
In comparison to 5754 equivalent part
20% Weight save achieved – circa
6kg per vehicle
9% Cost save per vehicle
12000 tonnes CO2 reduced from
fleet tailpipe emissions
本文档来自2014国际汽车技术年会 未经允许不得转载
High Strength Roadmap
20
Specific Ultimate Tensile Strength [Mpa / kg/m3]
To
tal E
lon
gati
on
fo
r F
orm
ing
[%
]
6xHS 330
7xHS 500
7xHS PII
e200 Advanz™ s615
本文档来自2014国际汽车技术年会 未经允许不得转载
Strength Dominated Sheet Products
21
Advanz™ s615 Status: Launch Ready
In-service T8x (2%+185°C 20min)
Yield Strength: 250 MPa
In-service Post Form Heat Treatment (T6)
Yield Strength: 290 MPa
Strength-toughness dominated parts (e.g. Lower Front Rail, B-pillar, Rocker)
PFHT is rivet-able with SPRs
T6 Yield Strength (MPa)
Industry Standard
Customer Specification
Novelis Advanz™ s615
本文档来自2014国际汽车技术年会 未经允许不得转载
DEVELOPMENT
OF WELDING
TECHNOLOGY
2012
WELDING
TECHNOLOGY
& FORMING
TECHNOLOGY
VALIDATION
2013
OEM
APPROVAL
PROCESS
Q1 2014
SERIES
PRODUCTION
SET UP
WITH OEM
Q3 2014
Aluminum Tailored Blanks
23 本文档来自2014国际汽车技术年会 未经允许不得转载
Aluminum Friction Stir Welding (FSW) Equipment
24
First Aluminum FSW Dedicated Line
in NORTH AMERICA (Q1 2014 Commissioning)
• 5 Axis for 2D welding
• 2M x 1.5M bed size
• 0.8 mm to 4 mm sheet thicknesses
• AA5000, AA6000 and AA7000 materials
First Aluminum LASER Dedicated Line
in EUROPE (Q3 2014 SOP of Structural Component)
• WTB developed welding concept
• Automatic part joining
• Optimized for process stability
• Manual or Fully Automated options
本文档来自2014国际汽车技术年会 未经允许不得转载
Tailored Aluminum Blanks − Door Structure Study
25
Cost Comparison Aluminum Assy vs. TAB®
TAB®
Δ NET WEIGHT - 5 %
Δ GROSS WEIGHT - 15 %
Δ VARIABLE COST - 5 %
Δ INVESTMENT - 39 %
WEIGHT COST PERFORMANCE ✓
本文档来自2014国际汽车技术年会 未经允许不得转载
Joining Productivity with Remote Laser Welding
27
Much faster than conventional
technique with filler metal
Allows more complex welds
Better weld sequence
optimization
The Challenge:
6xxx series alloys crack without
a filler wire
本文档来自2014国际汽车技术年会 未经允许不得转载
Advanz™ s200 RW - Key enabler for Remote Laser Welding
28
Advanz™ s200 RW is
weldable without filler metal
Maintains the benefits of
6xxx monolithic products
Approvals in progress with
multiple automakers for
several applications 0 0.3 0.4 0.5 0.6 0.7
10
12
20
22
Weld
ing S
pe
ed [m
/min
]
Crack free weld can be achieved
up to :
- Speed of: 22 m/min
- Gaps of: 0.4 mm
Gap (mm)
本文档来自2014国际汽车技术年会 未经允许不得转载
Opportunities for Advanz™ s200 RW and Remote Laser Welding
29
One-side Assembly for many modules
Potential reduction of adhesive bonding due to stiffness increase
Doors FD/RD (4 x 90 welds/car) Sidewall inner (120 welds/car) Tailgate (110 welds/car)
本文档来自2014国际汽车技术年会 未经允许不得转载
Closed-Loop System Drives Cost & CO2 Efficiency
Synchronize alloy selection with
the stamping strategy and the
closed-loop system strategy
Espec. 5xxx - 6xxx alloy mix
31 本文档来自2014国际汽车技术年会 未经允许不得转载
Closed-Loop System Drives Cost & CO2 Efficiency
Customer
Process Scrap
(All Suppliers)
6xxx
Hi Cu 6xxx
5xxx
Lo Cu 6xxx
Lo Mg 5xxx
Hi Mg 5xxx
Advanz™ s615
Advanz™ e600 / e170
5754
5182
ALLOY
SEGREGATION
BOM
ALLOY
PRODUCT MIX Early BOM visibility enables
comprehensive trade studies
and decisions
We continue to enhance
alloys for recycle content
and breadth of application
32 本文档来自2014国际汽车技术年会 未经允许不得转载