Globalisation and innovation in the field of aluminium alloys

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

Agenda

• Light weighting motivation

• Globalization

• Innovation


Light weighting motivation


Air pollution around the world


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

)


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


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

Globalization


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


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:


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


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


Innovation


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


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


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


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

Alloys for Strength and Crash Energy


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


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


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


Tailored Solutions for Material Utilization


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


http://www.google.com/url?sa=i&rct=j&q=novelis&source=images&cd=&cad=rja&docid=wQNDBX8Tw4w_mM&tbnid=xR10TZhxJOkMyM:&ved=0CAUQjRw&url=http://www.novelis.com/en-us/Pages/Image-and-Logo-Gallery.aspx&ei=-ZqoUfTEC6K_yQGksYHYDQ&bvm=bv.47244034,d.aWc&psig=AFQjCNGC5DPj3_sYE_MyXCi_w1qKtGq91w&ust=1370090607615593

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


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 ✓


High Speed Joining Solutions


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


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)


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)


Recycling


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


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


Documents

Globalisation and innovation in the field of aluminium alloys