Aluminium Sheet DevelopmentsAluminium Sheet Developments

for current and future BIW concepts for current and future BIW concepts

Aluminium Aluminium ExperienceExperience DayDay3030 augustusaugustus 2011201130 30 augustusaugustus 20112011

Dirk Van Dirk Van NieuwerburghNieuwerburgh

Contents Contents

I t d ti Al i Al i i E• Introduction Aleris Aluminium Europe• Aleris in Automotive

6016 ll tf li f b d l• 6016 alloy portfolio for body panels• Trends affecting material quality • 7xxx alloy development• Clad solutions• Aleris Aluminium in automotive extrusion business• Summary

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Standardisation <Standardisation <--> Diversification > Diversification Standardisation <Standardisation <--> Diversification > Diversification

Aleris Aluminium introductionAleris Aluminium introductionAleris Aluminium introductionAleris Aluminium introduction

Aleris EuropeAleris EuropePlantsPlantsPlantsPlants

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Rolling- and Extrusion CapabilitiesRolling- and Extrusion Capabilities

Aleris Aluminum DuffelAleris Aluminum DuffelSite overviewSite overviewSite overviewSite overview

Nete Rolling mill Automotive finishing line CALPNete g g

GC Off

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GreenmeltCasthouseExtrusion division Head Office

Location new cold mill investment 2012

Aleris Aluminium Duffel Aleris Aluminium Duffel Examples of product applicationsExamples of product applicationsExamples of product applicationsExamples of product applications

6Courtesy of Lingemann, OZ Racing, Grolleau, Presspart, Gillette, Lydall Gerhardi, SAG, Uponor

Aleris Aluminium in AutomotiveAleris Aluminium in AutomotiveAleris Aluminium in AutomotiveAleris Aluminium in Automotive

Growing Aluminum DemandGrowing Aluminum DemandOverview major European OEMsOverview major European OEMsOverview major European OEMsOverview major European OEMs

Vehicle production Rolled aluminum usage

2010 2015 2010 2015 2010 2015

OEMs CAGR CAGR

PSA 2.4 2.8 3.4% 20 35 12% 8 12

m units Al k tons Al kg p/LV

VW 2.0 2.4 4.2% 0 24 n/a 0 10

Ford 1.1 1.8 9.6% 0 4 n/a 0 2

GM 1.4 1.5 0.9% 2 5 25% 1 3

Daimler 1.2 1.2 1.3% 25 60 19% 22 48

Audi 1.0 1.2 4.9% 25 75 25% 26 61

BMW 0.9 1.2 5.2% 32 75 19% 35 63BMW 0.9 1.2 32 75 35 63

Volvo 0.4 0.5 7.2% 5 12 19% 14 24

JLR 0.2 0.3 8.6% 18 50 23% 96 177

Porsche 0 1 0 2 9 4% 4 6 8% 40 38Porsche 0.1 0.2 9.4% 4 6 8% 40 38

Others 8.0 10.6 5.8% 0 0 n/a 0 0

Totals 18.5 23.6 5% 131 346 22% 7.1 14.7

8Source: OEMs Alu Demand Projections, JDPowers Database, Team Analysis

Al content will double, but penetration still low (2.5% growing to 5% of body weight)

Aleris EuropeAleris EuropeAutomotive applicationsAutomotive applicationsAutomotive applicationsAutomotive applications

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Aleris Aluminium DuffelAleris Aluminium DuffelAutomotive applicationsAutomotive applications -- SegmentsSegmentsAutomotive applications Automotive applications SegmentsSegments

Outer panels 6xxx alloys – High customisation – Surface quality & treatments 6xxx alloys High customisation Surface quality & treatments Continuous annealing line compulsory (6xxx in T4 temper) Wide sheet share increasing OEM or Tier 1

Inner panels 6xxx & 5xxx alloys – Regular customisation – Surface treatments C ti li li tl d d Continuous annealing line mostly needed

(6xxx in T4 temper – special 5xxx qualities) Wide sheet share increasing OEM or Tier 1

Structural parts 5xxx alloys – Low customisation Batch annealing OEM down to Tier 3

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Aleris Aluminium Duffel Aleris Aluminium Duffel Continuous annealing capabilitiesContinuous annealing capabilitiesContinuous annealing capabilitiesContinuous annealing capabilities

CALP = CALP = Continuous Annealing Continuous Annealing Line with PretreatmentLine with PretreatmentLine with PretreatmentLine with Pretreatment

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Aleris Aluminium Duffel Aleris Aluminium Duffel Continuous annealing capabilitiesContinuous annealing capabilitiesContinuous annealing capabilitiesContinuous annealing capabilities

Main production steps in hpress shop

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6016 alloy portfolio for body panels6016 alloy portfolio for body panels6016 alloy portfolio for body panels6016 alloy portfolio for body panels

6xxx series alloys for BIW6xxx series alloys for BIW

6016 b i f d l t i E• 6016 : basis for developments in Europe• 6111 : basis for developments in USA• Variants : 6014, 6005A, 6451• Why 6xxx material :

– Good combination of formability in T4 and strength in “T6” conditionPaint bake response : low strength in T4 condition clearly higher– Paint bake response : low strength in T4 condition, clearly higher strength after paint baking (T4 YS 100-110 MPa, T6 YS 200-230 MPa)

– Good surface properties : no Lüderlines as for 5xxx alloys, roping control for outer body applicationscontrol for outer body applications

14Ecolite 160/210/250 Superlite® 200 ST/IH Superlite® 200 RF

Aleris Aluminium EN 6016 portfolioAleris Aluminium EN 6016 portfolioUniUni--alloy conceptalloy conceptUniUni alloy concept alloy concept

®Outer Panels

Superlite® 160 ST Standard EN6016Superlite® 200 ST Standard EN6016Superlite® 200 RF Roping Free EN6016Superlite® 200 IH Improved Hemming EN6016Superlite® 200 IF Improved Forming EN6016Superlite® 220 ST Standard EN6016

EcoliteTM 160 ST Standard EN6016EcoliteTM 160 RO Roping Optimised EN6016

Inner panels & Structural Parts

p g pEcoliteTM 210 ST Standard EN6016EcoliteTM 210 RO Roping Optimised EN6016EcoliteTM 250 ST Standard EN6016Sta da d 60 6

Si Fe Cu Mn Mg Cr Zn Ti Almin. 1,0 - - - 0,25 - - - - -max. 1,5 0,50 0,20 0,20 0,6 0,10 0,20 0,15 0,05 each 0,15 total remainder

Other

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All EN 6016All EN 6016All EN 6016All EN 6016

Aleris Aluminium EN 6016 portfolioAleris Aluminium EN 6016 portfolioUniUni--alloy conceptalloy conceptUniUni alloy conceptalloy concept

Strength Hemming Roping Formability

Outer panels

Superlite® 160 ST + +++ ++ +++

Superlite® 200 ST ++ ++ ++ ++Superlite 200 ST ++ ++ ++ ++

Superlite® 200 RF ++ ++ ++++ ++

Superlite® 200 IH ++ +++ ++ ++®Superlite® 200 IF ++ ++ ++ +++

Superlite® 220 ST +++ ++ ++ +

Inner panels & Structural Parts

EcoliteTM 160 ST + ++ - ++

EcoliteTM 160 RO + ++ + ++EcoliteTM 210 ST ++ ++ - ++

EcoliteTM 210 RO ++ ++ + ++EcoliteTM 250 ST ++++ + - +

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A suitable EN 6016 grade for every panel ! A suitable EN 6016 grade for every panel ! A suitable EN 6016 grade for every panel ! A suitable EN 6016 grade for every panel !

Trends affecting material qualityTrends affecting material qualityTrends affecting material qualityTrends affecting material quality

Design tendencies in BIWDesign tendencies in BIWAudi A6Audi A6Audi A6Audi A6

Aluminium panels :

C6 (2004)

Aluminium panels :MotorhoodFender

C7 (2011)

Aluminium panels :Motorhood

C7 (2011) FenderDoors

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Design tendencies in BIWDesign tendencies in BIWBMW 5BMW 5BMW 5BMW 5

Aluminium

Model 2003

Aluminium panels :MotorhoodFender2003

Model 2010

Aluminium panels :Motorhood2010 MotorhoodFenderDoors

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Design tendencies in BIWDesign tendencies in BIWMercedes EMercedes EMercedes EMercedes E

BR 211 (2002)

Aluminium panels :Motorhood(2002) MotorhoodFenderTrunk lid

BR 212

Aluminium panels :MotorhoodBR 212

(2008)MotorhoodFenderTrunk lid

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Design tendencies in BIW Design tendencies in BIW Mercedes F800 Style conceptMercedes F800 Style conceptMercedes F800 Style conceptMercedes F800 Style concept

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Tendencies outer panelsTendencies outer panels

P d d i f t ( h t li ) ki f bilit• Pronounced design features (character lines) making formability requirements higher

• Severe forming at some parts of panel increase requirements on surface aspect (roping) -> “paint lines”

• Severe forming causing hemming issues• Formability more important than strength after paint baking for some panelsy p g p g p• Higher strength to reduce weight for some panels

Guaranteed Rp0,2 (Mpa) after 2% + 185°C / 20 min.

100

150

200

250+10%

0

50

100

Superlite ® 160 ST Superlite ® 200ST/RF/IH/IF

Superlite ® 220 ST

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Challenge : keep cost acceptable for customers!Challenge : keep cost acceptable for customers!

Consequences for 6xxx portfolio developmentConsequences for 6xxx portfolio development

Diff t i t f diff t l diff ti t d t i l liti• Different requirements for different panels -> differentiated material qualities to be developed

• Increase formability without reducing strength• Increase strength without reducing formability• Increase surface quality level in general (also for visual inner panels)• Better hemming quality without reducing strengthBetter hemming quality without reducing strength

Continuous development efforts needed to achieve these targetsContinuous development efforts needed to achieve these targets

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Continuous development efforts needed to achieve these targetsContinuous development efforts needed to achieve these targets

Material developments in AluminiumMaterial developments in AluminiumMaterial developments in AluminiumMaterial developments in Aluminium

7xxx for Automotive7xxx for AutomotiveOverviewOverview

5xxx / 6xxx Alloys 5xxx / 6xxx Alloys 7xxx Alloys 7xxx Alloys

OverviewOverview

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High Strength Aluminium High Strength Aluminium --> 7xxx Alloys > 7xxx Alloys High Strength Aluminium High Strength Aluminium --> 7xxx Alloys > 7xxx Alloys

High Strength Aluminium AlloysHigh Strength Aluminium AlloysAleris HeritageAleris HeritageAleris HeritageAleris Heritage

Maximum Strength Rp0.2 250MPa

M i St th R 600MPMaximum Strength Rp0.2 600MPa

Mature 7xxx alloy technology supplied to a Mature 7xxx alloy technology supplied to a safety critical industrysafety critical industrysafety critical industrysafety critical industry

Development approach for Automotive Structural Parts : Development approach for Automotive Structural Parts : M di t th AlM di t th Al ZZ M tM t St t lit 400St t lit 400•• Medium strength AlMedium strength Al--ZnZn--Mg system : Mg system : Structurlite 400Structurlite 400

•• High strength AlHigh strength Al--ZnZn--MgMg--Cu system : Cu system : Structurlite 5xxStructurlite 5xx

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Structurlite 400 : Rp0.2 400 MPa Structurlite 5xx : Rp0.2 500 Structurlite 400 : Rp0.2 400 MPa Structurlite 5xx : Rp0.2 500 -- 590 MPa 590 MPa Structurlite 400 : Rp0.2 400 MPa Structurlite 5xx : Rp0.2 500 Structurlite 400 : Rp0.2 400 MPa Structurlite 5xx : Rp0.2 500 -- 590 MPa 590 MPa

7xxx for automotive7xxx for automotiveThe Banana DiagramThe Banana DiagramThe Banana DiagramThe Banana Diagram

60

70

on (%

)

40

50

long

atio

30

40 Mild

BH5xxx6xxx T4E

10

20

MART (B-steels)

6xxx T4

6xxx T6

T il St th (MP )

00 600 1200300 900 1600

MART (B steels)

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Tensile Strength (MPa)

7xxx for automotive7xxx for automotiveTheThe SPECIFICSPECIFIC Banana DiagramBanana DiagramThe The SPECIFICSPECIFIC Banana DiagramBanana Diagram

Taking into

60

70Taking into account density (weight)

40

50

on [%

]

30

40

Elon

gati

Mild

BH

10

20

MART(B-steels)0

0 50 100 150 200 250 300

MART(B steels)

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Specific Tensile Strength [MPa/kg/m3]

7xxx for Automotive 7xxx for Automotive Comparison with UHS steelComparison with UHS steel

AA 7xxx

Comparison with UHS steel Comparison with UHS steel

Boron steel2mm

AA 7xxx3.5mm

The crash performance is The crash performance is very similar in all resultsvery similar in all results

Mass saving with aluminium Mass saving with aluminium component is 40%component is 40%

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ppSLCSLC

7xxx for Automotive7xxx for AutomotiveChallenges to R&DChallenges to R&DChallenges to R&DChallenges to R&D

P i i th D ff l l t• Processing in the Duffel plant • Formability at the customer : simulation + adapted process• Lacquering• Joining technology : welding more difficult to impossible

-> Self piercing rivets

• Corrosion : FFC, IGC, SSC

• Application performance : crash, dynamic behaviour

AA6016 84µm Structurlite 400 80µm

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Application performance : crash, dynamic behaviour

7xxx for Automotive7xxx for AutomotiveLong qualification periodLong qualification periodLong qualification periodLong qualification period

31Source : Daimler WFP process

Very long testing period for really new material qualities Very long testing period for really new material qualities Very long testing period for really new material qualities Very long testing period for really new material qualities

Clad Products for product improvementClad Products for product improvementExamplesExamplesExamplesExamples

C i f 7 l d ith 6 5• Corrosion performance : 7xxx clad with 6xxx or 5xxx

Superlite® 200

Structurlite 400 / 5xx

Superlite® 200

• Hemming combined with high strength for 6xxx

®

Outside Superlite® 200 IH

Superlite® 250

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Cost versus technological advantage Cost versus technological advantage Cost versus technological advantage Cost versus technological advantage

Aleris Aluminium in Aleris Aluminium in

Automotive Extrusion businessAutomotive Extrusion business

Aleris Aluminum ExtrusionsAleris Aluminum ExtrusionsAutomotive applicationsAutomotive applicationsAutomotive applicationsAutomotive applications

Sunroof and

Bumper systems

rooftransport profilesAirbag ignition

and housings

Shock

ABS steering valves

absorbersAutomatic transmission valves

Drumbrake pumps

SuspensionB-pillars

valves pumps

Suspension arms

Side impact beamsCrash Braking

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Steering column parts

Crash management systems

Braking pistons

Aleris Aluminum ExtrusionsAleris Aluminum ExtrusionsAutomotive customersAutomotive customersAutomotive customersAutomotive customers

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SummarySummary

• Aluminium is getting an established material for BIW, but still at low volume

• Due to CO2 targets : steep increase of Al use expected

• Aleris Aluminium Duffel is a top player in 6xxx qualities for BIW• Aleris Aluminium Duffel is a top player in 6xxx qualities for BIW dedicated CALP line for automotive body sheet

• Design trends and weight reduction targets still put new challenges to Al sheet products : advanced 6xxx materials new 7xxx materials new 7xxx materials clad products to make combination of properties possible

• Aleris not only active in Rolled Products, but also in Extrusions towards automotive industry

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??Dirk.Van.Nieuwerburgh@aleris.coma eu e bu g @a e s co

T : +32 (0) 15 30 26 26

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