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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
2
Standardisation <Standardisation <--> Diversification > Diversification Standardisation <Standardisation <--> Diversification > Diversification
Aleris Aluminium introductionAleris Aluminium introductionAleris Aluminium introductionAleris Aluminium introduction
Aleris EuropeAleris EuropePlantsPlantsPlantsPlants
4
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
5
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
9
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
10
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
11
Aleris Aluminium Duffel Aleris Aluminium Duffel Continuous annealing capabilitiesContinuous annealing capabilitiesContinuous annealing capabilitiesContinuous annealing capabilities
Main production steps in hpress shop
12
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
15
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 ++++ + - +
16
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
18
Design tendencies in BIWDesign tendencies in BIWBMW 5BMW 5BMW 5BMW 5
Aluminium
Model 2003
Aluminium panels :MotorhoodFender2003
Model 2010
Aluminium panels :Motorhood2010 MotorhoodFenderDoors
19
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
20
Design tendencies in BIW Design tendencies in BIW Mercedes F800 Style conceptMercedes F800 Style conceptMercedes F800 Style conceptMercedes F800 Style concept
21
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
22
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
23
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
25
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
26
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)
27
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)
28
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%
29
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
30
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
32
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
34
Steering column parts
Crash management systems
Braking pistons
Aleris Aluminum ExtrusionsAleris Aluminum ExtrusionsAutomotive customersAutomotive customersAutomotive customersAutomotive customers
35
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
36