Norwegian aluminum competence

is of strategic importance to Benteler Automotive

1

NTNU Nettverkskonferanse 27. april 2016

S.-T. Strandlie

Benteler Automotive Raufoss

2

Confidential / Draft

© BENTELER International AG | Page 3

CMS Front –G30/31

BMW 5 Series

SOP 05/2016; 230,000 veh/yr

Beams: BAT Raufoss

Crashboxes: BAT Skultuna

Assy/Welding: BAT Jablonec

Plant Raufoss

New Projects – Aluminium Systems

Confidential / Draft

© BENTELER International AG | Page 4

CMS Front/Rear, LLP and Crossmember – SPA V54X, L541

Volvo S90/V90

SOP 04/2016

V54X 88,734 veh/yr

L541 52,628 veh/yr

Beam: BAT Raufoss

Crashboxes: BAT Raufoss

Assy/Welding: BAT Raufoss / BAT Skultuna

Cross member: BAT Raufoss BAT Jablonec (relocation)

Plant Raufoss

New Projects – Aluminium Systems

Front Crashbox

Front Beam

Rear Beam

Lower Load Path

Crossmember

There are currently some 1700

different extruders in the world Source: Aluminium Times

This is a large supplier base, but

with a big scatter in performance,

quality, cost, footprint, technology

etc.

Market is growing – Technology edge needed

Future Growth of Aluminium Extrusions in Automotive -

Body and Bumper

5

Source: Ducker Worldwide; Light Vehicle Metals Market Analysis

and Forecast June 12, 2012

The OEM’s starting to:

- Categorize material classes

- Define more strict standards

- Define suppliers for each class

- Meet best price globally

02/2014 I A. Artelius I Version 3

40.000 T in

2013

170.000 T in

2025

Market Driven Technology and Innovation Development

0

10

20

30

40

50

60

70

80

90

1970 1975 1980 1985 1990 1995 2000 2005 2010

WW

au

tom

oti

ve

pro

du

cti

on

Mill

ioner

yearMain sources: WMVD, SMMT, JAMA, IRF, CCFA, OICA.

Elaboration Freyssenet M., 2004 and updatings.

RollformingStretch bending and

solutionizingCross-section reforming

2-cavity

3D-bending

3-cavity

Hybrid die’s

Automation

Digital controls

U-profiles Stiff beams Hollow and flexible1-piece

Crash boxes

Welded

System

high strength alloy’s adaptedfor extrusion

Higher productivityImproved corrosion resistance

Ultra high strength

Product

Process

Material

Necessity of Continuous Technology and Innovation Development

- material, process and products

How can we stay in technology lead?

+

Manufacturing

value chain

Casting Extrusion Forming Finishing

Engineering

value

chain

Alloy and heat

treatment

Extrusion

process

Forming

process

Tool

design

Product

design

Prototyping and

Product verification

Integrated Optimization – Product, Process and Material

7

Pro

toty

pes

To

olin

g

Historical technology development

- customers, material, process and products

Success driven by market driven technology development

1970 1980 1990 20102000CMVSS AZT RCARFMVSS

MonobeamOpen stiff Open flexible

CB bolted

CB weldedClosed flexible

Closed stiffStick-in

Rollforming Stretch bending

and solutionizingCross-section

reforming2-cavity

3D-bend

Hybrid die’s 3-cavity

2D-ben

7030 (~360MPa)

7108 (~360MPa) 7021 (~480MPa)

Open

7108(~320MPa)

Closed7003 (~380MPa)

Corrosion

7046opt (~500MPa)

Extr optimized

7046 (~440MPa)

Closed

7108(~420MPa)

Closed

8A. Artelius / 01.07.2013

R&D and Innovation activities needs link to Centers of

Competence – Material, Process and Products

SimLAB - methods and tools for the virtual product development

NorMan - advanced manufacturing technology

AutoPart – spare parts manufacturing

AlFEB – Alloy development

AutoFlex – Tool change-over

Tax funding (typical funding: 250 kEUR/year)

2010 2011 2012 2013 2014 2015

AluCaW – Hybrid cast-extrusion

TIP – Traceability

2016

NextForm – additive manuf.

Lean Operations

User Controlled Innovation Project: industry in-kind 70%, R&D funding: 30% typical 3 yrs, ~ 3 MEUR To stimulate R&D activity in trade and industry, particularly activities that promote innovation and sustainable value creation.

Centre for Research Based Innovation: industry funding 25%, typcial 7 yrs, 30 MEUREnhance the capability of the business sector to innovate by focusing on long-term research based on forcing close alliances

between research-intensive enterprises and prominent research groups.

Knowledge-building Project for Industry: industry funding 20%, typcial 3 yrs, 3 MEURIndustry-oriented researcher training and long-term competence development in the community within topics that are crucial

to the development of business and industry.

SMART – Multi-material process and products

CASA – advanced structural analysis

9

Research and Advanced Development a necessity for long-term

competitiveness

Markedet er representert ved løpende kontakt gjennom industrien, dette er den viktigste

drivkreft for langsiktig Forskning og fremtidig Kompetansebehov.

Innovasjonen kommer til uttrykk gjennom smarte produkter og produksjonsprosser som må

utvikles paralellt.

Kortere ledetid fra ide til industiell implementering er et vesentlig konurransefortrinn for

Skandinavisk industri, dette kan foredles videre.

Et cluster med NTNU, Sintef og Internasjonale industribedrifter som kan dele /samarbeide på

felles problemstillinger og muligheter ved å skape en arena hvor studenter slipper inn i

fellesmiljø hvor forskning, pilotering og prototypproduksjon kan være en strategisk visjon med

potensiale i seg!!

Ny Teknologi - Innovative produkter/processer - Utvikle Talenter

Industriens drivkraft for samarbeid med NTNU

10

11