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• Aluminium in Automotive
• Market Outlook
• Rolled Products and Automotive
• Hydro inside
1
2
3
4
(2)
• Aluminium in Automotive
• Market Outlook
• Rolled Products and Automotive
• Hydro inside
1
2
3
4
(3)
Vehicle weight increase and it’s origins
Start of production
Ve
hic
le w
eig
ht in
Kg
Citroen GS
650
750
850
950
1050
1150
1250
1970 1974 1978 1982 1986 1990 1994 1998 2002
Fiat RitmoFord Escort
VW Golf IOpel Kadett
Renault
9Opel Kadett
Ford Escort
VW Golf IV
VW Golf III
VW Golf II
Fiat Tipo
Renault 19
Opel Astra
Peugeot 305
FiatBrava
Citroen ZX
Renault Megane
Toyota Corolla
Fiat
Sallo
Toyota
Corolla
Ford Focus
Peugeot
205
Opel Astra
Opel Kadett
Peugeot
307VW Golf V
Compact class
• Safety
• Legislation
• Driving performance
• Comfort
• Quality
(5)
Light weighting is 2nd best measure for emission reduction
Rolling resistance
Aerodynamic resistance
Vehicle weight
Drivetrain
Source: Dr. W. Ruch,"Die Strategische Bedeutung der Al-Technologie im Karosserieleichtbau bei AUDI",
2nd European Al-Automobile Conference, November 7-8, 2002, Bad Nauheim
(6)
Change in %
Red
uctio
n in
co
nsu
mptio
n in %
-35
-30
-25
-20
-15
-10
-5
0
0 10 20 30 40 50
Vehicle weight
Greener through reduced emissions and recycling
(7)
• Every kg aluminium substituted for traditional steel
saves up to 15 kg CO2 over the life cycle of a car1)
• Recycling of aluminium saves 95% of the
greenhouse gas emissions associated with primary
aluminium production, and requires only 5% of the
energy
• Nearly 90 % of automotive aluminium is recovered
and recycled
• Aluminium is infinitely recyclable without
degradation to the material
Source: www.drivealuminium.org, Life Cycle Assessment – Energy and CO2 Emissions of Aluminium-
Intensive Vehicles conducted by tge United States Department of Energy’s Oak Ridge National Laboratory
-10
0
10
20
30
40
50
60
70
80
90
Manufacturing Use End-of-Life Life cycle
Life Cycle CO2e Emissions (Kg)
Normal steel vehicle Low weight steel Aluminium intensive vehicle
1) Source: S. Faßbender, “Einsatzmöglichkeiten von Aluminium im Automobilbau”,
Einführung in die Technologie des Aluminiums, March 20-23, 2012, Aachen
Reduced fuel consumption
125 kg lighter vs. predecessor
Mercedes Benz SL
(8)
• 100 kg weight savings
• Reduce fuel consumption by ~0,3 l/100 km
or 600 l over life cycle of 200,000 km
• This equates to ~1.4 tons less CO2
emissions
Source: S. Faßbender, “Einsatzmöglichkeiten von Aluminium im Automobilbau”,
Einführung in die Technologie des Aluminiums, March 20-23, 2012, Aachen
Built to last with unmatchable performance
(9)
• Corrosion resistant, aluminium reduces need for
rust repair and increases vehicles lifespan
• Aluminium components are typically 40% to 50 %
lighter, but provide more structural stiffness than
heavier components they replace
• Higher rigidity of structures improves drivers feeling
for the road and allows faster and more and precise
control
Source: www.drivealuminium.org
Safety first!
(10)
• Absorbs twice as much crash energy as steel
• Allows increased size and energy absorption
capacity without increasing overall weight
• Folds predictably during crash, allowing vehicle to
absorb crash energy and therewith to protect
occupants
• Allows shorter stopping distances
• Aluminium in Automotive
• Market Outlook
• Rolled Products and Automotive
• Hydro inside
1
2
3
4
(11)
40 years of uninterrupted automotive aluminium growth
(12)
0
100
200
300
400
500
600
1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025
DUCKER
WORLDWIDE
In 2015, aluminium penetration
will reach the critical mass for
an explosive period of
growth from 2015 to 2025
In 2025, light vehicles will
be the most important
global market for
aluminium.
Source: Ducker Worldwide, ‘2015 North American Light Vehicle Aluminum Content Study’ , CRU, Hydro
Aluminium content – pounds per light vehicle (1 pound = 0.45 kg)
Increasing Al content in European light vehicles driven by rolled,
automotive body sheet
(13)
Source: Ducker Worldwide 2012
Al-content per car (EU27) Body, bumpers, IP and closures
121
134140
150
180
2006 2010 2012 2015 2020
Kg
9.310.7
11.5
16
27
2006 2010 2012 2015 2020
Kg per vehicle
Cast73%
Rolled13%
Extruded10%
Forged4%
Aluminium: “Stronger, tougher and more fuel efficient”
(14)
JAGUAR LAND ROVER
«Lightweight construction is a
core element of Jaguar’s DNA and
Jaguar is at the cutting-edge of
aluminium technology in
the automotive industry»
AUDI
«Audi believes aluminium still
offers abundant potential,
especially in the shape of the
new, higher-strength alloys»
The car industry embraces aluminium
BMW
«Aluminium plays a major
role in lightweight
construction at the BMW
Group»
Positive development in main growth driving segment
(15)
2014 2018 2022
World Body-in-White
demand in thousand tonnes
2014 2018 2022
1 500
2 100CAGR
20%
Europe Body-in-White
demand in thousand tonnes
280
530
670
CAGR
11%
500
Automotive Body-In-White
• Aluminium in Automotive
• Market Outlook
• Rolled Products and Automotive
• Hydro inside
1
2
3
4
(16)
Automotive
(17)
• No. 2 in Europe with 25% market share, No. 4 in BIW
• Supplying full portfolio with coils, strips and sheets for
chassis, structural components and BIW,
partly with special surface treatment
• Preferred supplier through differentiation
Position
Success
factors
• Innovation
• Full R&D and technical support
• Material models and simulation know-how
• Product properties
optimum surface, especially for outer body sheets
exact flatness
Variety of mechanical properties, depending on application
Pursuing attractive growth opportunities
(18)
Major step in automotive Body-in-White (BiW) market
• Installation of automotive line 3 (AL3) lifting capacity to
200 thousand tonnes per year
• ~130 M€ invest
• Step change in BiW production process
• Production start second half 2016
0
5
10
15
20
25
30
35
0
50 000
100 000
150 000
200 000
250 000
2008 2014 2017 2020
BrandsTonnes
Hydro BiW development
Hydro continuous annealing capacity
# of OEM brands Hydro is qualified for
(19)
-
New: Oxsilan® basedReference: Ti/Zr based
Failure mode in
lap shear test +
Strength loss after weathering (durability)
Better adhesive bonding performance
• achieving preferred failure mode
• improved durability through lower
strength loss after weathering
High strength structural joints by adhesive bonding
Oxsilan® coil passivation
(20)
• High formability and high corrosion resistance
due to optimized specification
• Strategic supplier to major European OEM’s
• Based on leading R&D competence
Forming optimized AA5182 variant
Single-part side panel
(21)
• Forming limits represent the main
challenge in automotive applications
• Clad alloy HA 6016-X allows for strongly improved
formability
• Customers need less joining operations to produce
one functional group
• Cost advantages over multi-piece solutions
• Compatible alloys with no downgrading of existing
recycling concepts
Ambition in automotive
• No. 2 in European BIW market
• Technology leader through
differentiation in innovation,
technical support, quality and
service
• Aluminium in Automotive
• Market Outlook
• Rolled Products and Automotive
• Hydro Inside
1
2
3
4
(23)
BMW 7 series
(24)
Alloys• 6xxx-Outer
• 5xxx-Inner
Car parts• Hood
• Doors
• Trunk lid
• Roof
• Side panel
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