Aluminum Innovation for the Global Automotive Industry Todd Summe Director, Global Automotive Technology, Novelis Inc.

August 4, 2014

Novelis is the Global Industry Leader in Aluminum Sheet

Existing Plant

GLOBAL ALUMINUM LEADER IN: 2

Existing Plant:

New Plant:

Brownfield Expansion

Greenfield Expansion

The Automotive Imperatives

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Achieving Breakthrough Results All Aluminum Range Rover (rel. to steel predecessor) Weight Aerodynamics

Fuel Efficiency Performance & Driveability Durability & Robustness NVH & Sound level Hours per Car # Parts

0%

4

20% Improvement

40%

Bodyside Evolution in Aluminum at JLR  One piece Advanz™ e170 bodyside the largest single aluminum automotive body panel in the world to date  Simple concept which brings weight and costs saving

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Source: JLR presentation, Eurocarbody 2012, R. Lloyd, G. Moyce, S. Black, M. Rickards

Bodyside Evolution in Aluminum at JLR

XJ (X350) Bodyside

XJ (X351) Bodyside

 NG5754  1.5mm  ALO70

 AA6111  1.2mm  ALO70

Range Rover Bodyside  Advanz™ e170  1.1mm  Alub VS

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Source: JLR presentation, Eurocarbody 2012, R. Lloyd, G. Moyce, S. Black, M. Rickards

Advanz™ c300 - Crash Energy Alloy

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

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Product Portfolio with Unique Benefits

Proprietary Products In-Production

Launch Ready

Standard Products

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Exterior

Inner / Structure

Advanz™ e170

Advanz™ s118

Advanz™ e600

Advanz™ e200

Strength

Advanz™ c300

Advanz™ s600

Advanz™ s200

5754 5182

Crash

Advanz™ s615

6111

Global Automotive R&D Program ALLOY INNOVATION

ENGINEERED SURFACES  Unified global pretreatment  Mixed body solutions  Optimized surface topography

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Forming

Joining

 Advanz™ e200  Advanced Form Fusion™  Elevated Temperature

 Fusion™ for RLW  Multi-material Joining

Strength / Crash

Recycling

 Tailored Aluminum Blank (FSW & LW)

   

 6xxx skin and structural  5xxx structural  End of Life vehicle

 Formability & crash characterization

Advanz™ s615 6xHS: 330 MPa 7xHS: 500 MPa 7xHS: Phase 2

APPLICATION TECHNOLOGY  Global technology & engineering

support

 Elevated temperature forming

characterization

Advanz™ e200 − Advanced Formability

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Advanz™ e200 − Advanced Formability HIGHER FLC0

MORE STRAIN HARDENING 250

30%

200

25%

Major strain (-)

0.40 0.35

20%

0.30

150 15%

0.25 100

0.20 Advanz™ e200

0.15 0.10

Advanz™ e170

0.05 0.00 -0.20

0.00

0.20

Minor strain (-)

0.40

10%

50

5%

0

0%

Advanz™ e200 Rp0.2 (Mpa)

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MORE ELONGATION

Advanz™ e170 RM (Mpa)

Advanz™ e200 Ag

Advanz™ e170 A80

Advanz™ e200 − Initial Component Evaluations INFLUENCE of FLCo on FORMING Advanz™ e170

BODY SIDE TRIALS Advanz™ e170

Advanz™ e200

Advanz™ e200

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R&D for Advanced Forming Elevated Temperature Strategy T89 T

T89 L

Low Temp Shock T

Low Temp Shock L

Examples

r 10

r6

r6

Warm forming 200-300C

5-7%

Hot forming 500-570C

10-15 %

Combined hot and cold

> 15 %

r4

Low temperature shock heat treatment hardly changed the flow curve but improved bendability 13

Expected Gain

High Strength Alloys

Total Elongation for Forming [%]

High Strength Roadmap

e200

Advanz™ s615 6xHS 330

7xHS PII 7xHS 500

Specific Ultimate Tensile Strength [Mpa / kg/m3] 15

Strength Dominated Sheet Products Advanz™ s615

6xHS-330

Status: Launch Ready

Status: Material Approval

 In-service T8x (2%+185°C 20min) Yield Strength: 250 MPa

 In-service T8x (2%+185°C 20min) Yield Strength: 330MPa

 In-service Post Form Heat Treatment (T6) Yield Strength: 300 MPa

 Solution for strength-dominated parts

 Strength-toughness dominated parts (e.g. Lower Front Rail, B-pillar, Rocker)

 Potential to eliminate of post-forming heat treatment processes (cost reduction)

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(e.g. B-pillar reinforcements)

7xHS Alloy Innovation PHASE I  > 500 MPa Yield Strength; Crash Intrusion  > 400 MPa Yield Strength; Crash Energy  Roll form hard temper  Warm form hard temper  Hot Form F-temper

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Tailored Solutions

Aluminum Tailored Blanks

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DEVELOPMENT OF WELDING TECHNOLOGY

WELDING TECHNOLOGY & FORMING TECHNOLOGY VALIDATION

OEM APPROVAL PROCESS

SERIES PRODUCTION SET UP WITH OEM

2012

2013

Q1 2014

Q3 2014

Aluminum Friction Stir Welding (FSW) Equipment

• • • •

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First Aluminum FSW Dedicated Line in NORTH AMERICA

First Aluminum LASER Dedicated Line in EUROPE

(Q1 2014 Commissioning)

(Q3 2014 SOP of Structural Component)

5 Axis for 2D welding 2M x 1.5M bed size 0.8 mm to 4 mm sheet thicknesses AA5000, AA6000 and AA7000 materials

• • • •

WTB developed welding concept Automatic part joining Optimized for process stability Manual or Fully Automated options

Tailored Aluminum Blanks − Door Structure Study

Cost Comparison Aluminum Assy vs. TAB® TAB® Δ NET WEIGHT

- 5%

Δ GROSS WEIGHT

- 15 %

Δ VARIABLE COST

- 5%

Δ INVESTMENT

- 39 %

WEIGHT 

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COST 

PERFORMANCE ✓

Advanced Joining Solutions

Joining Productivity with Remote Laser Welding  Much faster than conventional technique with filler metal  Allows more complex weld shapes with less geometrical constraints

 Better weld sequence optimization

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Advanz™ s200 for Remote Laser Welding  Advanz™ s200 is weldable without filler metal

 Maintains the benefits of 6xxx monolithic products  Cost effective  Approvals in progress with multiple automakers for several applications

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Advanz™ s200 for Remote Laser Welding

 Maintains the benefits of 6xxx monolithic products  Cost effective  Approvals in progress with multiple automakers for several applications

Welding Speed [m/min]

 Advanz™ s200 is weldable without filler metal

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Crack free weld can be achieved up to :

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- Speed of:

22 m/min

- Gaps of:

0.4 mm

12

10 0

0.3

0.4

0.5

Gap (mm)

25

0.6

0.7

Door Frame Flange Welding

GOOD

BAD

2.5

5

7.5 EDGE DISTANCE

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10 mm

Additional Opportunities for Advanz™ s200  One-side Assembly for many modules  Potential for significant reduction of adhesive bonding due to stiffness increase

 Replace steel remote welded panels by aluminum

Tailgate (110 welds/car)

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Doors FD/RD (4 x 90 welds/car)

Sidewall inner (120 welds/car)

Future Direction for Aluminum Automotive Solutions  High Form and High Strength Monolithic and Fusion™ Alloys

 Tailored Multi-Material Solutions  Increased Recycled Content

 Optimized Surface Texture and Treatment  Elevated Temperature Forming

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