Speeding Ahead Automotive Lightweighting2gjjon1sdeu33dnmvp1qwsdx.wpengine.netdna-cdn.com/... ·...
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Erwin Mayr Chief Strategy and Commercial Officer
Novelis, Inc.
Speeding Ahead –
Automotive Lightweighting
June 12, 2012
Chicago
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Agenda
Overview: Aluminum Sheet in Automotive Applications
Explosive Growth Ahead
Novelis – Leading the Way
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1970 1980 1990
Porsche 928
(hood, fender,
door)
Land Rover
Discovery 1
(hood, fender,
door)
Audi A8 ASF
(single sheet
supplier)
Daimler S
Class (hood,
decklid)
A Little Bit of History
Audi A6 (curved
blanks)
Audi A2
(sheet)
2000 2010
Trial for Audi
100
all aluminium
body
Jaguar XJ with
full aluminium
body
Aluminium goes
global: Extended
aluminium usage
in BIW even in
A/B segment
Novelis Fusion™
In BMW 5 series, 7
series and GT.
Novelis wins BMW
supplier innovation
award
2013 All-
aluminum body
Mercedes SL
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Legislation Trends World-Wide
Lightweight design is key to sustainable
mobility: the need to reduce CO2 emissions is
the #1 driver globally for increased adoption of
Aluminum
Auto CO2 Emission Trend (in g/km)
Weight reduction: 100 kg
Fuel reduction: 0.3 – 0.5 L/100 km
Reduction incl. secondary
measures: 0.8 – 1.1 kg CO2/100 km
July 2011: New CAFE
standards of 54.5 mpg for
American vehicle fleets by
2025
– CO2 emissions
reduced to 102 g/km
2025
USA
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Reduced Weight Up to 40% weight reduction
in key automotive components
Excellent Formability Excellent class-A surface,
sharp design
High Strength Great strength and
energy absorption
Resistance to Corrosion Aluminium oxide coating
prevents corrosion
Recyclability Nearly 90% of auto aluminium
is recovered and recycled
Adaptability Strong thermal and
electrical conductivity
Source: EAA
Aluminium – Material of Choice
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Material Price
Pot weight
saving (vs. steel)
Use/
applications
Aluminium $4-6/kg 20-45% Hang ons, then moving into structure
Steel $1.3/kg 10% Main structure, body shell, safety crash
Titanium $33-105/kg 50% For rigidity parts low series
Magnesium $13-26/kg 30-50% Complex use with coating
Carbon Fiber $52-105/kg 50% Crash, high strength-rigidity, skin ??
Main materials for Auto BIW
Limited use
Potential for future but price must come down
Source : Dr Füller, New Developments in Sheet Metal Forming
Schwabenlandhalle Fellbach, 04./05. Mai2010
Material Competition
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Agenda
Overview: Aluminum Sheet in Automotive Applications
Explosive Growth Ahead
Novelis – Leading the Way
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North American Auto Market
• Uses 90kg more
Aluminum (90% of
which is FRP)
• Combined with
other materials, this
saves 180kg/vehicle
• Estimated cost for
weight savings
<$1000/vehicle
• No compromise in
vehicle size
• 10% weight
reduction equals
5–7% fuel economy
improvement
2012
2025
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North American Auto Market
THIS WOULD REQUIRE:
80 kg FRP/vehicle * 15M vehicles/year
= 1.2M tons/year finished parts
= >2M tons/year FRP Coil
= ~ 2x current Novelis North American Total FRP Production
4
15
9
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European Story
Europe will increase aluminum
content by >25 kg/vehicle by 2025.
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THIS WOULD REQUIRE:
European Story
= ~.8x Europe Novelis Capacity
25 kg FRP/vehicle * 20M vehicles/year
= 500 kt/year finished parts
= >800 kt/year FRP Coil
= ~.8x Europe Novelis Capacity
1.5
~6
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Asian Story
If Asia realizes just over 50% of the
growth expected in North
America…
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Asian Story
THIS WOULD REQUIRE:
45 kg FRP/vehicle * 35M vehicles/year
= 1.6M tons/year finished parts
= >2.6M tons/year FRP Coil
~ 5 New Integrated Plants like Oswego ~ 26 New Cash Lines
5
20
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Steel: 99%
• Steel FRP demand will significantly increase despite material substitution
• Although AL-BiW will have a strong CAGR11-25 of 15-20%, it will remain a small player in comparison to steel
• Large long-term growth potential for aluminum
Aluminum in Perspective – vs. Steel
2025: 50 Mio Tons
FRP BiW Demand
2011: 30 Mio Tons
FRP BiW Demand
Steel: ~89%
Al: 11%
Al: 1.1%
CAGR:
~18%
Note: Vehicle production calculated using a 6% CAGR from 2011 to 2016 and a 3% CAGR from 2016 to 2025. Assumed average vehicle weight of 1,440 kg and 27% BiW
composition.
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Automotive Sheet in Perspective vs. Can
2012
Source: Novelis
2020 2016 2025
4.7 Mt 6.7 Mt 5.7 Mt ~8 Mt
340 kt 1.8 Mt 1.2 Mt ~5 Mt
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Agenda
Overview: Aluminum Sheet in Automotive Applications
Explosive Growth Ahead
Novelis – Leading the Way
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Novelis – Partner of Choice
Customers
more than two dozen
of the most recognized
automobile brands
in NA and Europe
World leader
for automotive
aluminum sheets
Novelis FusionTM
breakthrough
multi-alloy sheet
Global Organization
global availability of specs
Process and
engineering
expertise second to
none in the
aluminum industry
High-quality
exterior body sheet
in both Europe & NA
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Where Do You Find Our Products Today?
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Where Do You Find Our Products Today?
81 different models with Novelis Aluminium for hood/ bonnet
4.5 million vehicles with Novelis Aluminum for structural parts
and/or body panels
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Novelis wins the BMW Supplier Innovation Award
2011 in Lightweight Construction category
One-piece aluminum door inner with Novelis Fusion
material used in the BMW 5 Series, GT and 7 Series
Innovation & Partnership
BMW SUPPLIER INNOVATION AWARD 2011
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Novelis to Build First Manufacturing
Plant in China Newest Automotive Expansion Provides
Unmatched Global Footprint
April 11, 2012
May 5, 2011
Going Green: Novelis Invests In
Recycling Center Novelis announced investment in its Korean operations
to expand the capacity in the recycling
center and new casting capacity ….
November 7, 2011
Novelis Presented with BMW
Supplier Innovation Award Industry leader Novelis was presented today with BMW’s
Supplier Innovation Award in the Lightweight Construction
category for its Novelis Fusion™ product which provides auto
manufacturers with a 25% weight reduction over steel…
Jaguar Land Rover Selects Novelis as
Sole Supplier of Aluminum Sheet for Its
Range Rover Evoque Novelis is the preferred aluminum supplier of Jaguar Land Rover,
one of the branch leaders in the use of weight-saving metals in its
range of products. These include the Jaguar XJ, XF and XK models,
as well as Land Rover Defender, Discovery, Range Rover and
Range Rover Sport.
Sept. 13, 2011
Novelis Taking the Lead
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Novelis Expands into China
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Novelis China 120,000 metric tons
per year by 2015
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140
840
960
Today Tomorrow Thereafter
+1,025%
Global Aluminum Auto Sheet
Demand: Hoods and Doors
All car hoods are made of
aluminum, not just 20% of
luxury cars?
In addition, what if 50% of all
car doors are made of
aluminum?
1,800 kt
160 kt
Source: Novelis/ JD Power
What if…
Then…