NAPICJanuar 2019
The three pillars of Hydro’s current technology strategy
Operational excellence and
utilization of technology
competence and items1
Electrolysis technology –
world leading on productivity
and energy consumption2
Product solutions supporting
future growth in Al demand and
sustainability3
Innovation approach
(3)
The ‘Dimensional Views’ of Product Innovation
Pro
du
ct
co
st
Lead
time
Mar
ket p
rice
(Inno
vatio
n)
Domain for traditional
Lean PD initiatives
Domain for
differentiation and
competitiveness
Pro
du
ct
co
st
Lead
time
Mar
ket p
rice
(Inno
vatio
n)
Domain for traditional
Lean PD initiatives
Domain for
differentiation and
competitivenesspr
oduc
t mea
ning
sproduct performance
existin
g
adap
tion
radica
l
existing
adaption
radical
inn
ovati
ven
ess
Radical/DisruptiveTe
chno
logy
push
Design
thinking
Incremental
Transformational
prod
uct m
eani
ngsproduct perform
ance
existin
g
adap
tion
radica
l
existing
adaption
radical
inn
ovati
ven
ess
Radical/DisruptiveTe
chno
logy
pushT
echn
olog
y
push
Design
thinkingDesign
thinking
Incremental
Transformational
«An innovation is a successful development of a novelty, a creative idea or an invention with expanded customer and production benefits»
--Schumpeter, J.A. (1957)
The business’ view:
DC-casting
simulations
Corrosion
predictions
Rolling
simulat
ions
Formingsimulations
Extrusion
simulations
Weld
simulations
Mould
casting
Load
bearing
capacity
Crash
simulati
ons
Microstructure based
modelsNaMo Alsoft
AlflowClaNG Alprop
3IVM
Alstruc
GIA
• Dislocations
• Grainboundaries
• Thermodynamics
Atomistic modellingExperimental
techniques
1 nm
1 nm
Al
• Interfaces
• Diffusivities
• Precipitates
The design-engineer’s view:
The mechanical scientist’s view:The material scientist’s view:
Aluminium value chain
Bauxite Mining
GraphitePetrocoke
EnergyEnergy
TradeCastingSmeltingTradeRefining
Sodium hydroxid
Trade Trade
CryoliteAlloy
elements
Rolling
Casting
Extruding
Cold metal
Cold metal
Con-struction
Engi-neering
Packaging
Others
Transport
Trade Recycling
Trade
Transaction
Input
Process
Upstream Downstream
Energy
Trade
Energy
Trade
Energy
Trade
Energy
Trade
http://www.aluminiumleader.com/economics/world_market/
75% still in use…at least 50% still in “first use”
-300
-150
0
150
300
450
600
750
1950 1960 1970 1980 1990 2000 2010
Mill
ion tonnes A
l (c
um
ula
tive)
Unrecovered(inc. energyrecovery)
Process Losses
Destructive Uses
Recycled & In Use
In Use "First Life"
IN USE
“LOST”Ref: Hydro.com
•Educate
•Collaborate
•Explore
•Exploit
•Disseminate
Education
Courses
Courses Title
Expert in teamwork NTNU Trondheim - Alumnium for a lighter world, Randi Holmestad
Expert in teamwork NTNU Gjøvik - Manufacturing of the future, Geir Ringen
Course Alumnium lifecycle performance - starting fall 2018
Course Metal forming - fall 2018
Course Product development - aluminium in focus
PhDsName Focus
Christian Arne R. Brekke Robust design
Yen Mai Trinh Agile product development
Håkon Wiik Ånes Recrystallization – RX
Ali Shafqat Risk management
Lise Sandnes Solid state joining
Steinar Hillersøy Dyvik Modularization from free-form
Hasan Kamrul Advanced forming
Jørgen Blindheim Additive manufacturing
Christina Mitcheltree Barriers / enablers innovation
Carina Beste Automotive - TBD
Aksel Elkjær Multi criteria decision system
NN Forming
Master students• 16 MSc in 2018
• 13 students for project - fall 2018
• 2 students at Hydro Profile Academy
• Excursions to Raufoss, Holmestrand, Magnor and Sunndal
• Recruiting seminar at NTNU
Master 2018
Name Description Company
Sissel Marie Breivik 3D printing of dies for aluminium injection molding Rolvsøy Metallindustri
Sindre Selvig Aluminium structure for floating solar cells Ocean Sun
Henrik Markhus Aluminium structure for floating solar cells Ocean Sun
Kristoffer Sortland Engineer to order of aluminium large structrures Leirvik
Erik Rønning Aluminium based flood protection AquaFence
Markus Bekkelund Aluminium based flod protection AquaFence
Atle Lycke Set-based Concurrent Engineering in Norway Benteler, Neuman, SBS, KA
Elias Bragstad Hagen Engineer in Order manufacturing in Norwegian Industry UWS consortium
Nikolai Schjøtt Pedersen Evaluation of measurement solutions for flexible three dimensional stretch bending Benteler
Anders Magnus Gildberg Optimization of Aluminium Battery Housing for Electric Vehicles Benteler
Oscar Bruu klarpås Complexity in projects Nexans
Robert Hoven Collaboration in distributed large projects Rambøll
4 students from materials Materials? ?
Explore
Features of innovation in downstream aluminiumsuppliers:
Customer needs – Light weight, time to market, quality, HES, cost, functionalityRecombining – Material experiences from one sector to anotherRegulations – Emission and consumption regulations R&D frontier – product and process development Collaboration – More and more important
Where do innovations come from?
Chock to thesystem
Accidents
Regulations Inspiration –Eureka moment
Copying others Re-combining
Move theresearchborder
Customerneeds and wants
Explorealternatives
Collaboration
Topic Location Participants Demo
Light weighting ships Stord Maritime Cleantech / 10 partners from the cluster
Energy transmission towers Karmøy Hydro X
Assembly Trondheim Hydro / Sintef Industry
Energy transmission towers Raufoss Widenoja / Statnett X
Energy transmission towers Raufoss Widenoja / Statnett X
3D bending machine I4.0 Raufoss Benteler / Siemens / Intek / Sum Systems X
Electrification maritime sector Ålesund ÅKP / NTNU Ålesund / SINTEF Manufacturing / Rolls Royce / DigiCat
Thin walled casting Farsund Chassix
Pillow Plates Cryogen Hydrogen Trondheim ICT / Skala
AluQuebec Montreal Alcoa Innovation / Neuman / REGAL
REGAL Trondheim REGAL / University LAVAL
Welding Trondheim Hydro / Sintef Industry
Intellimast Lena Laje / Lena Metall / TotAl Innovation X
Fish farming systems Bergen OceanTech / TechnipFMC / Hydro X
Floating solar panels Raufoss Ocean Sun X
Urban Water Shuttle Oslo Fjellstrand / Hydro / Grenland Energy X
Additive Manufacturing Raufoss Norse / Hydro / TotAl-Gruppen
Bridges Trondheim Sintef Ocean / Hydro
Bridges Bergen ÅF Engineering / MultiConsult X
Education København Aluminium Danmark / Svenskt Aluminium
Structures Eindhoven TU Eindhoven / Hydro / Opart
Trucks Stryn Nomek
Light weight seminar Oslo Norsk Industri - Indistry Futurum
Workshops 2018
Workshops / Demos
Infrastructure
• Appearance
• Maintenance
• Flexibility
• Hang-on parts
• …
Shelters / protection
• Heat
• Cold
• Humidity
• Dry
• Noise
• Flood
• …
Bridges
Pedestrian and bicycle bridges (trend?)
Road bridges and decks
Temporary crossings (Norway to build roads for 45 billion NOK annually)
Life cycle models – cost and EOL
Value for society
Multi-material solutions
Design for flexibility and modularization
Approved solutions available for road authorities and entrepreneurs
67% of maintenance cost
related to steel
work and 25%related to
concrete/asphalt
Tilstandsrapport for bruk av
aluminium i bruer: I. Erga and O.
Steen Karlsen - 2017
Substitute
• Plast - packaging
• Copper (increasing price difference between Al and Cu, development in flexibility and design for conductivity, and need for light weight wiring …)
• Steel - transport
• …
Electrification
• Bicycles (Growing)
• Cars (Emerging)
• Ferries (20 ferries by 2021 in Norway)
• …
Batteries, trays, casings, racks …
+ general need for lightweighting
Ocean space• Fish farming (bigger, at sea, closed-loop –
growing market)
• Energy – floating solar panels, wind mills, wave power … "people live by the ocean"
• Subsea operations – mining, cleaning, oil-and gas exploration
• …
Stronger and sheaper then stainless steel
Design• Furniture – IKEA to use 300.000
ton alu in their coming products (appearance, lightweight, clickability, dis-assembly, sustainability …)
• Surface – electronic devices etc
• Adapt to things that we move frequently …
Portable
• Amusement (more frequent arrangements, remote areas, change-over-time etc)
• On site building safety
• Temporary buildings, constructions …
Inventory
Tubes/
Profiles
Casting3D printing cast
moulds
Tube forming
machine
Multi-axial testing
Stamping / cutting
Three dimensional
continuous stretch
bending
Extrusion
Robot 1 Robot 2
Inventory
Compo-
nentsAdaptive forming
Material properties
testingSaw
Decide
26 m
13 m
Existing
Required
One piece flow lab-line:
illustration of new
equipment
ManuLab• 3D-bending machine
• Tube-bending machine - multistack for draw- og roll-forming
• Water-jet cutting
• Hybond – Hybride joining materials
• 2D – adaptive bending
• Laser welding 20kW
• Gleeble – thermomchanical characterisation
• Welding / automation cell for large aluminium structures
Design
Unibody
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