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Next Generation Aluminum for Automotive Closures & Outer Panels
J.P. McGuire
Global Director Automotive & Industrial Product Technology
Arconic
Arconic at a Glance
53%
~14.5kPeople Globally
10Countries*
24Manufacturing Locations*
34%of revenue comes from Industrialand Building& Construction
of revenue comes from Aero, Auto & CommercialTransportation
$7.3B2019 Revenue
*Excludes service centers.
A global leader in aluminum sheet, plate and extrusions, as well as innovative architectural building products
DanvilleLancaster
Tennessee
◼ 1.4M sq. ft.
◼ ~900 employees
◼ North America’s premier commercial
transportation and industrial product producer
◼ Specializes in aluminum sheet and cast plate – has
painting and multi-cut slitter finishing capabilities
◼ Industry-leading high strength alloys to support
demands of new powertrain technologies on
thermal management systems
◼ 3.7M sq. ft.
◼ ~900 employees
◼ Leading automotive sheet producer
◼ Recent industrial capacity extension enables
significant new revenue opportunities
◼ Highly flexible facility able to produce auto,
industrial, and packaging
◼ Over $400M of growth capex completed in the last
five years
◼ 300K sq. ft.
◼ ~40 employees
◼ Automotive finishing location
◼ Continuous heat treat line
◼ Slit to width and cut to length line
◼ Automotive blanking operations
Portfolio of Assets with Wide Range of Capability for Auto Products
Davenport ◼ 6.5M sq. ft.
◼ ~2100 employees
◼ Premier aerospace and automotive mill globally
◼ 220" mill and Very Thick Plate Stretcher enables
production of the thickest and widest plate in the
aluminum rolling industry - products only Arconic
Corp. can manufacture
◼ Over $600M of growth capex completed in the last
seven yearsEstimated replacement cost of $8-$10 billion
Aluminization will Outpace Automotive Growth – Ducker 2020 Report
Move from Steel to Aluminum Closures Biggest Driver
1) Source: CRU Group, updated July 16, 2020. Data reported in kmt by CRU and converted to Billions of lbs.
Auto Body Sheet Consumption, North America1
1.8
2.1
1.6
2.0
2.4
2.8
3.0
2018 2019 2020 2021 2022 2023 2024
Billio
n lb
s
8% CAGR
• More than 900 million pounds of demand growth from 2019 levels expected over next five years
• Light trucks and SUVs made up 72% of 2019 North American market share and those vehicles have the
greatest amount of aluminum content3
Body and Closure Sheet Penetration – All Vehicles2
2) Source: Ducker Frontier, August 2020
3) IHS Markit
Electrification of Vehicles Driving Greater Aluminum Usage
Lbs.
/veh
icle
Electric Vehicle Range Improvement with Greater Aluminum Content
Total Aluminum use per vehicle – ICE/hybrid vs BEV
Source: Ducker 2020
Electric vehicles are
15%-27% more
aluminum intensive
than combustion
vehicles
Arconic: Offering a broad array of light weighting solutions
Arconic Automotive Sheet Alloys
6
OU
TER
SIN
NER
SS
tru
ctu
re/
Cra
sh
HIG
H
FO
RM
HIG
H
ST
REN
GT
H
6111
C4A8
C4A8
5182
5754
C1A0
C1A0
6013
C6A1
New 7xxx C Alloys
C8A9
C1A0
C12Z
6xxx
5xxx
7xxx
Applications Products Key Attribute
Flat hem & sharp
styling
Inner/Deep draw
High strength/
Energy absorption
High form
Under
development
New High Form C1A0 enables styling and up to 57% weight savings
High Form C1A0 compared to CR5 Steel
Steel vs. High Form 6000 Aluminum Design
IF CR5 SteelC1A0
Aluminum
Thickness
(mm)0.60 0.90
Density 7.85 2.83
Final Yield
Strength
(MPa)
~170 ~175
Weight
Savings
Potential
Base 57%Reference. High Form 6000 trial in production die designed for IF steel.]
• 57% weight savings going from steel to aluminum • 30 Lbs. saved per vehicle on this BSA example
Evolving Styling Trend – “Sharp and Crisp”Audi Q4 E-tron Concept
Reference: https://www.audi-mediacenter.com/en/photos/album/audi-q4-sportback-e-tron-concept-1634.
New C1A0 High Form Alloy Exhibits Superior Stretch Bending
Steve Makosey, Arconic Technical Center, internal data
C1A0 Outperforms C4A8/6022 and 5182
Punch Radii 0.5mm to 50mmt = 1.1mm
CAE Models Indicate Improved Performance of Next Gen 6000
Comparison of CAE Results: C1A0, C4A8, 6022
Confidential 10
High Form C1A0 High Hem C4A8 6022
C1A0 High Form 6000 Comparable to IF Steel in Dent Resistance
Dynamic Dent Testing Result Comparisons for steel and aluminum
CR5 IF Steel and Next Gen High Form 6000 at 50 to 57% Weight Differential
6022-replacement alloys C4A8 and C1A0 provide improved shelf life and hemming
Arconic High Form 6xxx Alloy Products
Comparison of 6xxx Alloys
Alloy ApplicationFlat Hem Rating (15% PS)
1mo 3mo 6mo
6022-T43 inners, outers 3 3-4 4
C4A8-T43 inners, outers 2 2 2-3
C1A0-T43 inners, outers 2 2 2-3
1
2
3
4
5
Hem Rating Scale
90d
180d
270d
Improved Flat Hem
Baseline
High Paint Bake
6022 C4A8 C1A0
80
90
100
110
120
130
140
0 50 100 150 200
TYS
(MP
a)
Natural Age (days)
TN 6022-T43
TN-TN C4A8-T43
C1A0
051015202530354045
-15-10-5051015202530354045
Ma…
Minor Engr …
6022-T43
C4A8-T43
Reduced Natural Aging
Improvement
Pretreatment: Arconic 951™ Offers Greatest Bond Durability Performance
Comparison with TiZr
TiZr was the industry standard for conversion coated aluminum sheet (primarily European OEMs)
TiZr Arconic 951™
Arconic 951™ pretreatment has since supplanted TiZr as the performance-based standard
14
Proving Ground Simulation Exposure (Stress Ring Test)
5 yr Simulation
(45-50 cycles)
10 yr Simulation
(100 cycles)
Arconic 951™
Lab Historic Arconic 951™
Production Historic
(2010+)
Pretreatment: Arconic 951™ Offers Greatest Bond Durability Performance
Arconic 951™ is 4X to 9X Stronger than TiZr
Demonstrated superior bond durability performance across OEM customer base (highest retained strength in use)
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15
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