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AEROSPACE ALUMINUM
2 www.aleris.com
Table of Contents
About Aleris .............................................................................................................. 3
Plant Koblenz ........................................................................................................... 4
Major Capabilities & Certifi cations ...............................................................................5
Plant Zhenjiang ........................................................................................................ 6
Major Capabilities & Certifi cations ...............................................................................7
Aluminum Aerospace Plate .................................................................................... 8
Aircraft Plate Dimensional Capabilities & Major Capabilities ..............................................9
Aluminum Aerospace Sheet ................................................................................. 10
Aircraft Sheet Dimensional Capabilities & Major Capabilities ........................................... 11
The Basis For Innovation and Quality ................................................................... 12
Quality Principles ................................................................................................... 14
Sustainability.......................................................................................................... 15
www.aleris.com 3
ABOUT ALERIS
We serve a variety of end-use industries, and are among the world’s leading suppliers of high-quality aluminum rolled products to the aerospace industry.
With more than 30 years of experience and know-how, Aleris supplies the industry with innovative aluminum materials which meet the rigorous requirements for aerospace manufacturers.
We specialize in the production of alumi-num plate and sheet material for fuselage and wing structure components according to standard or customized specifi cations.
Aleris is a global leader in the manufacture and sale of aluminum rolled products, with approximately 14 manufacturing facilities across North America, Europe and China.
4 www.aleris.com
PLANT KOBLENZ
Our Aleris plant in Koblenz, Germany, is one of the world’s leading facilities for high-quality rolled aluminum plate.
At Koblenz our skilled team produces plates, sheets and coils in more than 100 different alloys, which are used in applications for engineering, transportation, aerospace and other industrial segments.
Using state of the art equipment (including the world’s most powerful hot mill), Aleris Koblenz supplies the global aerospace industry with advanced aluminum materials of the highest quality, which meet not only the industry’s high standards but also all conceivable individual customer specifi cations.
Koblenz is backed by a leading research and development team that works with customers to deliver new solutions to the marketplace. Over the course of the many years that we have served the aerospace industry, we’ve developed various advanced alloys – like ultra-thick aluminum aircraft plates, mill-fi nished and polished aluminum aircraft sheets, as well as aluminum aircraft segments in customized sizes – which fully satisfy the specifi c requirements of the aerospace market.
Aleris has also introduced new low density alloys (scandium-containing) which represent an innovative step forward for aluminum in aerospace. Weight-savings from these new alloys translate into fuel effi ciency and lower operating costs for the airline industry.
ROOTED IN HISTORY, BUILT FOR THE FUTURE
In operation now for more than 50 years, the Koblenz plant embodies Aleris’ commitment to permanent quality improvement, a culture of systematic process optimization and a constant investment in state-of-the-art equipment.
Since inception, more than 450 million euros have been invested in Koblenz to expand the facility and its capabilities. Today, the plant is known for its innovation and quality. Through continued investment in modern production equipment and the ability to meet the highest standards for health, safety and environmental quality, the Koblenz plant is well-positioned to successfully serve the industrial needs of today’s global marketplace.
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MAJOR CAPABILITIES
CAST HOUSES
SCALPER
160“ HOT ROLLING MILL
128“ HOT ROLLING MILL
148“ COLD ROLLING MILL
SAWING CENTERS (WIDE PLATE, CNC, SEGMENT, LINER PLATE SAW)
HORIZONTAL HEAT-TREATMENT FURNACE, PLATE- AND VERTICAL FURNACES
STRETCHER UP TO 8,000 T
PLATE TESTING EQUIPMENT (E.G. ULTRASONIC TESTING, EDDY CURRENT TESTING)
CERTIFICATIONS
CERTIFIED FOR AEROSPACE: EN 9100QUALITY MANAGEMENT AUTOMOTIVE: ISO/TS 16949 GENERAL ROLLED PRODUCTS: DIN EN ISO 9001
CERTIFIED FOR DIN EN ISO 14001ENVIRONMENTAL MANAGEMENT SPECIALIZED COMPANY ACC. TO “WASSERHAUSHALTSGESETZ” EMAS
CERTIFIED FOR AEROSPACE NADCAP – HEAT TREATING NADCAP – NON-DESTRUCTIVE TESTING PLANT DUFFEL: HEAT TREATMENT STRETCHING
CERTIFIED FOR MANUFACTURE DIRECTIVE 97/23/ECOF PRESSURE EQUIPMENT
CE MARKING FOR CONSTRUCTION EN 15088
CERTIFIED FOR SHIPBUILDING BUREAU VERITAS DET NORSKE VERITAS GERMANISCHER LLOYD KOREAN REGISTER OF SHIPPING LLOYD´S REGISTER RULES ABS
6 www.aleris.com
PLANT ZHENJIANG
Our Aleris Zhenjiang, China, facility was established in 2013 to meet growing regional and global demand for aerospace and commercial plate products.
The plant, which spans 271,330 m2, represents a $350 million greenfi eld investment in technologically advanced aluminum plate production. It is one of only a handful of state-of-the-art aluminum plate facilities in the world – and the fi rst to be built outside of the U.S. and Europe.
Benefi tting greatly from the rich experience and expertise of its sister plants in other regions, specifi cally the Aleris facility in Koblenz, Germany, the Zhenjiang plant uses the most modern technology and personalized service to make high-end, high-quality aluminum products available for customers in Asia and all over the world.
INNOVATIVE TECHNOLOGY
Through cooperation with the Koblenz plant, the Zhenjiang plant benefi ts from more than 50 years of operational experience to support its own quality improvements, systematic process optimization and modern equipment.
The twin Zhenjiang and Koblenz plants share a very similar set of cutting-edge equipment for highly specialized products, which are used in applications for all modern industrial market segments. This primarily comprises aluminum plate for integrally machined structural components used in the aerospace industry. Typical alloys are 2024, 2124, 7075, 7175, 7475 and 7050 in various tempers.
In addition to sharing similar technology, processes and equipment, the plant in Koblenz has provided technical assistance to the start-up of Zhenjiang. Gaining this expertise complements the efforts of Zhenjiang engineers and supports the plant’s overall technology, quality and operation.
As one of the fi rst state-of-the-art plate mills in Asia, the Zhenjiang plant provides aluminum products for leading industry players throughout Asia Pacifi c and globally, including those in fast-growing industries. The Aleris Zhenjiang plant has been successfully qualifi ed by global aerospace manufacturers like Boeing, Airbus, Bombardier, COMAC and Avic, XAC and SAC. Working closely with these customers, Aleris Zhenjiang has started to produce aerospace-quality products and introduce them for all technically-demanding aluminum applications worldwide.
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MAJOR CAPABILITIES
CAST HOUSES
SCALPER
160“ HOT ROLLING MILL
HORIZONTAL HEAT-TREATMENT FURNACE
STRETCHER UP TO 6,000 T
PLATE SAWING CENTERS
PLATE TESTING EQUIPMENT (E.G. ULTRASONIC TESTING, EDDY CURRENT TESTING)
CERTIFICATIONS
CERTIFIED FOR AEROSPACE: EN 9100QUALITY MANAGEMENT GENERAL ROLLED PRODUCTS: DIN EN ISO 9001
CERTIFIED FOR DIN EN ISO 14001ENVIRONMENTAL MANAGEMENT
CERTIFIED FOR AEROSPACE SAE AS 9100 NADCAP – HEAT TREATING NADCAP – NON-DESTRUCTIVE TESTING
CERTIFIED FOR MANUFACTURE DIRECTIVE 97/23/ECOF PRESSURE EQUIPMENT
CERTIFIED FOR SHIPBUILDING BUREAU VERITAS DET NORSKE VERITAS KOREAN REGISTER OF SHIPPING RULES ABS GERMANISCHER LLOYD LLOYD´S REGISTER NK OF JAPAN
8 www.aleris.com
ALUMINUM AEROSPACE PLATE
With air travel projected to grow substantially over the next several years, the aerospace industry is building new aircraft to accommodate a growing number of air passengers and to replace older, less effi cient planes with newer, more fuel-effi cient models. Aluminum offers a high strength-to-weight ratio, energy effi ciency, and high tolerance to extreme temperatures – making it an ideal material for the manufacturing of aircraft. It can also be recycled repeatedly, making it a good choice as manufacturers pursue sustainability initiatives.
In order to help aerospace Original Equipment Manufacturers (OEMs) to develop and build light and cost-effi cient passenger and cargo aircrafts with lower fuel burn, reduced emissions and longer ranges, it has become increasingly important for us to technically support our customer’s programs with the very best solutions.
Working closely with OEMs, Aleris has developed aerospace products to meet the most stringent specifi cations to ensure the material’s properties, which include thickness, fatigue resistance, toughness and ductility, will optimize the performance of the aircraft structure.
ADVANTAGES OF DAMAGE TOLERANT ALUMINUM PLATES:
• thickness up to 280 mm (11”)• no signifi cant porosity• excellent fatigue performance• extreme low level of residual
stresses• practically no distortion after
machining• high strength• high ductility• excellent toughness
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2014
AMS 4029BS 2 L.93DMS 1580TH 5.313
2024
AIMS 03-02-004ABM 1-1005AIR 9048AMS 4037AMS 4041AMS-QQ-A-250/4AMS-QQ-A-250/5ASN-A3011BS 2 L.97BS 2 L.98CMS-AL-103DGQT 1.1.0.0036DAN 422EN 2419MEP02-035SMS 3204TH 5.312WL 3.1354
2124
AIMS 03-02-032AMS 4101AMS-QQ-A-250/29FMS 3002FMS 3008LMA-M7009MMS 149MEP 02-029
2214
AIR 9048CR 1.1.031
2219
A5-SA-121-1039A5-SA-133 1100-C-0019-MTAAMS 4295AMS 4600AMS 4613AMS-QQ-A-250/30DSN 1719.01MPS/2219/S&P/01SA-MU-42.549.04SMS 11920455 LV 09 003
2618
ABM 1-1006AIMS 03-02-021AIR 9048ASN-A 3355BAEM 1103DAN 422MEP02-020WL 3.1924
6061
AIR 9048AMS 4025AMS 4026AMS 4027AMS-QQ-A-250/11DAN 422WL 3.3214
7010
ABM 3-1029ABM 3-1030AMS 4204AMS 4205ASN-A3098ASN-A3101BAEM 1213BAEM 1218DAN 422DGQT 1.1.0.87D.T.D. 5120D.T.D. 5130EN 2684EN 2687OFWN 4017OFWN 4038SM 9102SMS 3206STD 113644TSM 42.03.66TSM 42.03.67TSM 42.03.71WL 3.4394
7020
AIR 9048
7050
AIMS 03-02-019AIMS 03-02-022AIMS 03-02-029ABM 3-1029ABM 3-1030AIR 9048AMS 4050AMS 4201BAEM 1213BAMS 516-001BAMS 516-003BMS 7-323 Type IBMS 7-323 Type IIICMMP 010DAN 422DGQT 1.1.0.97DGQT 1.1.0.0098DMS 2233DMS 2459EN 3982EN 3983KMB-SK2102LMA-M7050MEP02-014MEP02-036MFM 0017MMS 1420MMS 1439M3184MM3184OFWN 4029OFWN 4037OFWN 4040STD 113643STM 0887TSM 42.03.69TSM 42.03.70WL 3.4144YS-X-9005
7150
ABM 3-1031AMS 4252BAEM 1219BAMS 516-006DMS 2308
7075
AIR 9048AMS 4045AMS 4078AMS 4315AMS-QQ-A-250/12AMS-QQ-A-250/13AMS-QQ-A-250/24ASN-A3009BS 2 L.95DAN 422EN 2126MMS 159STD 113627TH 5.316/3TH 5.316/5WL 3.4364
7175
AIMS 03-02-008ASN-A3050CR 1.1.0.88OFWN 4033SMS 003
7475
AIMS 03-02-009AIR 9048AMS 4089AMS 4090AMS 4202BAMS 516-002DAN 422DMS 2184DMS 2234FMS-3004MEP 02-013 Std. TypeMEP 02-013 Type IM3188MM3188OFWN 4057STD 113637TSM 42.03.68WL 3.4384
Ultra thick plateCut-to-size shapesPre machined parts
MAJOR CAPABILITIES
Aircraft plate dimensional capabilitiesThickness up to 11” up to 280 mm
Width up to 130” up to 3,300 mm
Length up to 945” up to 24,000 mm
Other dimensions on request
CUT-TO-SIZE SHAPES WITH IMPROVED BUY-TO-FLY RATIO
The state-of-the-art CNC sawing center is capable to saw cut-to-size, tailor-made contours as well as more sophisticated special shapes. Additionally, cut plates can be provided with fi xation holes in order to minimize material handling times before machining.
Plate pre-machining can be offered to optimize cost savings and to minimize scrap handling at the customer site.
The cut-to-size and pre-machined parts are delivered to customers all over the world; all of the resulting scrap is being recycled in our own cast houses.
10 www.aleris.com
ALUMINUM AEROSPACE SHEET
Aleris supplies sheet and plate material for fuselage components for our customers, globally. Traditionally, the aluminum alloys used for these applications are conventional 2xxx and 7xxx series alloys like 2024, 7075 and 7475. For welded applications, 5xxx and 6xxx series alloys may also be used.
In order to supply optimal products and materials for light-weight fuselage constructions Aleris supplies a variety of aerospace sheet products from its Koblenz facility:
• standard coil sheet• wide coil sheet up to 2,600 mm (102’’) width• wide sheet up to 3,460 mm (136’’) width
HIGH QUALITY STANDARDS COMBINED WITH UNIQUE STATE-OF-THE-ART EQUIPMENT ENABLES ALERIS TO PROVIDE:
• broad portfolio (dimensions and alloys)• excellent surface properties (mill fi nished, bare, one side clad,
both sides clad, polished skin quality)
• high formability• best chemical milling quality• MRS-quality
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Aircraft sheet dimensional capabilitiesWide sheet O/F-Temper T-Temper
Thickness 0.100”– 0.472” 2.5 –12.00 mm 0.100”– 0.472” 2.5 –12.00 mm
Width up to 136” up to 3,460 mm up to 130” up to 3,300 mm
Length up to 590” up to 15,000 mm up to 590” up to 15,000 mm
Standard coil sheet and wide coil sheet O/F-Temper T-Temper
Thickness 0.032”– 0.158” 0.8 – 4.00 mm 0.032”– 0.183” 0.8 – 4.64 mm
Width 36”– 102” 914 – 2,600 mm 36”– 89” 914 – 2,250 mm
Length 39”– 472” 1,000 – 12,000 mm 39”– 590” 1,000 – 15,000 mm
Other dimensions on request
2024 BARE
AMS 4035AMS 4037AMS-QQ-A-250/4
ALCLAD 2024
AIMS 03-04-009AIMS 03-04-010AIMS 03-04-011AIMS 03-04-012AIMS 03-04-013AIMS 03-04-014AMS 4040AMS 4041AMS-QQ-A-250/5
2219 BARE
AMS 4031AMS 4295AMS-QQ-A-250/30
ALCLAD 2219
AMS 4096
6061 BARE
AMS 4025AMS 4026AMS 4027AMS-QQ-A-250/11
7075 BARE
AMS 4044AMS 4045AMS-QQ-A-250/12AMS-QQ-A-250/24
ALCLAD 7075
AMS 4048AMS 4049AMS-QQ-A-250/13AMS-QQ-A-250/25
ALCLAD 7475
AIMS 03-04-029DMS 2234
MAJOR CAPABILITIES
Wide sheetWide coil sheetStandard coil sheet
12 www.aleris.com
THE BASIS FOR INNOVATION AND QUALITY
With intensive, permanent, focused research and development work we ensure that our products and processes are continually improved in order to meet the highest quality standards. This is how we build on our technological position in the aerospace industry.
Our investment and consistent focus on research and development is directed at those innovations which meet the needs and goals of our customers. We develop tailor-made strategic processes, products and applications. And of course we support our customers’ activities in key market areas. Improvements relating to quality, costs and the environment always take center stage.
FIELD ENGINEERING SUPPORT
In addition to excellent material supply, it is one of our goals to provide our customers with comprehensive engineering support. Aleris fi eld engineers can help develop solutions together with our customers, using new technologies and processes to meet your requirements and to improve your products. They are the technological link between our customer needs and our internal capabilities.
Our fi eld engineering team provides• technical consulting,• product and material training,• problem solving in the fi eld,• direct technical support services,
based on the experience and know how that Aleris has fi ne-tuned over many years serving the aerospace industry. Aleris’ broad metallurgical knowledge allows for the rapid transfer of new customer requirements or applications into defi ned alloy properties and fabrication processes.
PRODUCT AND PROCESS TECHNOLOGY
The work of product and process technology is to ensure that Aleris products go through a robust and simultaneously effi cient metallurgical mass production process.
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RESEARCH AND DEVELOPMENT
Aleris has concentrated its research and development work in fi ve innovation centers, whereby the center at the Koblenz plant is specifi cally responsible for research and development in the aerospace sector.
To support customers in Asia Pacifi c, Aleris also invested in an innovation center in its Zhenjiang facility to support commercial plate and aerospace applications.
In Aachen there is another innovation center for more blue-sky, fundamental and cross-sector research purposes. The engineers there are responsible for developing new aluminum products with improved properties under laboratory conditions, which includes experimental trials and theoretical simulations. They also carry out small-scale testing of alloys and processes. As well as its strategic geographic location, Aachen offers close connections to the research facilities of RWTH Aachen University, one of the most respected higher education centers in the world. Aleris is one of the partners in the AMAP (Advanced Metals and Processes) cluster, working closely with university institutes and other industry partners on pre-competitive advanced solutions.
CORE RESEARCH AREAS
The core research areas for Aleris in the aerospace industry include advanced hard alloys and reduced-density alloys such as AlMgSc. Aleris can develop and test all major production and processing stages as pilot processes at the production scale.
Furthermore, all innovation centers use the latest analysis techniques, microscopes, x-ray machines, testing and measurement apparatus, partly in cooperation with external partners. The special aerospace equipment in Koblenz includes a trial casting machine, which allows casting of industrial-scale ingots for test programs. Our laboratory – with new equipment continuously added – supports our research efforts, whether it is alloy development or process improvement.
We can thus reliably and comprehensively provide our customers all information that is required to manufacture an optimal product.
Aleris can develop and test all major production and processing stages as pilot processes at the production scale.
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QUALITY PRINCIPLES
Quality principles are an essential element of Aleris manufacturing processes. Our objectives are to fulfi ll all customer requirements and we are committed to the continuous improve-ment of the quality of our products and services.
Our quality principles are defi ned and exemplifi ed by Aleris management and implemented within our organization. A documented quality system has been implemented and is continuously updated and expanded in scope. The system is based on, among other requirements, the international standard EN 9100.
Process control ensures that production takes place under controlled conditions and quality inspections are continuously carried out in various production facilities. In laboratories with state-of-the-art equipment, chemical tests ensure the proper composition of alloys and their resistance to corrosion. Mechanical tests on strength and fracture toughness, fatigue testing as well as metallographic examination on the structure of the material can also be provided.
QUALITY PHILOSOPHY
Our quality philosophy means “zero defects”. Our quality system takes into account continuously rising requirements of our customers as well as quality standards such as EN 9100 and Nadcap. Legislation and regulatory measures will also factor into our quality philosophy.
ENVIRONMENT, HEALTH AND SAFETY PRACTICES
In terms of environment, health and safety practices, we have ISO 14001 and EMAS for the Koblenz plant, as well as ISO 14001 for the Zhenjiang plant. Our Safety and Environment Policy and Principles are implemented within our company and are also subject to continuous improvement.
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CASE STUDY AEROSPACE:CLOSED LOOP RECYCLING
To reduce the need for primary aluminum as well as manufacturing waste, Aleris works with customers to create closed loop processes, in which customers send their waste back to Aleris to be recycled into new products. Aleris has established closed loop processes with aerospace customers that incorporate quality, logistics, volume and schedule requirements to ensure that product needs are met and that the appropriate scrap is collected and returned to Aleris for recycling.
SUSTAINABILITY
At Aleris, sustainability has always been core to our business. With both the know-how and the experience to partner with customers to help them capitalize on the unlimited potential of aluminum, we are helping to drive sustainable solutions, and supporting trends such as more fuel-effi cient airplanes.
We believe that Aleris and aluminum play an important role in improving the sustainability performance of the customers we serve. We are working to reduce our environmental footprint, and increase the use of recycled content in our products.
Our primary sustainability objective is to produce and sell increasingly sustainable aluminum products. We continuously work to develop innovative solutions that will better position aluminum as the material of choice for customers and consumers seeking high-performance solutions that will also reduce their carbon footprint.
We have partnered with customers to:• understand their key business and
sustainability drivers to inform new product development,
• implement closed loop manufacturing processes to help our customers reduce waste and incorporate more recycled content into their products,
• pursue life cycle assessments (LCAs) and environmental certifi cation to quantify the environmental benefi ts of certain products.
BENEFITS OF CLOSED LOOPSOLUTIONS
• A reduction in greenhouse gases and other environmental impacts through the use of recycled content aluminum as opposed to primary aluminum.
• Improved business continuity for both partners as the supply is guaranteed through this agreed process.
• The creation of a consistently high grade of aluminum alloy as nothing is lost via “downcycling” to lower alloys.
CLOSED LOOP
PROCESS
0001110000011111
Aleris produces aerospace aluminum
01
0002220000022222
Customer manufactures a plane part
02
0003330000033333
Part is built into the plane construction
03
0004440000044444
Scrap of production part is reused by Aleris
04
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Global HeadquartersAleris International, Inc.25825 Science Park DriveSuite 400Cleveland, Ohio 44122 · USAT +1 216 910 [email protected]
European Head offi ce Aleris Switzerland GmbHBalz Zimmermann-Straße 78058 Zürich Airport · SwitzerlandT +41 44 828 [email protected]
Asian Head offi ce Aleris (Shanghai) Trading Co., Ltd. Rm 3601-3602, SOHO Donghai PlazaNo. 299 Tongren RoadShanghai 200040 · ChinaT +86 21 2231 8000 [email protected]
www.aleris.com
Plant KoblenzAleris Rolled Products Germany GmbHCarl-Spaeter-Straße 1056070 Koblenz · GermanyT +49 261 891 7476
Plant Zhenjiang Aleris Aluminum (Zhenjiang) Co., Ltd.No. 1 Cai Jia RoadJingkou Industrial ParkZhenjiang, 212141Jiangsu · ChinaT +86 511 8530 7200
© 2015, Aleris Corporation
Care has been taken to ensure that this information is accurate, but Aleris, including its subsidiaries, does not accept responsibility or liability for errors or information which is found to be misleading.
Issue 5/15 · 10th release
