AEROSPACE ALUMINUM

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YOUR PARTNER IN ALUMINUM SOLUTIONS

We believe that it’s a win-win to enable our customers’ progress. Quality. Accountability. Integrity. These things are non-negotiable. When we collaborate with customers to find solutions, we’re contributing to their success and creating a better world.

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THINK BEYOND

At Aleris, aluminum isn’t just our work — it’s our passion. It represents opportunity, innovation and game-changing solutions to create a better world.

With Aleris Aerospace Aluminum, Aleris provides customers with the people, the tools and the resources that they need to realize the value that aluminum offers.

GLOBAL REACH becomes more important in business every minute of every day. Aleris is helping our customers meet international demand through global assets such as our newly built world-class plate mill in China, which allows us to serve fast-growing Asian markets.

SUSTAINABILITY is important to us. As a leading aluminum recycler with a safety-focused culture, Aleris looks after the environment the same way that we look after our people.

TECHNICAL PROGRESS is what drives our people. We’re not satisfied with today’s solutions. By always striving to develop new and innovative aluminum products for our customers, we ensure that we’re providing them the best materials to meet tomorrow’s challenges today.

CONSISTENCY in our quality, reliability and creativity come together to make Aleris the preferred choice for our customers, and as a result, a leading global producer of aircraft aluminum products.

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PLANT KOBLENZ

The Aleris plant in Koblenz, Germany, is one of the world’s leading rolled products mills for high-quality rolled aluminum plate. The plant produces plates, sheets and coils in more than 100 different alloys, which are used in applications for enginee-ring, trans portation, aerospace and other modern industrial segments. Through highly innovative and efficient operations, the Koblenz plant delivers more than 150,000 tons of semi-finished aluminum to Aleris customers around the globe every year.

This has enabled Aleris Koblenz to supplythe global aerospace industry with innova-tive aluminum materials of the highest qua lity, which meet not only the highest standards but also all conceivable individualcustomer specifications.

Both experience and know-how have been applied to develop special various alloys – like ultra thick aluminum aircraft plates, mill- finished and polished aluminum aircraft sheets, as well as aluminum aircraft seg- ments in customized sizes – which fully satisfy the requirements of the aerospace market.

BUILT FOR THE FUTURE, ROOTED IN HISTORY

With a heritage going back more than 50 years, the Koblenz plant embodies Aleris’ com mitment to permanent quality improvement, a culture of systematic process optimization and a constant investment in modern equipment.

Since its 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 and the ability to meet the highest standards of organization, working environment, health, safety and environmental quality, the Koblenz plant is well-positioned to successfully serve the industrial needs of today’s global market - place.

Our success is founded in offering innovative, customized solutions for our customers and maintaining long-term partnerships within the aerospace industry.

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MAJOR CAPABILITIESCAST 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)

CERTIFICATIONSCERTIFIED FOR AEROSPACE: EN 9100 QUALITY MANAGEMENT AUTOMOTIVE: ISO/TS 16949 GENERAL ROLLED PRODUCTS: DIN EN ISO 9001

CERTIFIED FOR DIN EN ISO 14001 ENVIRONMENTAL MANAGEMENT SPECIALIZED COMPANY ACC. TO “WASSERHAUSHALTSGESETZ” EMAS

CERTIFIED FOR AEROSPACE NADCAP – HEAT TREATING NADCAP – NON-DESTRUCTIVE TESTING

CERTIFIED FOR MANUFACTURE DIRECTIVE 97/23/EC OF 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

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PLANT ZHENJIANG

Aleris Zhenjiang, China, was established to meet growing regional and global demand for aerospace and commercial plate products. The new plant, which spans 271,330 m2 represents a $350 million greenfield invest - ment 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 first to be built outside of the U.S. and Europe.

SUPPORTING TOP PLAYERS AND FAST-GROWING INDUSTRIES IN ASIAN MARKETS

The Zhenjiang plant benefits greatly from the rich experience and expertise of its sister plants in other regions, specifically the Aleris facility in Koblenz, Germany. As a result, the Zhenjiang plant is able to deliver:

Innovative technology Through a technology transfer agreement with the Koblenz plant, the Zhenjiang plant benefits from more than 50 years of operational innovation to invest in its own quality improvements, systematic process optimization and modern equipment.

State-of-the-art equipmentThe twin Zhenjiang and Koblenz plants share nearly the same set of cutting-edge equipment for highly specialized products, which are used in applications for all mo dern 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.

We’re using innovative technology and personalized service to make high-end, high-quality aluminum products available for customers in Asia and all over the world.

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Established expertise In addition to sharing similar technology, processes and equipment, the plant in Koblenz transferred key managerial staff and technical engineers to Zhenjiang. Gaining this expertise complements the efforts of Zhenjiang engineers and supports the plant’s overall technology, quality and operation.

As one of the first state-of-the-art plate mills in Asia, the Zhenjiang plant provides aluminum products for leading industry players in China and throughout Asia, including fast-growing industries in the region. Working closely with our enginee-ring and transportation strategic partners overseas, Aleris aims to produce aerospace-quality products and introduce them for all technically-demanding aluminum applica-tions worldwide.

MAJOR CAPABILITIESCAST 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)

CERTIFICATIONSCERTIFIED FOR AEROSPACE: EN 9100 QUALITY MANAGEMENT GENERAL ROLLED PRODUCTS: DIN EN ISO 9001

CERTIFIED FOR AEROSPACE NADCAP – HEAT TREATING NADCAP – NON-DESTRUCTIVE TESTING

CERTIFIED FOR MANUFACTURE DIRECTIVE 97/23/EC OF PRESSURE EQUIPMENT

CERTIFIED FOR SHIPBUILDING BUREAU VERITAS DET NORSKE VERITAS KOREAN REGISTER OF SHIPPING RULES ABS

IN PROGRESS GERMANISCHER LLOYD LLOYD´S REGISTER

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In order to help the aircraft Original Equip - ment Manufacturers (OEM) to develop and build light and cost efficient passenger and cargo aircrafts with lower fuel burn, re duced emissions and larger ranges, it has become increasingly important for suppliers to tech nically support their programs. One major aspect of these programs is the substi - tution of assemblies and built-up structures by so-called integral or monolithic struc - tures.

An assembly usually consists of a number of formed sheets and extruded, forged and/or machined parts, which are riveted together or joined otherwise, whereby the entire structure integrates the function of all individual components.

The major challenge for a supplier of semi- finished aluminum is that, that the property combination of the raw material should not limit the performance of the integral structure when compared to a classical assembly. Therefore a number of limitations of aluminum plates have to be overcome: The maximum thickness of conventional aluminum plates have to be increased in order to allow machining of very heavy sections.

Several key properties of the plate material – such as fatigue resistance, toughness and ductility – have to be improved in order to compete with properties of other product forms like forgings. Additionally the residual stress level of the plate material have to be controlled to an extremely low level to achieve practically distortion free machi - na bility even with the large dimensions and the high aspect ratios involved.

ADVANTAGES OF DAMAGE TOLERANT ALUMINUM PLATES:

• thickness up to 280 mm (11”)• no significant porosity• excellent fatigue performance• extreme low level of residual stresses• practically no distortion after machining• high strength• high ductility• excellent toughness

ALUMINUM AEROSPACE PLATE

Ultra thick plateCut-to-size shapesPre machined parts

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2014

AMS 4029BS 2 L.93TH 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 422MEP02-035SMS 3204TH 5.312WL 3.1354

2124

AIMS 03-02-032AMS 4101AMS-QQ-A-250/29FMS 3002FMS 3008MMS 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-42.549.0455 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 2687MM0533OFWN 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 IIIDAN 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 3.4144

7150

ABM 3-1031AMS 4252BAEM 1219BAMS516-006DMS 2308

7075

AIR 9048AMS 4045AMS 4078AMS-QQ-A-250/12AMS-QQ-A-250/13AMS-QQ-A-250/24BS 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 IMM0565M3188MM3188OFWN 4057STD 113637TSM 42.03.68WL 3.4384

MAJOR CAPABILITIES

CUT-TO-SIZE SHAPES WITH IMPROVED BUY-TO-FLY RATIO

The state-of-the-art CNC sawing center allows a variety of plate cuts to saw tailor- made contours as well as the most difficult special shapes. The individual manufactu-red plate cuts can additionally be provi ded with fixing holes of 6 to 45 mm (0.24 to 0.177”) provided as passage holes or bag holes with or without a thread. They serve as the fast attachment of ring bolts and fixing devices.

Plate pre-machining can be offered to opti mize 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 recycling companies.

Aircraft plate dimensional capabilities Thickness 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

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Aleris Koblenz supplies sheet and plate material for fuselage components, mainly for European, Asian, North American and South American customers. Traditionally, the aluminum alloys used for these appli ca - tions were conventional 2xxx and 7xxx series alloys like 2024, 7075 and 7475 but also 5xxx and 6xxx series alloys for welded applications.

As part of the strategic plan to develop cost effective materials with highest quality pro - perty performance in extreme dimensions for various development projects, investment programs as well as other activities have been carried out enabling the plant in Kob - lenz to become one of the most important suppliers of semi-finished aluminum pro - ducts to the aerospace industry and a strong partner of the major airframe manufac tu - rers.

In order to supply optimum products and materials for light-weight fuselage construc- tions the sheet portfolio comprises the fol - lowing different product forms:• 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 MAKE IT POSSIBLE:

• extreme size range• excellent surface capabilities (mill finished,

bare, one side clad, both sides clad, polished skin quality)

• high formability• best chemical milling quality• MRS-quality

ALUMINUM AEROSPACE SHEET

Wide sheetWide coil sheetStandard coil sheet

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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 4031 AMS 4295AMS-QQ-A-250/30

ALCLAD 2219

AMS 4096

5024 BARE

AIMS 03-04-055*

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

Aircraft sheet dimensional capabilities Wide 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 500” up to 12.700 mm up to 500” up to 12.700 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”– 0.126” 0.8 – 3.2 mm

Width 36”– 102” 914 – 2.600 mm 36”– 89” 914 – 2.250 mm

Length 39”– 472” 1.000 – 12.000 mm 39”– 472” 1.000 – 12.000 mm

Other dimensions on request

MAJOR CAPABILITIES

* Qualification complete, customer paperwork pending

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PLANT DUFFEL

BilletsDrawn / extruded rods and barsSmall and intermediate profiles

Hard aluminum alloys play a major role in complex applications in airplanes and auto - mobiles. Particular emphasis should be given to the AlEco62Sn alloy, a 100 % lead- free alloy for machining applications.

Aleris Duffel (Belgium) is specialized in hard alloys in round and flat bar shape for complex machining and milling applications for products such as steering valves, lan - ding gear parts (high-load structural com po - nents), fuel adaptors and heat exchanger parts.

Using its indirect 50 MN press, the Ebner horizontal solution annealing furnace and the 800-t stretcher, Aleris Duffel offers opti mum production conditions for these tasks. Modern ageing furnaces allow the closest tolerances thereby guaranteeing high-end products. With its extraordinary drawing force, the 800-t stretcher helps to minimize residual stresses for all hard alloys in order to achieve close dimensional tolerances after machining. These facilities enable international cus to mers to procure aluminum profiles and bars with outstan-ding technological pro perties.

ALERIS DUFFEL IS EQUIPPED WITH THEFOLLOWING INFRASTRUCTURE:

• Cast house• 50 MN heavy press (indirect)• 16 MN press (modernization 2010)• Ebner horizontal solution annealing furnace• Various drawing benches• 800-t stretcher• Short-length sawing installation

In addition to its technological competen ce, customer proximity and a consistent focus on customer requirements are strong advan - tages offered by Aleris Duffel, resul ting in customized products with a consis tant high degree of verifiable quality – in many cases developed in cooperation with our custo - mer. Aleris complies with these requirements for its customers worldwide as a reliable partner with a high delivery performance.

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QUALITY PRINCIPLES AND CUSTOMER APPROVALS

QUALITY PRINCIPLES

The quality principles is an essential ele - ment of the company policy. Its objectives are a continuous im provement in the quality of the products, the services and to fulfill all customer requirements.

The quality principles are formulated by the company management, implemented and known within the corporation. To ensure these quality principles, a documen ted quality system has been implemented. The quality system will be continuously updated and expanded in scope. The demand of the quality system are based among other requirements on the international standard EN 9100.

Process control ensures that production takes place under controlled conditions. Quality inspections are continuously carried out in various production facilities. In labo - ratories with state-of-the-art equipment, chemical tests ensure the proper composi-tion 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 pro - vided.

QUALITY PHILOSOPHY

Our quality philosophy ”means zero de- fects”. The quality system takes into account the customer’s continuously rising requirements and quality standards such as EN 9100 and Nadcap. Legislation and regulatory mea su res will also factor into our quality philosophy.

ENVIRONMENT, HEALTH AND SAFETY PRACTICES

In terms of environment, health and safety practices, we have ISO 14001 in both European plants and EMAS for the Koblenz plant. Aleris wide we have our Safety and Environment Policy and Principles implemen - ted and update this continuously.

ALERIS ALUMINUM DUFFEL BVBACUSTOMER APPROVALS(ALPHABETIC LISTED)

• Airbus• BAE Systems-MAS• Boeing• Lockheed Martin• Messier Dowty Serck Aviation• Mettis Aerospace• Raytheon Aircraft• etc.

ALERIS ROLLED PRODUCTS GERMANY GMBH PLANT KOBLENZCUSTOMER APPROVALS(ALPHABETIC LISTED)

• Airbus• BAE Systems• Boeing• Bombardier• Cessna• EADS• Embraer• Gulfstream• Lockheed Martin• Raytheon Aircraft• etc.

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With intensive, permanent, focused research and development work we ensure that our products and processes are continually improved and meet the highest quality standards. This is how we build on our tech - nological position in the aerospace industry.

Our investment and consistent focus on re search 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. To fulfill these requirements our orga - nizational structure are continuously refined and adapted to current demands. The same applies to field engineering support, pro - duct and process technology (PPT), classic research and development (R&D) and intel - lectual property.

FIELD ENGINEERING SUPPORT

In addition to excellent material supply, it is one of our strategic goals to provide our customers with comprehensive engineering support. Aleris field engineer can help de velop solutions together with our custo - mers, using new technologies and proces-ses to meet your requirements and to improve your pro ducts. They are the tech - nological link be t ween the customer needs and our production capabilities, and we view this activity as mutually beneficial, joint development.

Our customer engineering team can pro vide technical consulting, product and material training, problem solving in the field, pro vi - ding direct technical support services based on the experience Aleris has gained. Aleris’ broad metallurgical knowledge allows for the rapid transfer of new customer require - ments or applications into defined alloy pro- perties and fabrication processes.

THE BASIS FOR INNOVATION AND QUALITY

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PRODUCT AND PROCESS TECHNOLOGY

The work of product and process tech - no logy is to ensure that Aleris products go through a robust and simultaneously effi - cient metallurgical mass production pro cess.

RESEARCH AND DEVELOPMENT

Aleris has concentrated its research and development work in three innovation centers, whereby the center at the Koblenz plant is specifically responsible for R&D in the aerospace sector. In Aachen there is another innovation center for more blue- sky, fundamental and cross-sector research purposes. The engineers there are respon-sible for developing new aluminum pro ducts with improved properties under labo ra tory conditions, which includes experimental trials and theoretical simulations. They also carry out small-scale testing of alloys and processes. As well as its good geogra phic location, Aachen offers close connections to the research facilities of RWTH Aachen University, one of the most res pec ted higher education centers in the world. Aleris is one of the partners in the AMAP (Advanced Metals and Processes) cluster, working closely with university insti tutes and other industry partners on pre-compe ti tive advanced solutions.

CORE RESEARCH AREAS

The core research areas for Aleris in the aerospace industry include hard alloys like AA7181, reduced-density alloys such as AlMgSc and also aluminum-lithium alloys, which are both light and strong and resis - tant to corrosion and fatigue. Aleris can develop and test all major production and processing stages as pilot processes at the production scale. Furthermore, all inno-vation centers use the latest analysis techni - ques, microscopes, x-ray machines, testing and measurement apparatus, partly in co - operation with external partners. The special aerospace equipment in Koblenz includes a trial casting machine, which makes it possible to cast industrial-scale ingots for test programs. The laboratory area here not only serves to approve production: new testing equipment is continuously added for physical and chemical testing to parti cu - lar customer specifications. This enables research into the materials themselves, their properties and their applications in the aerospace industry to be optimized – from alloy development, casting, rolling and processing through to the performance of the finished product. Aleris can thus pro - vide its customers reliably and comprehen-sively with all the information they need to manufacture an optimal product.

Airbus

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Global HeadquartersAleris International, Inc.25825 Science Park DriveSuite 400Cleveland, Ohio 44122 · USAT +1 216 910 3400info@aleris.com

European Head office Aleris Switzerland GmbHBalz Zimmermann-Straße 78058 Zürich Airport · Switzerland T +41 44 828 1400info.europe@aleris.com

Asian Head office Aleris (Shanghai) Trading Co., Ltd. Suite 2804, Wheelock Square No.1717 Nanjing Road West Shanghai 200040 · ChinaT +86 21 2231 8000 info.china@aleris.com

www.aleris.com

Plant KoblenzAleris Rolled Products Germany GmbHCarl-Spaeter-Straße 1056070 Koblenz · GermanyT +49 261 891 7479

Plant Duffel Aleris Aluminum Duffel BVBAA. Stocletlaan 872570 Duffel · BelgiumT +32 15 30 2237

Plant Zhenjiang Aleris Aluminum (Zhenjiang) Co., Ltd.No. 1 Cai Jia Road Jingkou Industrial ParkZhenjiang, 212141Jiangsu · ChinaT +86 511 8530 7220

© 2014, Aleris CorporationIssue 6/14 · 8th release