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