Slide 1: Technology: Continuous step-changes
Technology: Continuous step-changes Klaus Vieregge (1)
Slide 2: Agenda
• 1 Vision • 2 Competitive edge • 3 Step Changes • 4 Industry trends
Slide 3: Agenda
• 1 Vision • 2 Competitive edge • 3 Step Changes • 4 Industry trends
Slide 4: Vision
Vision Innovative and customer-oriented Research and Development with unique competence and flexibility for the whole process chain of the rolling of Al materials. (4)
Slide 5: Agenda
• 1 Vision • 2 Competitive edge • 3 Step Changes • 4 Industry trends
Slide 6: Organisation
Organisation Materials Testing Sheet Metallo- Business graphy Metal Forming Center Casthouse Joining Service & Foundry Centers Rolling Corrosion Mill Rolling Testing Ingots Surface Extrusion Research Treatment Departments Rolling Rolling Technology Products Etching Recycling Processes Chemical Works
Slide 7: Missions
Missions Research Departments: • Development and optimization of products and processes to preserve existing and to open new markets. • Support the operative units to improve the productivity of processes and the quality of products. Service Centres: • Support project work by providing first class l
Slide 8: Missions – Service Centres & Business Centre
Missions – Service Centres & Business Centre State-of-the-art analytic equipment Unique laboratory equipment (8)
Slide 9: Strategy – Our Assets
Strategy – Our Assets Increased focus on innovation and implementation: • Efficient innovation process and fast commercialization − Focus on Step Change projects • Strong involvement of R&D in product and process developments with Rolled Products‘ customers, and their customers • Pre-competitive res
Slide 10: Strategy – Involvement of R&D
Strategy – Involvement of R&D Example: Automotive (10)
Slide 11: Strategy – Plant Support
Strategy – Plant Support Quality Monitoring in HARP Cast Houses Process Input Furnace Inline Product Melting Casting Operation Treatment Pot room metal Chemistry Geometry + Weight Scrap (pre-, postconsumer) Temperature Microstructure Alloying elements Hydrogen (grain/cell size, porosity, …) Grain re
Slide 12: Strategy – Process Development / Modelling
Strategy – Process Development / Modelling Modelling & Model application Process Technology Tribology & Surfaces Foil - Rolling & Product Support N.B. Human Hair: 40 – 120 µm (12)
Slide 13: Strategy – Product Development
Strategy – Product Development Example: Automotive (13)
Slide 14: Strategy – Contacts and Networks
Strategy – Contacts and Networks • Membership in Hydro internal Networks • Membership in Associations and Committees − EAA (European Aluminium Ass.) − GdA (Association of the German Aluminium Industry) −… • Cooperation with Universities − RWTH Aachen – AMAP Cluster (Advanced Metals and Processes) −
Slide 15: Strategy – Contacts and Networks
Strategy – Contacts and Networks Open Innovation Research Cluster Research-Cluster for NF-Metals at RWTH Aachen (15)
Slide 16: Agenda
• 1 Vision • 2 Competitive edge • 3 Step Changes • 4 Industry trends
Slide 17: Step Changes – Definition
Step Changes – Definition Step Change: Definition: Development of next generation of current operating processes, existing products, respective novel processes and products. Potential: Medium to high business potential, medium risk, medium efforts, medium to long term. (17)
Slide 18: Step Changes – Lithography
Step Changes – Lithography (18)
Slide 19: Step Changes – Lithography
Step Changes – Lithography HPS (Hydro Pre-treated Surface) Dedicated surface treatment for lithographic sheets to improve the product quality and the customer’s processes (production of offset printing plates) Optimized HPS processes HPSplus • Higher cost efficiency and greener: less energy consumpt
Slide 20: Step Changes – Automotive
Step Changes – Automotive (20)
Slide 21: Step Changes – HA 6016-X
Step Changes – HA 6016-X Functional Al-layers • New clad alloy significantly improves formability • Enhancing freedom of design • Cost advantages over multi piece solutions on customer side • Compatible alloys - no downgrading of existing recycling concepts Press trial with HA 6016-X on die designed
Slide 22: Step Changes – Heat Exchanger
Step Changes – Heat Exchanger (22)
Slide 23: Step Changes – Heat Exchanger
Step Changes – Heat Exchanger Cu free header HA 3903-R Cross section after severe Optimized material combination to corrosion test (SWAAT) enhance corrosion resistance Standard HA 3903-R Corrosion potential Header Tube Header Fin noble less noble (23)
Slide 24: Step Changes – Foil
Step Changes -— Foil eo- " *Blue-effici ient song ~ “Thickness tolerance “ploy change” | eduction” Change from | Stabilization of 1200 to 8079 process alloy with conditions higher Fe leading to increase of tent senten yield for customer 2005 201 Foil initiative” Low consumptions, low emissions & pur
Slide 25: Step Changes – Can
Step Changes — Can “BrilliEnd” “Crfree” New surface cleaning Cr-free pre- procedure treatment for “Brilli—nd” CES material 2006 2012 “New BrilliEnd surface” Application of epoxy-free lacquer systems on Cr- free pre- treated coatings 201 Customer value creation thro’ “New Can Body Stock" New Can Body
Slide 26: Agenda
• 1 Vision • 2 Competitive edge • 3 Step Changes • 4 Industry trends
Slide 27: Industry Trends
Industry Trends • Advanced materials − Materials designed to have superior characteristics or functionality • Life cycle assessment − Recycling • Cloud technology • 3D printing • Big data (Industry 4.0) (27)
Slide 28: Industry Trends - Flashlights
Industry Trends - Flashlights Full Aluminium Concept Light weight designs • Enabling the substitution of steel by aluminium for vehicles with design roots in steel • Enabling freedom of design for new aluminium based BIW design • Show-up potential of light weighting in hybrid and full electric vehic
Slide 29: Infinite Aluminium – Hydro
INFINITE ALUMINIUM HYDRO