Novelis and Automotive

A long-term partnership

Brighter ideas with aluminium

Aluminium is the Material of Choice
For Automotive Lightweight Designs

Increasingly during the past two decades our mobility-oriented society has pushed
the development envelope of all aspects of the motor car. Components in aluminium
offer many advantages in the areas of weight saving, product design, strength and
processing. Previously the domain of the luxury, sports and racing car, we now find
more and more applications in high volume production motor cars as a result of the
increased competitiveness and overall advantages offered by aluminium solutions.
Vehicle Structures, Body Panels and Closures
The automotive market is the aluminium industrys
fastest-growing sector. People want more fuel-
efficient cars that produce fewer greenhouse gas
emissions, but without sacrificing safety, comfort and
performance.
Aluminium plays a key role in helping the automotive
industry meet these needs as it enables vehicle weight
to be dramatically reduced. This is especially the case
for aluminium used in vehicle structures, body panels
and closures. Indeed, aluminium-based light-weighting
is the lowest-cost and technically most attractive
option available to achieve this goal.
As a result, aluminium utilisation has grown
significantly in recent years, with an increasing
number of car companies opting for either aluminium-
intensive designs or material hybrid concepts in
which aluminium plays a significant role. In addition
to overall mass reduction, weight distribution is also
of great importance for the driving dynamics of a
car. Here again, aluminium offers designers greater
flexibility when balancing the weight of the car. As an
example of this, approximately 20% of European cars
are now made with aluminium sheet bonnets.
Last, but by no means least, aluminium is 100%
recyclable
Novelis and Automotive
A Long-Term Partnership

Novelis is the leading global aluminium sheet supplier. Our automotive business unit
is at the forefront of innovation and a valued partner to OEMs (Original Equipment
Manufacturers) and their Tier 1 subcontractors. Indeed, Novelis is the undisputed
leader in the aluminium automotive sheet business, with more than ninety vehicle
platforms using Novelis material.

It was in 1976 that Novelis, Alusuisse at that time, designed and patented the first
6000 series alloy dedicated to automotive outer panels: Anticorodal 120 [AC120].
This innovative approach, combined with a very extensive and long-lasting working
relationship with most major car manufacturers, has led to a growing list of new
products and services being supplied by Novelis for its customers in the automotive
sector.
Key Novelis Automotive Milestones
1976: AC120 patented
1983: Audi first trial of a full aluminium body using Novelis sheet
1986: Cadillac Allant - first aluminium body on steel monocoque chassis
1991: Development of EDT (Electro Discharge Texture) to help improve customers
stamping processes
1992: Sole supplier of aluminium for the new Audi A8, using the Audi Space Frame
concept
1996: First use of dry lubricant
2000: Launch of Audi A2, with Novelis as the sole supplier of aluminium sheet
2001: First supplier of outer panel in coil format
2002: First aluminium-intensive Jaguar XJ, using Novelis AVT (Aluminium Vehicle
Technology)
2002: Superior outer alloy AC170PX available
2002: Laser cutting facility commissioned, enabling Novelis to supply sheet closer to
the required shape, resulting in easier scrap management, better stamping,
2003: Audi uses the new Novelis PX technology on the A8. These fast bake-hardening
alloys cut out an extra heat treatment step at the OEM.
2004: Novelis AC300 used for the BMW 5 Series front structure. This is the first
high-strength alloy specially developed specifically for crash-stressed
constructions.
2005: Introduction of the new pedestrian safety alloy for hood inners
2007: Market launch of the unique multi-alloy Novelis Fusion casting technology
2008: Novelis starts supplying automotive sheet to Asia, with Hyundai as first
customer in the region
2010: Novelis adds Daimler in Asia to its customer list

Novelis is widely acknowledged to be the trendsetter and technological leader in this

strategic market.

With almost 40 years experience of supplying major OEMs,

Novelis has an undisputed leadership position. The company
is committed to developing its automotive business by
working closely with its customer base all around the world
to offer the products and service package that they need.
Novelis has a Global Presence
Worldwide Assets and Expertise

Novelis is unique in the aluminium flat rolled products sector. As a pure-play

producer of value-added rolled aluminium products, Novelis leverages a highly-
focused business model to drive performance. The companys worldwide assets and
expertise provide an unequalled offering to customers. For the automotive market,
Novelis has a presence on three continents: Europe, North-America and Asia.
Europe:
The Sierre hot rolling plant and the facility in
Nachterstedt are Europes leading producers of
automotive sheet. Having two plants qualified for
automotive ensures security of supply.
Sierre,
in Switzerland, is a fully integrated system,
covering the entire process from casting to finishing.
The casthouse, which was commissioned in 2008,
is capable of casting standard single alloys as well
as multi-alloy ingots using the innovative casting
technology, Novelis Fusion.
Nachterstedt, in Germany, offers cold-rolling,
continuous heat treatment and surface finishing. In
September 2009, additional continuous annealing
and lacquering capacity was commissioned,
enhancing Novelis aluminium sheet offering and
increasing its flexibility in meeting customer needs.
Both plants have laser cutting capability, providing
customers with the shape requested.
The two plants are qualified to the following standards
ISO 9001:2008, ISO TS/16949:2009, ISO 14001:2004 and
OHSAS 18001:2007. In addition, they hold a number of
customer-specific certifications, including Jaguar Land
Rover Q1 supplier status.
North America:
Automotive sheet starts its life at the casthouse in
Oswego, New York state, which is Novelis largest
wholly-owned fabrication facility in North America. The
site is also home to the first Novelis Fusion casting
facility.
The material produced in Oswego is subsequently
processed at the Kingston plant in Ontario, Canada. The
cold rolling, finishing and annealing equipment at this
location are uniquely designed to produce automotive
sheet.
Asia:
Our Asian facilities are based in South Korea, from
where we supply either locally or export to other Asian
countries. The automotive material is currently supplied
from the specialised Novelis operations in other regions
and the Korean team manages the customer contact
with the support from Europe. A customised logistics
concept has been developed for the market to fulfil the
timing and quality requirements. As demand increases
in Asia, Novelis will develop its infrastructure to ensure
that it can meet the growing market needs.
Best Practice Sharing:
The sharing of best practices between Novelis sites
and teamsis a pre-requisite, both for operations and
also for technology and development. The aim is to
achieve excellence and consistency in execution and
quality; enable highly-efficient development; and
bring new solutions to the market quickly.
Novelis Comprehensive Product Offer
Customised Rolled Aluminium Solutions

Novelis delivers customised rolled aluminium solutions for structures, body panels
and closures. The starting point is the aluminium alloy selected for a specific
application. An outer panel, for example, with high surface quality requirements and
very sharp design criteria needs different material performance to a structural part
driven by strength.
The Novelis automotive portfolio includes:
6000 series alloys for outer and inner body-in-white
applications
5000 series alloys for inner / structural parts
A range of multi-layer sheet products, using Novelis
Fusion casting technology to deliver different core
properties and surface characteristics
A specific 6000 series outer panel alloy with limited
ageing properties, ideal for overseas shipment
Specially-designed high-strength sheet products for
load path applications
Sheet with superior energy absorption behaviour for
crash-relevant parts
Not only does Novelis provide the right alloy, but the
complete set of features to make it a tailor-made sheet
solution:
Texture: mill finish or EDT (Electro Discharged
Texture)
Shape: coils, slit coils, rectangular and trapezoidal
sheets, laser-cut blanks, and developed blanks for
defined geometries.
Lubricant: oil or dry lubricants
Pre-treatments: a range of solutions that improve
bonding performance, corrosion resistance or the
painting process

Horizontal Scale
250 m +5 m

Millfinish 0.0

50 m Ra = 0.4 m -5 m

EDT

100 m Ra = 1.0 m

Comparison of EDT and Mill Finish

Novelis Fusion
The new aluminium

Novelis Fusion is a Novelis-proprietary technology that enables the company to

offer its customers multi-alloy rolled aluminium with combinations of different
core properties and surface characteristics that provide performance benefits not
achievable with conventional aluminium. Customers in the automotive market have
led the take-up of the new technology.
A new element for car design
Lightweight design: one of the greatest challenges
in building vehicles. Safety, driving performance and
quality must not be compromised. Novelis Fusion
meets these needs with truly unique combinations
of features. The outcome: Novelis Fusion unleashes
the potential that redefines the boundaries of
lightweight design.
Unbeatable style hits the road
Novelis Fusion opens the door to automotive sheet
with both strength and improved formability to enable
new design options. Novelis Fusion has made huge
advances into the heat exchanger market and is
already on the road with body in white applications.
Once impossible to imagine, light weight, dimensional
stability, strength and exceptional formability combine
to widen the dimensions of design.
OUTER LAYER
CORE
OUTER LAYER
Novelis Fusion: true metallurgical bond and
uniform interface between alloy layers
Novelis is a Leader in Innovation
Unparalleled Material Expertise

Global Technology Organisation

Novelis uses advanced scientific techniques and applied knowledge to deliver

innovative, customer-driven solutions. We bring these to the market quickly and
meet or exceed customer expectations by leveraging our extensive research and
development capabilities. The Novelis technology network provides world-leading
technical support from its centres in Aurora (USA), Kingston (Canada), Ulsan (Korea)
and Europe. With each centre excelling in its own specialist areas, development
knowledge and expertise can be share rapidly between teams and facilities around
the globe.

Novelis Global Technology Centre, Kingston,

Ontario, Canada
Leading-Edge Technology

The facilities in Kingston and Sierre (Switzerland) are centres of excellence for the
development of rolled aluminium solutions for our automotive customers. Novelis
specialist team of experienced scientists, engineers and technicians provides
development expertise and customer design support for the automotive market
including:

Alloy development/optimisation for improved properties (e.g. strength, formability,

corrosion resistance, etc.)
Molten metal and advanced solidification technology
Adhesive bonding, different joining techniques
Innovative manufacturing technologies
Advanced surface treatment technologies
The modelling of forming processes and product performance (e.g. crash
behaviour)
Materials testing, e.g. metallography, electron microscopy, mechanical and forming
tests
FEM (Finite Element Method) simulations to support customers designs e.g.
pedestrian safety behaviour
Pilot facilities for the development of new and emerging technologies

Novelis Innovation Centre and casthouse complex,

Sierre, Switzerland
Novelis and Automotive
Additional Rolled
Aluminium Solutions

The Novelis range of rolled aluminium products for automotive is not limited
to vehicle structures, body panels and closures. Solutions are also supplied to
manufacturers of heat exchangers and heat protection tubes, as well as car trim and
sealing systems.
Automotive Heat Exchangers Car Interiors

Nearly all heat exchangers in new vehicles are now
made from aluminium. Light weight, corrosion
resistant and durable, aluminium is a perfect match
for todays exacting requirements for heat exchangers
used in climate control, engine cooling and auxiliary
cooling needs.
Novelis is a world class supplier of light gauge, narrow-
slit aluminium fin stock and brazing sheet used in
the production of heat exchangers. Our product is
the material of choice for OEM and after-market
component manufacturers in the auto industry.
Our materials are highly engineered products with
superior gauge control capabilities, precise narrow
width tolerances and exacting chemical and physical
properties. Each of these critical variables is met with
industry-leading technology and product development
support.
Novelis supplies aluminium solutions for car trims and
sealing systems for the automotive industry.
While the trims protect the bodywork from damage,
e.g. car doors, they are also used as a design feature,
sometimes with decorative elements and emblems.
They can also be profiled and/or combined with rubber
extrusions, as frame or roof trimmings.
In addition, Novelis rolled aluminium is used in sealing
systems, ensuring a flexible connection between the
doors and the passenger compartment, and between
the boot lid and the bodywork, protecting the interior
of a vehicle and ensuring impermeability even at high
speeds

Flexible Tubes

Novelis is one of the leading suppliers of flexible tubes

and hoses for the international automotive industry.
The product range includes heat protection tubes,
air ducts, exhaust tubes as well as energy absorption
elements.
 Novelis Inc. is the worlds largest producer of rolled aluminium and the
global leader in beverage can recycling. It is a growth-oriented company,
drawing upon industry-leading technology, experience and expertise to
develop and deliver an expanding portfolio of premium rolled aluminiuim
products. Novelis is an important part of the worldwide Aditya Birla Group
of companies as a wholly-owned subsidiary of Hindalco Industries Ltd.

Novelis Europe Headquarters

Sternenfeldstrasse 19 CH-8700 Ksnacht / Zrich Switzerland
Tel: + 41 44 386 2287 Email: automotive@novelis.com
For more information on Novelis, please visit www.novelis.com