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A long-term partnership
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 As a result, aluminium utilisation has grown
fastest-growing sector. People want more fuel- significantly in recent years, with an increasing
efficient cars that produce fewer greenhouse gas number of car companies opting for either aluminium-
emissions, but without sacrificing safety, comfort and intensive designs or material hybrid concepts in
performance. which aluminium plays a significant role. In addition
to overall mass reduction, weight distribution is also
Aluminium plays a key role in helping the automotive of great importance for the driving dynamics of a
industry meet these needs as it enables vehicle weight car. Here again, aluminium offers designers greater
to be dramatically reduced. This is especially the case flexibility when balancing the weight of the car. As an
for aluminium used in vehicle structures, body panels example of this, approximately 20% of European cars
and closures. Indeed, aluminium-based light-weighting are now made with aluminium sheet bonnets.
is the lowest-cost and technically most attractive
option available to achieve this goal. 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 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: Not only does Novelis provide the right alloy, but the
complete set of features to make it a tailor-made sheet
6000 series alloys for outer and inner body-in-white solution:
applications
5000 series alloys for inner / structural parts Texture: mill finish or EDT (Electro Discharged
A range of multi-layer sheet products, using Novelis Texture)
Fusion casting technology to deliver different core Shape: coils, slit coils, rectangular and trapezoidal
properties and surface characteristics sheets, laser-cut blanks, and developed blanks for
A specific 6000 series outer panel alloy with limited defined geometries.
ageing properties, ideal for overseas shipment Lubricant: oil or dry lubricants
Specially-designed high-strength sheet products for Pre-treatments: a range of solutions that improve
load path applications bonding performance, corrosion resistance or the
Sheet with superior energy absorption behaviour for painting process
crash-relevant parts
Horizontal Scale
250 m +5 m
Millfinish 0.0
50 m Ra = 0.4 m -5 m
EDT
100 m Ra = 1.0 m
Lightweight design: one of the greatest challenges Novelis Fusion opens the door to automotive sheet
in building vehicles. Safety, driving performance and with both strength and improved formability to enable
quality must not be compromised. Novelis Fusion new design options. Novelis Fusion has made huge
meets these needs with truly unique combinations advances into the heat exchanger market and is
of features. The outcome: Novelis Fusion unleashes already on the road with body in white applications.
the potential that redefines the boundaries of Once impossible to imagine, light weight, dimensional
lightweight design. stability, strength and exceptional formability combine
to widen the dimensions of design.
OUTER LAYER
CORE
OUTER LAYER
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:
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 Novelis supplies aluminium solutions for car trims and
made from aluminium. Light weight, corrosion sealing systems for the automotive industry.
resistant and durable, aluminium is a perfect match
for todays exacting requirements for heat exchangers While the trims protect the bodywork from damage,
used in climate control, engine cooling and auxiliary e.g. car doors, they are also used as a design feature,
cooling needs. sometimes with decorative elements and emblems.
Novelis is a world class supplier of light gauge, narrow- They can also be profiled and/or combined with rubber
slit aluminium fin stock and brazing sheet used in extrusions, as frame or roof trimmings.
the production of heat exchangers. Our product is
the material of choice for OEM and after-market In addition, Novelis rolled aluminium is used in sealing
component manufacturers in the auto industry. systems, ensuring a flexible connection between the
Our materials are highly engineered products with doors and the passenger compartment, and between
superior gauge control capabilities, precise narrow the boot lid and the bodywork, protecting the interior
width tolerances and exacting chemical and physical of a vehicle and ensuring impermeability even at high
properties. Each of these critical variables is met with speeds
industry-leading technology and product development
support.
Flexible Tubes