Automotive Market a Target for Aluminum Process Innovation

Alcoa Inc. has introduced a manufacturing technique designed to supply stronger, more formable aluminum sheet metal for next-generation automotive platforms.

The process changes the microstructure of the metal to produce an alloy that is 30% stronger and 40% more formable than the aluminum in use today, and 30% lighter and twice as formable as high-strength steel.

Known as MicroMill, the process continuously casts molten metal onto a conveyor where it is flattened and then rolled into sheet stock in 20 minutes, compared to typical lead times of 20 days. Bypassing the slab casting stage reduces energy and water requirements, as well as emissions. Four MicroMills can fit in the floor space allocated to a conventional rolling mill.

Alcoa says the throughput and operational efficiencies are the result of a manufacturing technique that is more responsive to today’s automotive applications. Sheet metal made by Alcoa can be shaped into automobile panels and will have enhanced dent-resistance and reparability.

These improvements should alleviate some of the perceived industry weariness to adopt aluminum-based vehicles. Ford recently launched the 2015 Ford F-150 with a body of 95% aluminum alloy, and other manufacturers are preparing similar offerings. While the 2015 F-150 is far from being the first aluminum-based auto, it is the only vehicle marketed for its workmanship and ruggedness to use such a heavy ratio of aluminum components. Automakers are switching to lighter materials to meet upcoming fuel mandates, which ultimately require 54 MPG by 2025.

MicroMill won't be commercially available until 2018, so standard automotive aluminum will continue to be used and improved. High capital costs likely mean MicroMill alumin

um will be relegated to specific applications, but its short lead times could make it a just-in-time manufacturing option.