Collaboration: Real World, Robust Applications Enabling Widespread BIW Aluminum Sheet

Don Whitacre Novelis North America Automotive

GALM Detroit 2016

Who We Are

Weight Reduction/ Regulatory Compliance

Sustainability Safety

Affordability Manufacturing Robustness

Performance

Aluminum will continue to play a pivotal role in the evolution of future vehicle design because it delivers these key benefits to automakers:

Catalyzing Lightweight Automotive Design

Innovation

Exterior Inner/Structure Strength Crash

Standard Products

AA6016

AA5182

AA6111

RC5754

RC5182

Novelis Global Products

Advanz™ e170 Advanz™ c300* Advanz™ e600

Advanz™ s118*

Advanz™ s600

Novelis New Product Launches Advanz™ e200*

Advanz™ s200

Advanz™ s615

Advanz™ Fusion e200* Advanz™ s7xx

AA5754

Novelis Unique Portfolio of Alloys

*Available in Europe.

Novelis Automotive BiW Sheet Capacity Worldwide, 2013 vs. 2017

Europe North America 360

250 360

60

820

325

Novelis Global

+250%

Novelis Automotive BiW capacity 2014 vs. 2017, in kt

2013 2017

+600% +44%

4 production lines §  3 lines SOP 2014 - 2016

3 production lines §  2 lines in operation since

> 10 years §  1 line SOP 2015

1 production line §  SOP 8/2014

100 15 +667%

Asia

Wo We Are

Cadillac CT6

Novelis is creating long-term business relationships and helping our customers take advantage of the benefits of lightweighting and sustainability.

Novelis: From "First Mover” to “First Choice” in Material Supply

Mixed material construction body-in-white made up of 62 percent aluminum; same final weight as smaller CTS.

2016 CT6 Advancing Mixed Use Body Structures

Material Mix in the CT6

Cadillac CT-6 is a good indication of what the future looks like: OEMs choosing the right material for each part.

Al/Steel/Other, % wt §  CT6: 62/38/0 §  7-series: 26/66/3 §  S-Class: 33/64/3 §  Q7: 50/50/0

Low Strength Steels (Mild Steel)

High Strength Steels (HSS): BH, P, HSLA

Advanced High Strength Steels (AHSS): DP

Press Hardened Steels (PHS)

Aluminum Sheets: 6xxx series

Aluminum Sheets: 5xxx series

Aluminum Extrusion 6xxx

Aluminum Extrusion 7xxx

Cast Aluminum

Other

Types of Joining Present in CT6 in The CT6

§  Steel RSW spots: 1624 §  Steel Arc braze: 0.5m §  Aluminum RSW spots: 1621

§  Aluminum Arc Weld: 9.2m §  Flow Drill Screws: 745 §  Self-Pierce Rivets: 357 §  Aluminum Laser Weld: 7.4m §  Structural Adhesive: 293m

Comparing CT6 to the Competition

BMW 7 series   Mercedes S-class Cadillac CT6  

Cadillac CT-6 is lighter than both S-Class and BMW 7 series despite lack of carbon fiber. A high bending frequency gives it class leading NVH and quietness.

CT6 Material Mix Example: Front Compartment Side Overview

What: §  Rail: Triple Hollow 7xxx-T7 extrusion §  Shocktower: High Integrity Die Cast (6xxx) §  Wheelhouse closeout: 6xxx sheet §  Extensions to FBHP: AHSS, HSS §  Joining: FDS, RSW, MIG welding, adhesive

Material Driver: §  Shocktower: Stiffness, strength (durability), integration §  Extensions: Strength §  Closeouts: Strength, joining

HI Al die cast

7xxx-T7

CT6 has a very significant body design, because:

CT6 is leap ahead for both

GM and the industry Selected

materials part-by-part

CT6 has a future-oriented material mix that is very

light and stiff yet mass-producible.

Collaboration – Expectations from Our Customers

Production Development Support

Align with OEM Processes

Closed Loop

Technology Leader

Competitive in Cost

§  Partnerships on development of significant new products

§  Collaboration on specification development

§  Collaboration on innovation: §  Input/idea sharing early in the advanced

development process

§  Collaboration across boundaries: multi-material solutions

Collaboration: The Key to “Win-win” Success

The Future

We see more change in the next five years than there’s been in the last 50. – Dan Ammann, President of General Motors

U.S. Fuel Efficiency Regulations

Analysts predict that the midterm evaluation of CAFÉ standards will maintain, if not increase regulatory benchmarks

2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

Final Rule 2017-2025 Standards

Draft Technical Assessment

Report for public comment

(June 2016)

Proposed Determination/Notice

of Proposed Rulemaking

for public comment

Final Determination

(April 2018)

Mobility

§  New mobility services in addition to – or in some cases replacing – traditional car ownership model require robust solutions

§  This requires new, efficient lightweight technologies for body structure

§  Higher recyclability needed due to heavy use

§  New entrants rely more heavily with collaboration with suppliers than traditional OEMs

Globalization Cadillac CT6

BMW x3

Mercedes C-Class

Range Rover Evoque

Jeep Renegade

Opel Insignia & Buick LaCrosse

Jaguar XF

Weight Reduction/ Regulatory Compliance

Sustainability Safety

Affordability Manufacturing Robustness

Performance

Aluminum will continue to play a pivotal role in the evolution of future vehicle design because it delivers these key benefits to automakers:

Catalyzing Lightweight Automotive Design

Innovation

Aluminum sheet is still small in automotive … by a long way

Source: Wood Mackenzie, own research

80 Mt Steel for automotive, 2015

2.2 Mt Aluminum sheet for automotive, 2020

1Mt Aluminum sheet for automotive, 2015

2.2 Mt Aluminum sheet for automotive, 2020

~40 kt Magnesium sheet in 2014

~12 kt CFRP for automotive in 2015

1Mt Aluminum sheet for automotive, 2015

Aluminum sheet is big compared to CFRP and Magnesium

Bodyside Evolution in Aluminum at Jaguar/Land Rover

XJ (X350) Bodyside NG5754 §  1.5mm §  2003

XJ (X351) Bodyside AA6111 §  1.2mm §  2009

Range Rover (L405) Advanz™ e170 §  1.1mm §  2012

F-Type Bodyside Advanz™ e600 §  0.9mm §  2013

Robust Formability Innovation: Advanz™ Fusion e200

§  Aluminum Multilayer Sheet For High Formability §  Core: AlMgSi alloy of the AA6016 family §  Clad: ductile Aluminum of the 5xxx family §  Novelis Advanz™ Fusion e200 combines high

formability with hemming performance. The achieved draw depth with Novelis Advanz™ Fusion e200 significantly exceeds other 6xxx alloys. Novelis Advanz™ Fusion e200 can make bending radii smaller than 0.2mm after 15% prestrain.

Conclusions

1 § Recent North American AIV launches changed the game for aluminum

2 § CAFÉ 2025 will require more innovation on more platforms

3 § Successful implementation of innovative

products depends on robust, proven-out, preferably “drop-in” solutions

4 § The key to robustness is collaboration:

§  Early involvement in specification and part development §  Advanced innovation projects

Ready to Collaborate? Don Whitacre 248-668-5106 donald.whitacre@novelis.com www.novelis.com