April 05, 2013 at 10:00 AM EDT
Breakthrough Alcoa Technology Enabling Mass Production of Aluminum Intensive Vehicles Licensed to Industry Globally

Alcoa (NYSE:AA) today announced that its breakthrough “Alcoa 951” pre-treatment bonding technology—an enabler for adhesive bonding of automotive structures—has been licensed to Chemetall in an exclusive global distribution agreement. The Alcoa technology is the new pre-treatment bonding standard for aluminum sheet, extrusion and casting suppliers across the automotive industry. Chemetall is the leading supplier of surface treatments to the automotive industry, globally.

The use of aluminum in cars is expected to nearly double by 2025 according to automotive original equipment manufacturers (OEMs), and today is already the second-most-used material to produce cars. As OEMs work to continue to make cars more fuel efficient, many are expanding aluminum use from heat exchangers, wheels, drive shafts, engine blocks, hoods and deck lids to developing aluminum intensive vehicles (AIVs) by converting the body in white, or body structure, to aluminum. As OEMs use aluminum body structures to improve fuel efficiency, new joining and assembly methods are required. “Alcoa 951” is a patented, non-chrome approach for enhancing bond durability and enabling more cost-effective, mass production of AIVs.

In customer trials, “Alcoa 951” has been proven to be up to nine times more durable than titanium zirconium applications used in the automotive industry in the past. These results led OEMs to specify “Alcoa 951” and request Alcoa to license it to other suppliers in the industry, hence the agreement with Chemetall. “Alcoa 951” technology is being incorporated into the $300 million automotive expansion underway at Alcoa’s Davenport (Iowa) Works facility, scheduled for completion by the end of 2013.

“‘Alcoa 951’ is a perfect example of Alcoa Technology Advantage at work to create value for our customers,” said Kay Meggers, Alcoa Executive Vice President and Group President of Alcoa Global Rolled Products. “The use of this technology is helping to enable greater use of aluminum throughout the industry and helping make mass-produced aluminum-intensive vehicles possible. This ultimately saves significant fuel for consumers who say fuel efficiency is a top factor in their purchase decision.”

“We look forward to partnering with Chemetall to provide ‘Alcoa 951’ to help enable commercialization of adhesive bonding of aluminum structures in high-volume automotive applications. This, in turn, will drive lighter vehicle weights and enable the integration of sheet, extrusions, and castings to ultimately improve fuel efficiency,” said Dr. Raymond Kilmer, Alcoa Executive Vice President and Chief Technology Officer. “The process was developed as a result of collaboration between the Alcoa Technical Center and our automotive business. We’re excited to see it commercialized.” The Alcoa Technical Center is the world’s largest light metals research facility and is located outside Pittsburgh, PA.

About Alcoa 951 Adhesive Bonding

“Alcoa 951” employs an organic, environmentally-friendly system tailored for both the aluminum substrate and the structural adhesives used for joining. The pre-treatment delivers far superior bond durability compared to conversion coating systems such as the titanium zirconium often used in the past. In fact, customer trials show its durability is up to nine times stronger than titanium zirconium.

The surface treatment is applied through an immersion or spray application in which the organic components bond with oxides present on the metal surface. The molecular structure chemically binds aluminum oxide with one end, and adhesive with the other. This creates a strong link at the molecular level resulting in lasting, durable joints for automotive structures.

The minimal level of treatment on the surface makes it essentially “transparent” to downstream steps in the automotive manufacturing process such as forming, resistance spot welding and painting.

Other commercially available conversion coatings, which generally contain heavy metals and are measurably thicker, lead to potential environmental concerns and diminished performance in other steps in the manufacturing process. The attractiveness of “Alcoa 951” lies in its repeatability and its simplicity. It does not incorporate exotic components that threaten the ability to implement the product on a large scale, and it brings the type of benign environmental impact that addresses the need for the “cradle-to-cradle” life cycle required for aluminum.

About Alcoa

Alcoa is the world’s leading producer of primary and fabricated aluminum, as well as the world’s largest miner of bauxite and refiner of alumina. In addition to inventing the modern-day aluminum industry, Alcoa innovation has been behind major milestones in the aerospace, automotive, packaging, building and construction, commercial transportation, consumer electronics and industrial markets over the past 125 years. Among the solutions Alcoa markets are flat-rolled products, hard alloy extrusions, and forgings, as well as Alcoa® wheels, fastening systems, precision and investment castings, and building systems in addition to its expertise in other light metals such as titanium and nickel-based super alloys. Sustainability is an integral part of Alcoa’s operating practices and the product design and engineering it provides to customers. Alcoa has been a member of the Dow Jones Sustainability Index for 11 consecutive years and approximately 75 percent of all of the aluminum ever produced since 1888 is still in active use today. Alcoa employs approximately 61,000 people in 30 countries across the world. For more information, visit www.alcoa.com and follow @Alcoa on Twitter at twitter.com/Alcoa and follow Alcoa on Facebook at www.facebook.com/Alcoa.

About Chemetall

Chemetall, a division of Rockwood Holdings, Inc. (NYSE: ROC), is a leading global supplier of special chemicals with a focus on processes for the surface treatment of metals and plastics. Chemetall is headquartered in Frankfurt am Main, Germany, and comprises about 40 companies worldwide. With 1,900 employees, the Group achieved sales of about 537 million Euro (2011). More at www.chemetall.com.

Contacts:

Alcoa
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Kelly Pasterick, 212-836-2674
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Kevin G. Lowery, 412-553-1424
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Monica Orbe, 212-836-2632
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