Blake Zuidema Novelis and Aluminum Transportation Group

1. Dr. Blake
Zuidema
WELCOME

2. The Rise of BEVs
Inflection Point

3. How do we
get there?
Where to? What next?

4. Industry
Response
Auto Aluminum

5. The Plan
• Design Engineering
• New Alloys, Products & Grades
• Future Vehicles
• Next Generation Fabrication
• Recycling & Sustainability

6. Design
Engineering

7. Design
Engineering
• Establish Open Access Resource: Ensure easy
access to detailed and relevant design data for
forming and manufacturing simulation.
• Optimize Joining Designs and Processes: Develop
more robust joining technologies, including
adhesives, with emphasis on dissimilar materials.
• Improve Aluminum Component
Manufacturability & Process Design: Design
components and subsystems for higher strength,
improved formability/ease of fabrication, and
increased corrosion resistance.

8. New Alloys,
Products & Grades

9. New Alloys,
Products &
Grades
• Tailor Alloys for High Performance in OEM-Specific
Applications: Develop affordable, ultra-high-
strength, corrosion-resistant aluminum grades.
• Harness Data Analytics & Predictive Modeling of
Alloy Properties: Modernize simulation/material
property cards for CAE for safety, durability, etc. to
cut costs and shorten development time.
• Expedite Testing and Qualification of Next
Generation Alloys: Achieve industry consensus on
fit-for-purpose material specs and testing, including
joining and bonding durability.

10. Future
Vehicles

11. Future
Vehicles
• Reduce Overall Part and Sub-system
Costs: Develop cost-effective aluminum solutions
to meet all structural and safety requirements of
battery enclosures.
• Create Alloys Specifically for Electric Vehicle
Batteries: Balance customer design requirements
for stable dimensions/tolerances with material
properties and cost of processing.
• Tailor Designs for Battery Enclosures: Improve
alloys and processes to enhance battery
component functionality and flexibility.

12. Next Generation
Fabrication

13. Next
Generation
Fabrication
• Develop Advances in Formability: Develop higher-
formability aluminum grades that can substitute for
mild steels without compromising design.
• Enable Real-Time Process Data Collection at All
Manufacturing Steps: Implement real-time process
data collection for sharing across the automotive
aluminum value chain to enable effective use of
Industry 4.0, machine learning, and AI.
• Develop Innovative, Cost-Effective Next Generation
Fabrication Processes: Overcome the hurdles of
high CAPEX new technology deployments by
extensive use of digital twins and relevant scale
prototyping.

14. Recycling &
Sustainability

15. Recycling &
Sustainability
Develop High-Speed / High-Volume Sorting and
Recycling:
Develop the next generation of high-speed, alloy-
selective, low-cost sorting technology for shredded
scrap; ensuring state-of-the-art technologies for
closed-loop recycling are widely available.
Enable and Ensure Life Cycle Management Across
the Value Chain:
Develop comprehensive systems for tracking and
recording global scrap flow.
Recycle Bonded and Riveted Joints:
Efficiently shred and separate dissimilar metals and
alloys that are bonded, welded or riveted.

16. Ongoing
Discussion

17. Auto
Aluminum
Looking ahead for

18. Contact
Drivealuminum.org
@DriveAluminum
@AluminumNews
Link to the Roadmap