Arconic RSR Overview GALM Joining, Forming & Manufacturing Technologies Conference Graham Musgrove, P.E., Project Engineer Automotive November 30,

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1 Arconic RSR Overview GALM Joining, Forming & Manufacturing Technologies Conference Graham Musgrove, P.E., Project Engineer Automotive November 30, 2016

2 Arconic Company Profile EPS Engineered Products and Solutions GRP Global Rolled Products TCS Transportation and Construction Solutions APP AFSR AFE ATEP AAP BCI MPS AWTP BCS LAE Arconic Fastening Systems and Rings Aerospace and Automotive Products 2015: $2.2B Revenue 8,200 Employees 2015: $2.8B Revenue 4,200 Employees 2

3 AFSR: Where We Are Facili&es Suppor&ng Automo&ve Waco, Texas Blind Fasteners Telford, UK Blind Fasteners Suzhou, China Blind Fasteners Melbourne, Australia Inserts Kelkheim, Germany Latches St. Cosme, France Specialty Nuts Kingston, New York InstallaJon Tools Carmel, Indiana DistribuJon Tracy, California DistribuJon Mexico City, Mexico Sales Office Sao Paulo, Brazil Sales Office Kolkata, India Sales Office Tokyo, Japan Sales Office 3

4 RSR Commercialization Team Developing the Next Generation Multi-Material Automotive Joining Technology Arconic Technical Center (ATC) with ~400 employees is the world s largest light metals research and development center with extensive expertise in aluminum welding, alloy development, surface coatings and corrosion for the automotive industry. Arconic Fastening Systems & Rings (AFSR) with over 8,000 employees in 13 countries and revenue of $2.2B, AFSR is a global supplier of engineered fastening solutions to aerospace, automotive, heavy truck, rail, green energy and other industries.

5 RSR Uniquely Differentiated to Meet Emerging Auto Trends Automotive is moving to a combination of conventional / high strength aluminum and ultra high strength steels which cannot be joined with resistance spot welding and self pierce riveting RSR can join a variety of dissimilar materials with minor modifications to the capital infrastructure in place today Aluminum Intensive Conventional Al to Al High strength Al to Al Aluminum Closures Conventional Al to Al Conventional Al to St Steel & Aluminum High strength Al to St./UHSS Limited Joining Options Steel / UHSS Aluminum High Strength Al Mg & Composites not shown 5

6 Arconic RSR (Resistance Spot Riveting) A new technology being commercialized by the Arconic Fastening Systems and Rings group leveraging existing RSW infrastructure for high performance joining in current and future material combinations R1009 Joint Cross Sec&on Arconic Fastening Systems and Rings 2mm Al RSR AL UHSS Aluminum & Steel Fastener Families + Installa&on Equipment Conven&onal RSW Infrastructure High Performance Mul&-material Joints 6

7 RSR Process Pilot and Self-Piloting Technology Developed to Meet Customer Demands 7

8 Arconic RSR Performance: Current versus Future Automotive Materials RSR Exceeds Strengths of Competing Technologies for Current and Future Automotive Materials Average Joint Tensile Shear Strength, kn Current Materials 5xxx Al, 6xxx Al and Advanced High Strength St 2mm 6022-T4 to 1.2mm 590MPa 6xxx /6xxx RSW Avg Min Future Auto OEM Material Direction High Strength Al and Ultra High Strength St 2mm 7075-T6 to 1.2mm 590MPa 7xxx/7xxx RSW Avg Min Outside SPR Limits 2mm 7075-T6 to 1.2mm 980MPa 980MPa RSW Min Future Materials 590MPa RSW Min Current Materials SPR 8

9 RSR Family Family of fasters developed for a variety of sheet combinations including both piloted and self-piloted applications Aluminum Fastener Family Steel Fastener Family RSR-R4-2 RSR-R4-4 22% Head Diameter 33% Head Height RSR-R4-6 Low Profile Head Join steel to aluminum (bare or coated), magnesium and composites Join aluminum to aluminum, painted metal (steel or magnesium) and composites Zinc electroplated for enhanced corrosion protection RSR-R4-4 (LPH) Lower weld currents required than traditional aluminum spot welding 9

10 Steel RSR Family Grip Range for Various Applications Small Number of Fastener Sizes Handle Wide Grip Range Grip Length for Steel RSR Applications RSR-R4-6 RSR-R4-4 Piloted RSR-R4-2 Self-Piloted Grip Length, mm 10

11 Innovative Strengths & Adaptability Leverage Existing Joining Technology to Expand Beyond Steel Sheet Combinations St to St Spot Weld St to St Spot Weld St to Al RSR Al to Al RSR Al to Al Spot Weld Al to St RSR STEEL RSR ALUM. RSR Seamlessly transition between conventional spot welding to RSR on the same welding equipment 11

12 RSR Joint Examples Applications being developed for variety of materials and product forms for both piloted and self-piloted Steel Fastener Family Aluminum Fastener Family 2 Thickness 3 Thickness Sheet to Tube 2 Thickness 3 Thickness Top Sheet (Rivet Feed Side) Bottom Sheet (Weld Side) Self Pilot Available? Al, painted Al Mg, painted Mg Composites St to UHSS Yes * Self-Pilot not possible through composite materials or non-conducjve coajngs Al, painted Al Mg, painted Mg Composites, St to UHSS, painted St Al No 12

13 RSR Pilot Line Now Available Arconic Developing Fastener and Installation Equipment for OEMs Pilot and Production Cells Rivet Delivered to Electrode Gun Delivers Rivet to Workpiece Feed System Pulls Out During Heating and Welding 100kVA C-Gun Pilot Station 13

14 RSR Technology 1 Leverage existing RSW capital and logistics Significant capital cost avoidance while reducing development costs 3 Current material optimized, future material capable - including ultra high strength aluminum, steels, magnesium, composites 2 Multiple material combinations - same joining cell - no changeover Reduced manufacturing footprint by consolidating joining technologies 4 Equipment available in 2018 Commercializing fastener family and joining equipment Developing applications and design guidelines with OEMs 14

15 Further Information Graham Musgrove Project Engineer Automotive Arconic Fastening Systems and Rings, USA Jay Sahadew Marketing Manager Arconic Fastening Systems and Rings Limited, UK +44 (0) Stop by our booth in the Exhibition Hall 15

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