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16 th ARABAL ARAB INTERNATIONAL ALUMINIUM CONFERENCE 20-22 NOVEMBER 2012. Prospects of Aluminium Downstream Industries in Qatar for Development of Automotive Sector. Presentation By: Shambhu Prasad Senior Expert . Content of presentation. Introduction of GOIC

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Presentation by shambhu prasad senior expert

16th ARABAL ARAB INTERNATIONAL ALUMINIUM CONFERENCE

20-22 NOVEMBER 2012

Prospects of Aluminium Downstream Industries in Qatar for Development of Automotive Sector

Presentation By:

Shambhu Prasad

Senior Expert


Presentation by shambhu prasad senior expert

Content of presentation

  • Introduction of GOIC

  • Use of aluminium in automotive

  • Overview of aluminium industry in Qatar

  • Prospects of aluminium downstream industry in Qatar to support automotive sector


Goic establishment and objective s

GOIC - Establishment and objectives

Gulf Organization for Industrial Consulting (GOIC) was established in 1976 by the Gulf States. The Republic of Yemen joined the organization in 2009. The establishing of GOIC was to be an industrial consultative-coordinative institution that provides research and distinguished industrial consulting services for both public as well as private sectors. Its goal was also to meet the need for a source of information that works on reinforcing industry and industrial investments through the flow of knowledge and information.

3


Goic programs

GOIC - Programs

  • Manufacturing Investment Opportunity Program (MIOP).

  • Industrial Studies and Policies Program (ISP).

  • Sub-contracting and Partnership Exchange Program.

  • Industrial Technical Assistance Program (ITA).

  • Industrial Market Intelligence Portal (IMI).

  • Training and Capacity Development (TCD) Program.

  • Regional Coordination and Cooperation Program

  • Market study, Pre-feasibility, Feasibility studies, Sector studies, Multi – client studies

4


Goic partnerships coalitions and cooperation agreements

GOIC - Partnerships, Coalitions and Cooperation Agreements

  • World Trade Organization (WTO).

  • The United Nation Industrial Development Organization (UNIDO).

  • United Nation Conference for Trade and Development (UNCTAD).

  • Economic and Social Committee for West Asia (ESCWA).

  • Organization for Economic Cooperation and Development (OECD).

  • The Japanese Cooperation Center for the Middle East (JCCME)

  • The Korean institute for industrial economic and trade (KIET).

  • The Arabian institute for planning other nongovernmental organizations.

5


Aluminium is the second most used materials in a modern car

Aluminium is the second most used materials in a modern car

Source: BentelerAutomotive


Why aluminium in automotive

Why aluminiumin automotive?


Average aluminium usage increased to 140 kg car in 2011

Average aluminium usage increased to 140 kg/car in 2011


Aluminium penetration in different models of cars

Aluminiumpenetration in different models of cars


Aluminium parts components in cars

AluminiumParts & Components in cars

  • Power train:

    • Pistons, engine blocks, cylinder head, fuel systems, heat shield, heat exchangers, miscellaneous engine components, transmission & drive shaft

  • Chassis and suspension:

    • Side frames, suspension parts, wheels, steering system, brake system

  • Car body & structures

    • BIW (body in white), doors, hoods, fenders, dash board, carrier, bumpers, seat frames, interior, exterior closure panel, instrument panel structure, windshield surround structures, electrical distribution systems


Aluminium parts components in cars1

AluminiumParts & Components in Cars


Aluminium usage in cars components increasing

Aluminium usage in cars components increasing


Aluminium castings in cars

Aluminiumcastings in cars

  • The automotive industry is the largest market for aluminum castings

  • It accounts for more than 50% of aluminium used in cars

  • Cast aluminum transmission housings and pistons have been commonly used in cars and trucks throughout the world for many years.


Typical aluminium castings in automotive

Typical Aluminium Castings in Automotive

Oil Pan

Housings

Rear body

Cast parts & components componentsUnitech


Challenges in making aluminium castings for automotive applications

Challenges in making aluminium castings for automotive applications

  • Engine components require high integrity, stiffness, retention of properties at moderate elevated temperatures, and good wear resistance

  • Chassis and suspension components require high integrity, good strength/ductility, fatigue endurance, crashworthiness, and weldability

  • Body components require high integrity, thin walls, high ductility, crashworthiness, and weldability

  • Turbulence can lead to the entrapment of air or other cavity gases

  • Quenching the components for heat treatment may cause their distortion and straightening adds additional cost

  • Development of alloys that meet high strength and ductility requirements without the need for heat treatment


Aluminium extrusions in cars

Aluminium Extrusions in Cars

  • Frame & body structure

  • Drive shaft

  • Transmission parts

  • Door & window frames

  • Reinforcement beams

  • Running boards

  • Roof racks

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Typical extruded aluminium componemts in automotive

Typical extruded aluminiumcomponemtsin automotive


Challenges in making aluminium extrusion parts for automotive

Challenges in Making Aluminium Extrusion Parts for Automotive

  • Developing suitable alloys to meet accurate and repeatable physical and mechanical properties

  • Precise requirement of product integrity and formability

  • Near Net Shape Extrusion technology

  • Stretch forming & hydro forming for obtaining accurately formed interconnecting components

  • Intricate, multi-chambered hollow sections for condenser tubes adopting precision die and novel die insert technologies

  • Design & engineering solution for component, parts and structural assemblies

  • Specific heat treatment practices for standard alloys

  • Final fabrication & assembly techniques.


Aluminium sheet components for automotive

Aluminiumsheet components for automotive


Challenges in making aluminium sheet components for automotive

Challenges in Making Aluminium Sheet Components for Automotive

  • Development of new alloys

  • Development of suitable forming processes (stamping, tailor-welded blanks, hydroforming, electromagnetic forming, and warm forming)

  • Continuous die design development

  • More efficient and/or lower-cost continuous joining processes for panel joints

  • Methods for reducing or eliminating slivers during cutting

  • Minimizing metal required for achieving flat hems and avoiding splitting while bending by 1800


Aluminium usage in heat exchangers

Aluminium usage in Heat Exchangers

  • Heat exchangers in automotive sector: Engine cooling (radiator), oil cooling, and condensers and evaporators in air conditioning system, heaters, charge air, exhaust gas and fuel cooling / heating

  • Advantage of Aluminium for Heat exchangers

    • High thermal conductivity

    • Reliable manufacturing process (brazing)

    • Excellent corrosion resistance

    • Good formability

    • Adequate strength to resist temperature and pressure cycles

    • Environmentally friendly

    • Commercial availability of a wide range of aluminium alloys and product forms to meet different design options


Aluminium usage in heat exchangers contd

Aluminium usage in Heat Exchangers…contd.

  • The majority of the heat exchangers used in today’s automobiles are based on tube / fin designs.

  • Aluminiumheat exchangers for automotive applications are today generally produced by controlled atmosphere brazing (dominating method) and vacuum brazing

  • Input is flat rolled materials, e.g.: Unclad fin stock for radiators, charge air coolers, heaters, etc. and clad fin stock for condensers.

  • Clad header plates and side plates, Clad strip for welded or folded tubes for radiators, charge air cooler, heaters, etc.

  • Clad plates for evaporators and oil coolers


Typical aluminium radiators in cars

Typical aluminium radiators in cars


Aluminium heat exchangers in cars

AluminiumHeat Exchangers in cars

Brazed liquid-to-liquid oil cooler

Simple brazed aluminium radiator with plastic tanks


Aluminium heat exchangers in cars contd

Aluminiumheat exchangers in cars…contd.

All-aluminium heater core

Engine oil cooler with attached oil filter housing


Aluminium heat exchangers in cars ctd

AluminiumHeat Exchangers in Cars…ctd.

Power steering oil cooler

Air cooled transmission oil cooler

Power steering oil cooler


Aluminium heat exchangers in cars ctd1

AluminiumHeat Exchangers in cars…ctd.

Internal heat exchanger for R-744 (CO2) air conditioning systems

Evaporator used in R744 A/C circuits


Aluminium industries in qatar overview

AluminiumIndustries in Qatar - Overview

  • Qatalum Smelter: 585,000 TPA of extrusion billet and foundry alloys ingot

  • Qatar Aluminium Extrusion Plant of 9,000 TPA capacity

  • 25 companies making aluminium fabricated products

    • Windows, doors, kitchen, facades, hand rails, aluminiumkitchen

    • One company producing foil rolls.

    • Powder coating facilities for aluminium extruded products

    • Cutting facilities for aluminium sheets

    • Aluminiumpanels

  • Major imported aluminium products in Qatar

    • Profiles & structure

    • Plate, sheet and foils

    • Tubes

    • Wires & Cables

    • Casks & drums

    • Household and other articles


Automotive sector development plan qatar

Automotive Sector Development Plan - Qatar

  • Qatar’s 2030 Vision aims at diversifying its economy, creating knowledge-based industries, and creating skilled jobs in Qatar.

  • For automotive sector development it is planned to build an industrial automotive clusters in Qatar in line with the 2030 Vision.

  • Private Sector initiatives are in the offing including founding of Qatar AG in 2010 to meet the above objective.

  • Qatar smelter will be the main anchor to the aluminium automotive cluster development.


Aluminium downstream opportunities for automotive industrial clusters

Aluminiumdownstream opportunities for automotive industrial clusters


Aluminium downstream opportunities for automotive industrial clusters contd

AluminiumDownstream Opportunities for Automotive Industrial Clusters … contd.


Aluminium downstream opportunities for automotive industrial clusters contd1

AluminiumDownstream Opportunities for Automotive Industrial Clusters … contd.


What are the challenges

What are the challenges ?

  • Market: Initial dependence on overseas market

  • Access to technology and process

  • Meeting specification and standards and obtaining certification

  • Acceptance of the products by the OEM and car manufacturers

  • Continuous developments of new design and quality in consultation with car manufacturers to survive in the market


How to proceed

How to Proceed?

  • Identify well established OEMs and Level 1 suppliers of automotive parts and components for collaboration

  • Acquisition of well-established manufacturing plant to have access to process know-how and technology

  • Conduct market study to identify target market to start with as GCC market is still in a stage of infancy. Enter into marketting and sales tie-up.

  • Establish plant in Qatar with collaboration and support of the identified OEM / Level -1 suppliers


Presentation by shambhu prasad senior expert

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