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Presentation By: Shambhu Prasad Senior Expert

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

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  1. 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

  2. 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

  3. 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

  4. 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

  5. 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

  6. Aluminium is the second most used materials in a modern car Source: BentelerAutomotive

  7. Why aluminiumin automotive?

  8. Average aluminium usage increased to 140 kg/car in 2011

  9. Aluminiumpenetration in different models of cars

  10. 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

  11. AluminiumParts & Components in Cars

  12. Aluminium usage in cars components increasing

  13. 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.

  14. Typical Aluminium Castings in Automotive Oil Pan Housings Rear body Cast parts & components componentsUnitech

  15. 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

  16. Aluminium Extrusions in Cars • Frame & body structure • Drive shaft • Transmission parts • Door & window frames • Reinforcement beams • Running boards • Roof racks 16

  17. Typical extruded aluminiumcomponemtsin automotive

  18. 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.

  19. Aluminiumsheet components for automotive

  20. 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

  21. 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

  22. 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

  23. Typical aluminium radiators in cars

  24. AluminiumHeat Exchangers in cars Brazed liquid-to-liquid oil cooler Simple brazed aluminium radiator with plastic tanks

  25. Aluminiumheat exchangers in cars…contd. All-aluminium heater core Engine oil cooler with attached oil filter housing

  26. AluminiumHeat Exchangers in Cars…ctd. Power steering oil cooler Air cooled transmission oil cooler Power steering oil cooler

  27. AluminiumHeat Exchangers in cars…ctd. Internal heat exchanger for R-744 (CO2) air conditioning systems Evaporator used in R744 A/C circuits

  28. 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

  29. 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.

  30. Aluminiumdownstream opportunities for automotive industrial clusters

  31. AluminiumDownstream Opportunities for Automotive Industrial Clusters … contd.

  32. AluminiumDownstream Opportunities for Automotive Industrial Clusters … contd.

  33. 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

  34. 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

  35. Thank You

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