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Breakthrough Automotive Alloy 40% More Formable and 30% Stronger than Aluminum Used Today

Alcoa has unveiled breakthrough manufacturing technology, the Alcoa Micromill™, that will manufacture the most advanced aluminum sheet on the market. The Micromill will enable the next generation of automotive aluminum products and equip Alcoa to capture growing demand.

"This technology will unlock the next generation of automotive products with strength, formability and surface quality combinations never before possible. It will allow our customers to redefine the boundaries of vehicle design, supporting the creation of lighter, more fuel efficient, safer and more stylish vehicles for the future," said Alcoa Chairman and Chief Executive Officer Klaus Kleinfeld.

The Alcoa-patented Micromill process dramatically changes the microstructure of the metal, allowing the production of an aluminum alloy for automotive applications that has 40 percent greater formability and 30 percent greater strength than the incumbent aluminum used today while meeting stringent automotive surface quality requirements.

Additionally, automotive parts made with Micromill material will be twice as formable and at least 30 percent lighter than parts made from high strength steel. The Micromill alloy has formability characteristics comparable to mild steels.

Micromill aluminum sheet that is 40 percent more formable is easier to shape into intricate forms, such as the inside panels of automobile doors and external fenders, which today are generally made of steel. The 30 percent increase in material strength will improve dent resistance, enabling the production of automotive sheet that is thinner and even lighter than previous generations. Automakers will also benefit from reduced system cost by streamlining the number of aluminum alloys used in their manufacturing process.

It will also be the fastest, most productive aluminum casting and rolling system in the world. A traditional rolling mill takes around 20 days to turn molten metal into coil, Micromill does it in just 20 minutes.

The Micromill also has a significantly smaller footprint than a traditional rolling mill, at just one quarter the size, and lowers energy use by 50 percent. The Alcoa Micromill technology and the differentiated metal it will produce are covered by more than 130 patents around the world.

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