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July 22, 2002

Alcoa Aerospace Announces Two New Products and Contract to Supply Rolls-Royce Trent 900

PITTSBURGH--(BUSINESS WIRE)--July 22, 2002--Alcoa Aerospace announced today during the Farnborough Air Show in England the introduction of two new products, the Fortress(TM) blast-resistant cargo container and a machined, forged aluminum door structure using Alcoa's new proprietary 7085 alloy. Alcoa Aerospace also announced that its Howmet Castings unit will supply investment cast engine structural components for the Rolls-Royce Trent 900(R) engine program, which will be used on the Airbus A380 commercial aircraft.

The three releases follow:

Alcoa Aerospace's Adds Fortress(TM) Blast-Resistant

Cargo Container to Growing Line of Airline Security Products

FARNBOROUGH, England--July 22, 2002--Alcoa Aerospace has developed a new blast-resistant cargo container for airlines that brings together the company's aluminum design and production experience with its expertise in aluminum-based armor protection.

Preliminary definition of the Fortress(TM) Container has been completed, and a full-scale prototype is being shown for the first time on Alcoa's exhibit stand at this week's Farnborough Air Show (Hall 4, Stand D14).

"Our Fortress Container is part of Alcoa Aerospace's growing line of products that provide enhanced safety and security for airlines, their passengers and employees," said Pat Hassey, the Alcoa executive vice president responsible for the company's aerospace market sector. "It joins our Fortress(TM) Reinforced Cockpit Door, which currently is undergoing U.S. Federal Aviation Administration certification." The containers are transported in under-floor holds of airliners and carry both passenger luggage and cargo.

Features of the Fortress Container include its modular kit design and a rugged latching system. The kit concept allows containers to be rapidly assembled for use, and it facilitates repairs by enabling the easy replacement of damaged panels. The modular panels also can be assembled at varying lengths inside an airliner's under-floor cargo hold to serve as a protective lining.

The Fortress Container uses hardened aluminum alloys for both the frame and skin. Advanced welding processes being introduced in the aerospace industry are used to fix the skin to the container's frame.

The aluminum container structure is designed to resist pressure loads from an explosion, while an interior Kevlar lining provides protection from blast fragments. In designing the Fortress Container, Alcoa used its experience gained in developing aluminum armor for the Bradley Fighting Vehicle, the HMMWV (Humvee) and other military applications.

The prototype container on display at Alcoa's Farnborough Air Show exhibit stand is an LD-3 version, which is the worldwide standard for wide-body airliners. Other versions may be developed by Alcoa for smaller, narrow-body aircraft. U.S. government certification targeted for the first half of 2003.

Alcoa is the world's leading producer of primary aluminum, fabricated aluminum and alumina, and is active in all major aspects of the industry. Alcoa serves the aerospace, automotive, packaging, building and construction, commercial transportation and industrial markets, bringing design, engineering, production and other capabilities of Alcoa's businesses as a single solution to customers. In addition to aluminum products and components, Alcoa also markets consumer brands including Reynolds Wrap(R) aluminum foil, Alcoa(R) wheels, and Baco(R) household wraps. Among its other businesses are vinyl siding, closures, precision casting and electrical distribution systems for cars and trucks. The company has 129,000 employees in 38 countries.

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Alcoa Aerospace Introduces Machined, Forged Aluminum Door Structure

FARNBOROUGH, England--July 22, 2002--A forged aluminum door skeleton featuring Alcoa's proprietary new 7085 alloy and offering aircraft manufacturers weight and cost savings was introduced by Alcoa Aerospace at Farnborough International 2002 today.

This first application for this door, which is a machined forging, is for over-wing emergency exits. However, second-generation applications are expected for cargo and passenger doors.

"We are able to offer significant part consolidation and assembly time reductions by integrating our metallurgical, component design and manufacturing know-how," according to Mary Ellen Bowers, vice president and general manager of aerospace and industrial products for Alcoa's Wheel and Forged Products business. "The effective combination of advanced quench and stress relief practices with sophisticated machine fixturing and optimized metal removal practices gives us the capability of offering our customers a new and attractive alternative to traditional, built-up structures.

"In some cases, we have seen part counts reduced from 147 to 40 and fastener requirements cut from almost 1,400 to 450," Bowers reported. "This translates to assembly times shortened by up to 80% and reductions in production line floor space of as much as 60%. All this combines to offer our customers reductions in both recurring and non-recurring costs between 20 and 25%."

Alcoa has been working with many air framers on this new application for wrought, monolithic products. Current alloys for this application include 7050 or Alcoa's new, proprietary alloy 7085. Machined gauges as low as 1.3 mm are characteristic in these door structures. This structure also provides weight savings typically of 20% compared to built-up assemblies.

"The use of concurrent engineering has been exceptionally valuable in developing these cost-effective structural applications," Ms. Bowers observed. "We have been able to address every part of the value chain to help our customers...from rapid prototyping to scrap loop integration."

Alcoa is the world's leading producer of primary aluminum, fabricated aluminum and alumina, and is active in all major aspects of the industry. Alcoa serves the aerospace, automotive, packaging, building and construction, commercial transportation and industrial markets, bringing design, engineering, production and other capabilities of Alcoa's businesses as a single solution to customers. In addition to aluminum products and components, Alcoa also markets consumer brands including Reynolds Wrap(R) aluminum foil, Alcoa(R) wheels, and Baco(R) household wraps. Among its other businesses are vinyl siding, closures, precision casting and electrical distribution systems for cars and trucks. The company has 129,000 employees in 38 countries.

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Alcoa Howmet Receives Engine Structural Commitment

For Rolls-Royce Trent 900

DARIEN, Conn.--July 22, 2002--Alcoa Howmet Castings has been selected to supply an investment cast engine structural component for the Rolls-Royce Trent 900(R) engine program, the propulsion system for the Airbus A380 commercial aircraft. The agreement will cover the production of a high-pressure/intermediate-pressure bearing support structure component for approximately 250 engine sets. Delivery of development castings is required in 2002 and production engine delivery is scheduled for 2004.

According to James Stanley, Alcoa vice president and Howmet president and ceo, the order commitment is a significant relationship milestone and important to the company's strategic business development.

The component will be cast in IN718 alloy at the Howmet casting facility in Hampton, Virginia where tooling is already in progress. Frank Reuwer, Howmet's regional business manager, says the new order reflects the company's commitment to customer satisfaction. "Howmet has recently expanded its large structural capabilities in Hampton. Our drive for continuous improvement and streamlined process approach allows us to deliver the highest quality and value within the customer's cost objectives."

Alcoa is the world's leading producer of primary aluminum, fabricated aluminum and alumina, and is active in all major aspects of the industry. Alcoa serves the aerospace, automotive, packaging, building and construction, commercial transportation and industrial markets, bringing design, engineering, production and other capabilities of Alcoa's businesses as a single solution to customers. In addition to aluminum products and components, Alcoa also markets consumer brands including Reynolds Wrap(R) aluminum foil, Alcoa(R) wheels, and Baco(R) household wraps. Among its related businesses are vinyl siding, closures, and electrical distribution systems for cars and trucks. The company has 129,000 employees in 38 countries. Alcoa Howmet Castings (www.howmet.com) is the world's largest manufacturer of precision castings, primarily for jet aircraft and industrial gas turbine engines.