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| October 30, 2003
Alcoa Technology Improves New Audi A8 Sedan
PITTSBURGH--(BUSINESS WIRE)--Oct. 30, 2003--Alcoa announced today
that it has provided automotive aluminum structural technology to Audi
AG, the German automaker, for its second-generation A8 sedan. Alcoa's
automotive structural technology in the A8 offers drivers outstanding
stability and sets new standards in safety performance, while
maintaining one of the automotive industry's lightest luxury sedan
body shells.
According to Audi, its new A8 achieves "maximum stability with
minimum mass" through the effective integration of multiple aluminum
product forms supplied by Alcoa from its manufacturing facility in
Soest, Germany.
"Alcoa's work with Audi in the application of aluminum to
strengthen the performance of an integrated body structure system
represents nothing less than revolutionary progress in automotive
design and manufacturing that began with our collaborative, pioneering
efforts on the original A8," according to Rick Milner, president of
Alcoa Advanced Transportation Systems.
"The functional integration capabilities provided by the complex
designs and part geometries of Alcoa's high-strength, ductile die
castings and partially-hydroformed extrusions were also instrumental
in stiffening the space frame structure on the new A8 to improve its
handling and safety performance. The presence of Alcoa's newest cast
and extruded components also facilitated the use of more automated
assembly techniques to help Audi manage their production costs,"
according to Milner.
Audi's new aluminum space frame features fewer components than its
predecessor...267 versus 334. Newly-designed, larger and more complex
Alcoa Vacuum Die Castings have replaced combinations of castings,
extrusions and sheet components used in the original space frame to
consolidate parts and reduce total systems cost.
The new A8 also features other "firsts" in the use of Alcoa's
proprietary casting technologies. Four AVDC castings are used in the
doors. The luxury sedan also represents the first application of a new
Alcoa casting alloy that does not require water quenching after heat
treatment.
From a manufacturing perspective, Alcoa's Soest facility met all
of Audi's delivery performance targets throughout the launch of the
A8. This was a significant challenge since the ramp up to series
production included a 33% expansion in the size of the location,
featuring the addition of two new vacuum die casting machines, a
significant expansion of the plant's shipping and receiving area and
expansion of the location's prototyping capability, including new
measurement, fixturing, testing and assembly facilities.
"The addition of these capabilities, in combination with the
experience of launching the first A8 and our on-going close
cooperation with Audi, allowed us to manage the ramp up of the new
model and manage costs at the same time. We were able to take
advantage of the stability of our work force and involve employees who
had participated in the first A8 launch. This combination of
experience and resources created significant advantage for Audi and
Alcoa," according to Luigi Mattina, Soest's plant manager.
The wide variety of Soest's processing capabilities...from vacuum
die casting to extrusion forming to hydroforming...coupled with the
plant's expanding knowledge of prototyping, fixturing, joining and
assembly...make it one of Alcoa Advanced Transportation System's most
versatile operations. "We now have almost 10 years worth of experience
in helping our customers go from concept to prototype to pre-series to
series products," Mattina concluded.
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 to customers. In addition to
aluminum products and components, Alcoa also markets consumer brands
including Reynolds Wrap(R) foils and plastic wraps, Alcoa(R) wheels,
and Baco(R) household wraps. Among its other businesses are vinyl
siding, closures, precision castings, fastening systems, and
electrical distribution systems for cars and trucks. The company has
127,000 employees in 41 countries. More information can be found at
www.alcoa.com.
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