AEROSPACE ALUMINUM

YOUR PARTNER IN ALUMINUM SOLUTIONS

We believe that it’s a win-win to enable our customers’ progress.

Quality. Accountability. Integrity. These things are non-negotiable.
When we collaborate with customers to find solutions,
we’re contributing to their success and creating a better world.

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THINK BEYOND

At Aleris, aluminum isn’t just our work — it’s our passion.

It represents opportunity, innovation and game-changing solutions
to create a better world.

With Aleris Aerospace Aluminum, GLOBAL REACH becomes more important TECHNICAL PROGRESS is what drives our
Aleris provides customers with the in business every minute of every day. people. We’re not satisfied with today’s
people, the tools and the resources Aleris is helping our customers meet solutions. By always striving to develop
that they need to realize the value international demand through global assets new and innovative aluminum products for
that aluminum offers. such as our newly built world-class plate our customers, we ensure that we’re
mill in China, which allows us to serve providing them the best materials to meet
fast-growing Asian markets. tomorrow’s challenges today.

SUSTAINABILITY is important to us. CONSISTENCY in our quality, reliability

As a leading aluminum recycler with a and creativity come together to make Aleris
safety-focused culture, Aleris looks after the preferred choice for our customers,
the environment the same way that we and as a result, a leading global producer
look after our people. of aircraft aluminum products.

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 PLANT KOBLENZ

Our success is founded in offering innovative, customized

solutions for our customers and maintaining long-term
partnerships within the aerospace industry.

The Aleris plant in Koblenz, Germany, is BUILT FOR THE FUTURE,

one of the world’s leading rolled products ROOTED IN HISTORY
mills for high-quality rolled aluminum
plate. The plant produces plates, sheets and With a heritage going back more than
coils in more than 100 different alloys, 50 years, the Koblenz plant embodies
which are used in applications for enginee- Aleris’ com­mitment to permanent quality
ring, trans­portation, aerospace and other improvement, a culture of systematic
modern industrial segments. Through highly process optimization and a constant
innovative and efficient operations, the investment in modern equipment.
Koblenz plant delivers more than 150,000
tons of semi-finished aluminum to Aleris Since its inception, more than 450 million
customers around the globe every year. euros have been invested in Koblenz to
expand the facility and its capabilities. Today,
This has enabled Aleris Koblenz to supply the plant is known for its innovation and
the global aerospace industry with innova- quality. Through continued investment in
tive aluminum materials of the highest modern production and the ability to meet
qua­lity, which meet not only the highest the highest standards of organization,
standards but also all conceivable individual working environment, health, safety and
customer specifications. environmental quality, the Koblenz plant
is well-positioned to successfully serve the
Both experience and know-how have been industrial needs of today’s global market­-
applied to develop special various alloys – place.
like ultra thick aluminum aircraft plates, mill-
finished and polished aluminum aircraft
sheets, as well as aluminum aircraft seg-
ments in customized sizes – which fully
satisfy the requirements of the aerospace
market.

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MAJOR CAPABILITIES
CAST HOUSES
SCALPER
160“ HOT ROLLING MILL
128“ HOT ROLLING MILL
148“ COLD ROLLING MILL
SAWING CENTERS (WIDE PLATE, CNC, SEGMENT, LINER PLATE SAW)
HORIZONTAL HEAT-TREATMENT FURNACE, PLATE- AND VERTICAL FURNACES
STRETCHER UP TO 8,000 T
PLATE TESTING EQUIPMENT (E.G. ULTRASONIC TESTING, EDDY CURRENT TESTING)

CERTIFICATIONS
CERTIFIED FOR AEROSPACE: EN 9100
QUALITY MANAGEMENT AUTOMOTIVE: ISO/TS 16949
GENERAL ROLLED PRODUCTS: DIN EN ISO 9001
CERTIFIED FOR DIN EN ISO 14001
ENVIRONMENTAL MANAGEMENT SPECIALIZED COMPANY ACC. TO
“WASSERHAUSHALTSGESETZ”
EMAS
CERTIFIED FOR AEROSPACE NADCAP – HEAT TREATING
NADCAP – NON-DESTRUCTIVE TESTING
CERTIFIED FOR MANUFACTURE DIRECTIVE 97/23/EC
OF PRESSURE EQUIPMENT
CE MARKING FOR CONSTRUCTION EN 15088
CERTIFIED FOR SHIPBUILDING BUREAU VERITAS
DET NORSKE VERITAS
GERMANISCHER LLOYD
KOREAN REGISTER OF SHIPPING
LLOYD´S REGISTER
RULES ABS

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 PLANT ZHENJIANG

We’re using innovative technology and personalized service

to make high-end, high-quality aluminum products available
for customers in Asia and all over the world.

Aleris Zhenjiang, China, was established to SUPPORTING TOP PLAYERS State-of-the-art equipment
meet growing regional and global demand AND FAST-GROWING INDUSTRIES The twin Zhenjiang and Koblenz plants
for aerospace and commercial plate products. IN ASIAN MARKETS share nearly the same set of cutting-edge
The new plant, which spans 271,330 m2 equipment for highly specialized products,
represents a $350 million greenfield invest­- The Zhenjiang plant benefits greatly from which are used in applications for all mo­dern
ment in technologically advanced aluminum the rich experience and expertise of its industrial market segments.
plate production. It is one of only a handful sister plants in other regions, specifically
of state-of-the-art aluminum plate facilities in the Aleris facility in Koblenz, Germany. This primarily comprises aluminum plate for
the world – and the first to be built outside As a result, the Zhenjiang plant is able to integrally machined structural components
of the U.S. and Europe. deliver: used in the aerospace industry. Typical alloys
are 2024, 2124, 7075, 7175, 7475 and 7050
Innovative technology in various tempers.
Through a technology transfer agreement
with the Koblenz plant, the Zhenjiang
plant benefits from more than 50 years
of operational innovation to invest in
its own quality improvements, systematic
process optimization and modern
equipment.

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Established expertise MAJOR CAPABILITIES
In addition to sharing similar technology, CAST HOUSES
processes and equipment, the plant in SCALPER
Koblenz transferred key managerial staff
160“ HOT ROLLING MILL
and technical engineers to Zhenjiang.
Gaining this expertise complements the HORIZONTAL HEAT-TREATMENT FURNACE
efforts of Zhenjiang engineers and supports STRETCHER UP TO 6,000 T
the plant’s overall technology, quality and PLATE SAWING CENTERS
operation.
PLATE TESTING EQUIPMENT (E.G. ULTRASONIC TESTING, EDDY CURRENT TESTING)

As one of the first state-of-the-art plate

mills in Asia, the Zhenjiang plant provides
aluminum products for leading industry
players in China and throughout Asia, CERTIFICATIONS
including fast-growing industries in the CERTIFIED FOR AEROSPACE: EN 9100
region. Working closely with our enginee- QUALITY MANAGEMENT GENERAL ROLLED PRODUCTS: DIN EN ISO 9001
ring and transportation strategic partners CERTIFIED FOR AEROSPACE NADCAP – HEAT TREATING
overseas, Aleris aims to produce aerospace- NADCAP – NON-DESTRUCTIVE TESTING
quality products and introduce them for all CERTIFIED FOR MANUFACTURE DIRECTIVE 97/23/EC
technically-demanding aluminum applica- OF PRESSURE EQUIPMENT
tions worldwide. CERTIFIED FOR SHIPBUILDING BUREAU VERITAS
DET NORSKE VERITAS
KOREAN REGISTER OF SHIPPING
RULES ABS
IN PROGRESS GERMANISCHER LLOYD
LLOYD´S REGISTER

www.aleris.com 7
 ALUMINUM AEROSPACE PLATE

Ultra thick plate

Cut-to-size shapes
Pre machined parts

In order to help the aircraft Original Equip­- The major challenge for a supplier of semi- ADVANTAGES OF DAMAGE TOLERANT
ment Manufacturers (OEM) to develop finished aluminum is that, that the property ALUMINUM PLATES:
and build light and cost efficient passenger combination of the raw material should
and cargo aircrafts with lower fuel burn, not limit the performance of the integral • thickness up to 280 mm (11”)
re­duced emissions and larger ranges, it has structure when compared to a classical • no significant porosity
become increasingly important for suppliers assembly. Therefore a number of limitations • excellent fatigue performance
to tech­nically support their programs. One of aluminum plates have to be overcome: • extreme low level of residual stresses
major aspect of these programs is the substi­- The maximum thickness of conventional • practically no distortion after machining
tution of assemblies and built-up structures aluminum plates have to be increased • high strength
by so-called integral or monolithic struc­- in order to allow machining of very heavy • high ductility
tures. sections. • excellent toughness

An assembly usually consists of a number Several key properties of the plate material
of formed sheets and extruded, forged – such as fatigue resistance, toughness and
and/or machined parts, which are riveted ductility – have to be improved in order
together or joined otherwise, whereby the to compete with properties of other product
entire structure integrates the function of forms like forgings. Additionally the residual
all individual components. stress level of the plate material have to
be controlled to an extremely low level to
achieve practically distortion free machi­-
na­bility even with the large dimensions and
the high aspect ratios involved.

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CUT-TO-SIZE SHAPES WITH IMPROVED Aircraft plate dimensional capabilities
BUY-TO-FLY RATIO
Thickness up to 11” up to 280 mm
The state-of-the-art CNC sawing center Plate pre-machining can be offered to Width up to 130” up to 3,300 mm
allows a variety of plate cuts to saw tailor- opti­mize cost savings and to minimize Length up to 945” up to 24,000 mm
made contours as well as the most difficult scrap handling at the customer site.
special shapes. The individual manufactu­ Other dimensions on request
red plate cuts can additionally be provi­ded The cut-to-size and pre-machined parts are
with fixing holes of 6 to 45 mm (0.24 to delivered to customers all over the world;
0.177”) provided as passage holes or bag all of the resulting scrap is being recycled in
holes with or without a thread. They serve our own recycling companies.
as the fast attachment of ring bolts and
fixing devices.

MAJOR CAPABILITIES

2014 2214 6061 7050 7150 7175

AMS 4029 AIR 9048 AIR 9048 AIMS 03-02-019 ABM 3-1031 AIMS 03-02-008
BS 2 L.93 CR 1.1.031 AMS 4025 AIMS 03-02-022 AMS 4252 ASN-A3050
TH 5.313 AMS 4026 AIMS 03-02-029 BAEM 1219 CR 1.1.0.88
AMS 4027 ABM 3-1029 BAMS516-006 OFWN 4033
2219 AMS-QQ-A-250/11 ABM 3-1030 DMS 2308 SMS 003
2024 A5-SA-121-1039 DAN 422 AIR 9048
A5-SA-133 1100-C-0019- WL 3.3214 AMS 4050
AIMS 03-02-004
MTA AMS 4201 7075 7475
ABM 1-1005
AMS 4295 BAEM 1213
AIR 9048 AIR 9048 AIMS 03-02-009
AMS 4600 7010 BAMS 516-001
AMS 4037 AMS 4045 AIR 9048
AMS 4613 BAMS 516-003
AMS 4041 ABM 3-1029 AMS 4078 AMS 4089
AMS-QQ-A-250/30 BMS 7-323 Type I
AMS-QQ-A-250/4 ABM 3-1030 AMS-QQ-A-250/12 AMS 4090
DSN 1719.01 BMS 7-323 Type III
AMS-QQ-A-250/5 AMS 4204 AMS-QQ-A-250/13 AMS 4202
MPS/2219/S&P/01 DAN 422
ASN-A3011 AMS 4205 AMS-QQ-A-250/24 BAMS 516-002
SA-MU-42.549.04 DGQT 1.1.0.97
BS 2 L.97 ASN-A3098 BS 2 L.95 DAN 422
55 LV 09 003 DGQT 1.1.0.0098
BS 2 L.98 ASN-A3101 DAN 422 DMS 2184
DMS 2233
CMS-AL-103 BAEM 1213 EN 2126 DMS 2234
DMS 2459
DGQT 1.1.0.0036 BAEM 1218 MMS 159 FMS-3004
2618 EN 3982
DAN 422 DAN 422 STD 113627 MEP 02-013 Std.
EN 3983
MEP02-035 ABM 1-1006 DGQT 1.1.0.87 TH 5.316/3 Type
KMB-SK2102
SMS 3204 AIMS 03-02-021 D.T.D. 5120 TH 5.316/5 MEP 02-013 Type I
LMA-M7050
TH 5.312 AIR 9048 D.T.D. 5130 WL 3.4364 MM0565
MEP02-014
WL 3.1354 ASN-A 3355 EN 2684 M3188
MEP02-036
BAEM 1103 EN 2687 MM3188
MFM 0017
DAN 422 MM0533 OFWN 4057
MMS 1420
2124 MEP02-020 OFWN 4017 STD 113637
MMS 1439
WL 3.1924 OFWN 4038 TSM 42.03.68
AIMS 03-02-032 M3184
SM 9102 WL 3.4384
AMS 4101 MM3184
SMS 3206
AMS-QQ-A-250/29 OFWN 4029
STD 113644
FMS 3002 OFWN 4037
TSM 42.03.66
FMS 3008 OFWN 4040
TSM 42.03.67
MMS 149 STD 113643
TSM 42.03.71
MEP 02-029 STM 0887
WL 3.4394
TSM 42.03.69
TSM 42.03.70
WL 3.4144
7020
AIR 9048

www.aleris.com 9
 ALUMINUM AEROSPACE SHEET

Wide sheet
Wide coil sheet
Standard coil sheet

Aleris Koblenz supplies sheet and plate In order to supply optimum products and
material for fuselage components, mainly materials for light-weight fuselage construc-
for European, Asian, North American and tions the sheet portfolio comprises the fol­-
South American customers. Traditionally, lowing different product forms:
the aluminum alloys used for these appli­ca­- • standard coil sheet
tions were conventional 2xxx and 7xxx • wide coil sheet up to 2,600 mm
series alloys like 2024, 7075 and 7475 (102’’) width
but also 5xxx and 6xxx series alloys for • wide sheet up to 3,460 mm (136’’) width
welded applications.

As part of the strategic plan to develop cost HIGH QUALITY STANDARDS COMBINED
effective materials with highest quality pro­- WITH UNIQUE STATE-OF-THE-ART
perty performance in extreme dimensions EQUIPMENT MAKE IT POSSIBLE:
for various development projects, investment
programs as well as other activities have • extreme size range
been carried out enabling the plant in Kob­- • excellent surface capabilities (mill finished,
lenz to become one of the most important bare, one side clad, both sides clad,
suppliers of semi-finished aluminum pro­- polished skin quality)
ducts to the aerospace industry and a strong • high formability
partner of the major airframe manufac­tu­- • best chemical milling quality
rers. • MRS-quality

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MAJOR CAPABILITIES

2024 BARE 2219 BARE 6061 BARE ALCLAD 7075

AMS 4035 AMS 4031 AMS 4025 AMS 4048
AMS 4037 AMS 4295 AMS 4026 AMS 4049
AMS-QQ-A-250/4 AMS-QQ-A-250/30 AMS 4027 AMS-QQ-A-250/13
AMS-QQ-A-250/11 AMS-QQ-A-250/25

ALCLAD 2024 ALCLAD 2219

7075 BARE ALCLAD 7475
AIMS 03-04-009 AMS 4096
AIMS 03-04-010 AMS 4044 AIMS 03-04-029
AIMS 03-04-011 AMS 4045 DMS 2234
AIMS 03-04-012 5024 BARE AMS-QQ-A-250/12
AIMS 03-04-013 AMS-QQ-A-250/24
AIMS 03-04-055*
AIMS 03-04-014
AMS 4040
AMS 4041
AMS-QQ-A-250/5

* Qualification complete, customer paperwork pending

Aircraft sheet dimensional capabilities

Wide sheet O/F-Temper T-Temper

Thickness 0.100”– 0.472” 2.5 –12.00 mm 0.100”– 0.472” 2.5 –12.00 mm
Width up to  136” up to   3.460 mm up to  130” up to   3.300 mm
Length up to  500” up to 12.700 mm up to  500” up to 12.700 mm

Standard coil sheet and wide coil sheet O/F-Temper T-Temper

Thickness 0.032”– 0.158” 0.8 – 4.00 mm 0.032”– 0.126” 0.8 – 3.2 mm
Width 36”– 102” 914 – 2.600 mm 36”–  89” 914 – 2.250 mm
Length 39”– 472” 1.000 – 12.000 mm 39”– 472” 1.000 – 12.000 mm

Other dimensions on request

www.aleris.com 11
 PLANT DUFFEL

Billets
Drawn / extruded rods and bars
Small and intermediate profiles

Hard aluminum alloys play a major role in ALERIS DUFFEL IS EQUIPPED WITH THE
complex applications in airplanes and auto­- FOLLOWING INFRASTRUCTURE:
mobiles. Particular emphasis should be
given to the AlEco62Sn alloy, a 100 % lead- • Cast house
free alloy for machining applications. • 50 MN heavy press (indirect)
• 16 MN press (modernization 2010)
Aleris Duffel (Belgium) is specialized in hard • Ebner horizontal solution
alloys in round and flat bar shape for annealing furnace
complex machining and milling applications • Various drawing benches
for products such as steering valves, lan­- • 800-t stretcher
ding gear parts (high-load structural com­po­- • Short-length sawing installation
nents), fuel adaptors and heat exchanger
parts. In addition to its technological competen­ce,
customer proximity and a consistent focus
Using its indirect 50 MN press, the Ebner on customer requirements are strong advan­-
horizontal solution annealing furnace and tages offered by Aleris Duffel, resul­ting in
the 800-t stretcher, Aleris Duffel offers customized products with a consis­tant high
opti­mum production conditions for these degree of verifiable quality – in many cases
tasks. Modern ageing furnaces allow the developed in cooperation with our custo­­-
closest tolerances thereby guaranteeing mer. Aleris complies with these requirements
high-end products. With its extraordinary for its customers worldwide as a reliable
drawing force, the 800-t stretcher helps partner with a high delivery performance.
to minimize residual stresses for all hard
alloys in order to achieve close dimensional
tolerances after machining. These facilities
enable international cus­to­mers to procure
aluminum profiles and bars with outstan­
ding technological pro­perties.

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 QUALITY PRINCIPLES
AND CUSTOMER APPROVALS

QUALITY PRINCIPLES Process control ensures that production ALERIS ALUMINUM DUFFEL BVBA
takes place under controlled conditions. CUSTOMER APPROVALS
The quality principles is an essential ele­- Quality inspections are continuously carried (ALPHABETIC LISTED)
ment of the company policy. Its objectives out in various production facilities. In labo­-
are a continuous im­provement in the ratories with state-of-the-art equipment, • Airbus
quality of the products, the services and to chemical tests ensure the proper composi- • BAE Systems-MAS
fulfill all customer requirements. tion of alloys and their resistance to • Boeing
corrosion. Mechanical tests on strength • Lockheed Martin
The quality principles are formulated by the and fracture toughness, fatigue testing as • Messier Dowty Serck Aviation
company management, implemented and well as metallographic examination on the • Mettis Aerospace
known within the corporation. To ensure structure of the material can also be pro­- • Raytheon Aircraft
these quality principles, a documen­ted vided. • etc.
quality system has been implemented. The
quality system will be continuously updated
and expanded in scope. The demand of the QUALITY PHILOSOPHY ALERIS
quality system are based among other ROLLED PRODUCTS GERMANY GMBH
requirements on the international standard Our quality philosophy ”means zero de- PLANT KOBLENZ
EN 9100. fects”. The quality system takes into CUSTOMER APPROVALS
account the customer’s continuously rising (ALPHABETIC LISTED)
requirements and quality standards such
as EN 9100 and Nadcap. Legislation and • Airbus
regulatory mea­su­res will also factor into • BAE Systems
our quality philosophy. • Boeing
• Bombardier
• Cessna
ENVIRONMENT, HEALTH AND • EADS
SAFETY PRACTICES • Embraer
• Gulfstream
In terms of environment, health and safety • Lockheed Martin
practices, we have ISO 14001 in both • Raytheon Aircraft
European plants and EMAS for the Koblenz • etc.
plant. Aleris wide we have our Safety and
Environment Policy and Principles implemen­-
ted and update this continuously.

www.aleris.com 13
 THE BASIS FOR INNOVATION AND QUALITY

With intensive, permanent, focused research FIELD ENGINEERING SUPPORT

and development work we ensure that
our products and processes are continually In addition to excellent material supply, it is
improved and meet the highest quality one of our strategic goals to provide our
standards. This is how we build on our tech­- customers with comprehensive engineering
nological position in the aerospace industry. support. Aleris field engineer can help
de­velop solutions together with our custo­-
Our investment and consistent focus on mers, using new technologies and proces­
re­search and development is directed ses to meet your requirements and to
at those innovations which meet the needs improve your pro­ducts. They are the tech­-
and goals of our customers. We develop nological link be­tw
­ een the customer needs
tailor-made strategic processes, products and our production capabilities, and we
and applications. And of course we support view this activity as mutually beneficial, joint
our customers’ activities in key market development.
areas. Improvements relating to quality, costs
and the environment always take center Our customer engineering team can pro­vide
stage. To fulfill these requirements our orga­- technical consulting, product and material
nizational structure are continuously refined training, problem solving in the field, pro­vi­-
and adapted to current demands. The same ding direct technical support services based
applies to field engineering support, pro­- on the experience Aleris has gained. Aleris’
duct and process technology (PPT), classic broad metallurgical knowledge allows for
research and development (R&D) and intel­- the rapid transfer of new customer require­-
lectual property. ments or applications into defined alloy pro-
perties and fabrication processes.

14 www.aleris.com
Airbus

PRODUCT AND PROCESS TECHNOLOGY CORE RESEARCH AREAS

The work of product and process tech­- The core research areas for Aleris in the
no­logy is to ensure that Aleris products go aerospace industry include hard alloys like
through a robust and simultaneously effi­- AA7181, reduced-density alloys such as
cient metallurgical mass production pro­cess. AlMgSc and also aluminum-lithium alloys,
which are both light and strong and resis­-
tant to corrosion and fatigue. Aleris can
develop and test all major production and
RESEARCH AND DEVELOPMENT processing stages as pilot processes at the
production scale. Furthermore, all inno­
Aleris has concentrated its research and vation centers use the latest analysis techni­-
development work in three innovation ques, microscopes, x-ray machines, testing
centers, whereby the center at the Koblenz and measurement apparatus, partly in co­-
plant is specifically responsible for R&D operation with external partners. The special
in the aerospace sector. In Aachen there is aerospace equipment in Koblenz includes
another innovation center for more blue- a trial casting machine, which makes it
sky, fundamental and cross-sector research possible to cast industrial-scale ingots for
purposes. The engineers there are respon- test programs. The laboratory area here not
sible for developing new aluminum pro­­ducts only serves to approve production: new
with improved properties under labo­ra­tory testing equipment is continuously added
conditions, which includes experimental for physical and chemical testing to parti­cu­-
trials and theoretical simulations. They also lar customer specifications. This enables
carry out small-scale testing of alloys and research into the materials themselves, their
processes. As well as its good geogra­phic properties and their applications in the
location, Aachen offers close connections aerospace industry to be optimized – from
to the research facilities of RWTH Aachen alloy development, casting, rolling and
University, one of the most res­pec­ted higher processing through to the performance of
education centers in the world. Aleris is the finished product. Aleris can thus pro­-
one of the partners in the AMAP (Advanced vide its customers reliably and comprehen-
Metals and Processes) cluster, working sively with all the information they need
closely with university insti­tutes and other to manufacture an optimal product.
industry partners on pre-compe­ti­tive
advanced solutions.

www.aleris.com 15
Global Headquarters Plant Koblenz
Aleris International, Inc. Aleris Rolled Products Germany GmbH
25825 Science Park Drive Carl-Spaeter-Straße 10
Suite 400 56070 Koblenz · Germany
Cleveland, Ohio 44122 · USA T +49 261 891 7479
T +1 216 910 3400
[email protected] Plant Duffel
Aleris Aluminum Duffel BVBA
European Head office A. Stocletlaan 87
Aleris Switzerland GmbH 2570 Duffel · Belgium
Balz Zimmermann-Straße 7 T +32 15 30 2237
8058 Zürich Airport · Switzerland
T +41 44 828 1400 Plant Zhenjiang
[email protected] Aleris Aluminum (Zhenjiang) Co., Ltd.
No. 1 Cai Jia Road
Asian Head office Jingkou Industrial Park
Aleris (Shanghai) Trading Co., Ltd. Zhenjiang, 212141
Suite 2804, Wheelock Square Jiangsu · China
No.1717 Nanjing Road West T +86 511 8530 7220
Shanghai 200040 · China
T +86 21 2231 8000
[email protected] Picture used by courtesy of Airbus.

www.aleris.com

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