Alcoa 2014 Annual Report Download - page 15

Innovation for the Long Haul
From rolled aluminum sheet products on tanks and flatbeds, to aluminum solutions
for doors, fuel tanks, radiators and wheels, plus industrial fasteners, our commercial
transportation products cover trucks and trailers from top to bottom. Alcoa helps
truck drivers travel lighter so they can carry more payload and use less fuel—
key drivers of the commercial vehicle industry.
We are the global leader in forged aluminum commercial vehicle wheels, and in
2014, we unveiled the world’s lightest heavy-duty truck wheel. Introduced in the
United States, the Ultra ONETM wheel weighs 40 pounds, 47% lighter than a steel
wheel of the same size, helping to save up to 1,450 pounds per rig (based on
conversion from standard steel to wide-based aluminum). Our aluminum wheel
solutions are expected to deliver growth for the long haul, with an estimated
compound annual growth rate for Alcoa wheels sales of 17% from 2010 to 2018.
Alcoa will bring the Ultra ONETM wheel to Europe in the second half of 2015.
Our advanced aluminum solutions also protect loads on railways. Alcoa’s technical
experts in Russia developed a new proprietary aluminum alloy for grain hoppers for
transporting bulk cargo and grain, which need extra protection from harsh weather.
The aluminum hopper can carry an 80-ton load, 12.5% more than a comparable
steel hopper.
Defending with Innovation
Alcoa meets the needs of today’s U.S. armed forces by creating advanced and
affordable solutions that are lighter, faster and stronger. In 2014, Alcoa produced
the world’s largest single-piece closed die forged aluminum hull for combat vehicles
to improve troop protection. Alcoa manufactured the single-piece part, which was
co-designed by Alcoa and the U.S. Army Research Laboratory, to replace today’s
welded and assembled hulls. Based on early modeling and simulation, single-piece
underbody structures could provide two times better protection against blasts—
such as those caused by Improvised Explosive Devices—than traditional hulls,
primarily by eliminating welded seams. Single-piece hulls can also reduce vehicle
weight and assembly time, and, therefore, overall cost.
1. The world’s largest single-piece closed die forged
aluminum hull, such as the one shown here for
combat vehicles, is part of a joint Alcoa-U.S. Army
initiative launched in 2013. Alcoa produced the forging
at its plant in Cleveland, using its 50,000-ton forging
press, the world’s most advanced hydraulic press.
2. Alcoa also rolled out its most durable, easy-to-
maintain commercial truck wheel—the Dura-Bright®
EVO wheel. It stands up stronger against the weather,
road salts, grime and cleaning agents that can
corrode and dull standard commercial truck wheels.
3. To take five pounds out of our lightest
heavy-duty truck wheel, our experts at the
Alcoa Technical Center—the world’s largest
light metals research center—invented a new
alloy, the patented MagnaForce™ alloy. It is
on average 17% stronger than the industry
standard, Alcoa’s 6061 alloy, in similar applications.
4. Steel fasteners made by Alcoa Fastening
Systems in Texas, U.S. and Telford, U.K. secure
the aluminum hopper. Commercial production
is planned for 2015.
4
13