Alcoa Claims Stunning Advance in Aluminum

Alcoa Inc. describes its new Micromill process as a dramatic breakthrough in aluminum production and performance.

Alcoa claims the new technique slashes production time by 99.9%, reduces energy usage by 50% and shrinks the floorspace required for production by 75%.

The process results in metal that is 30% stronger and 40% more formable than current aluminum sheet, according to the company. It says Micromill output is a single automotive grade that meets the industry's surface quality standards and can be used in virtually all body and structural applications currently employing aluminum.

Alcoa touts the new aluminum alloy as 30% lighter and twice as formable as today's high-strength steel. It also says the material is compatible with the patented aluminum welding process now being implemented by General Motors Co.

The Micromill process takes 20 minutes to turn molten aluminum into coil metal compared with 20 days for current production techniques, according to Alcoa. it says the system also is flexible enough to shift output from automotive to industrial to packaging products at the push of a button.

Alcoa has been testing the Micromill process at a pilot facility in San Antonio, Tex., with the help of an unidentified strategic development customer. The company says customer trials have verified the material's performance and surface quality for exterior panels. Now the material is being qualified for use in next-generation production vehicles.