First time right

It wasn’t long before the impacts on supply chains became apparent. OEMs responded to cancellations from airlines by reducing and postponing their aircraft construction plans. This led to forecast demand for new parts and raw materials being revised downward to avoid further exacerbating the financial strain on the supply industry by accumulating excess stockpiles. AMAG had previously established itself as the first port of call for high-quality aviation sheets for specialist applications, including low-stress MRS sheets and single-side clad coils for the GLARE material used in the fuselage of A380s (Figure 1). The economic turmoil presented a significant challenge for the company’s aviation plate activities, which were still very much in their infancy at the time, in part because advanced negotiations with various OEMs regarding framework agreements stalled and broke down.

Despite this, the company convinced the OEMs to stay the course and progress the qualification process so that, once the crisis had passed, AMAG could meet the sharp rise in demand for raw materials. By 2010, less than five years after delivering its first aviation plate, AMAG was successfully qualified for all principal plate specifications for the three leading aircraft manufacturers (Airbus, Boeing and Embraer) - although only for the small dimensions it was capable of producing at the time.Fortunately, it was not long before the aviation industry found its wings again, and a sharp increase in demand for new aircraft soon followed. Thanks primarily to more efficient engines and optimized aerodynamics, these new aircraft had far lower operating costs than their predecessors. In the single-aisle market, for example, Airbus launched the A320neo family, which Boeing swiftly followed with the next evolution of its established 737 series, the 737MAX. In parallel with this, the regional jet market also saw a number of innovations, such as the CSeries from Bombardier (known today as the Airbus A220) and the second generation of the Embraer E-Jet family.

Expanding capacities and capabilities at the integrated site in Ranshofen

In light of these fast-moving developments, it soon became clear that the capacities and production capabilities of the Ranshofen site would soon become a limiting factor on growth. This is why, following AMAG’s IPO in April 2011, the first order of business was approving the AMAG 2014 expansion project. A central element of this project was a new hot rolling mill with a connected plate processing plant, which could accommodate rolling slabs measuring up to 2,300 mm wide and 600 mm thick from a new EMC casting pit. This laid the foundations for future production of aviation plates with thicknesses of up to 152.4 mm (6.00 in), thereby covering a significant proportion of global demand for different plate sizes. AMAG’s new production capabilities were warmly welcomed by customers.Commissioning the new production route in the new plant led to numerous re-qualification procedures for existing approvals as well as new qualification procedures for the increased dimension ranges, new alloys and new specifications. From a technological perspective, particular highlights include the expansion of 7050 plates to maximum thickness and the recently completed development of 7475 plates in accordance with Airbus specifications. The latter product is the main alloy for AMAG components and is therefore particularly significant for the AMAG Group’s aviation product portfolio.

Covering the broadest possible product spectrum in terms of qualifications and dimensions is certainly an advantage when it comes to securing long-term success as a rolling mill in the aviation industry. In order to supplement the portfolio with new products, a second strategic expansion project - AMAG 2020 - was launched a few years later, this time involving a cold rolling mill with a continuous heat-treatment furnace. This decision put the company on course to exploit the market for technologically demanding products integrated in fuselage exteriors. In this context, it is important to note the company’s successful qualification for Airbus fuselage exteriors in widths of up to 2,100 mm in early 2022.AMAG tackles the challenges that arise in the course of material qualification with relish, as these processes enable our customers to access a wider range of premium aviation materials made in Ranshofen. In addition, AMAG conducts ongoing research into potential ways to optimize the characteristics of existing standard alloys. Technical aspects of processes and materials are central considerations in this work. This makes it possible, for example, to optimize materials’ machinability by drawing on the decades of experience AMAG components has as a long-established parts manufacturer. This is a further synergy - in addition to wide-ranging sustainability-related aspects - made possible by the integration of different value-creation steps under the AMAG umbrella.

Sustainability

The aviation industry is feeling the full impact of the drive for sustainability. As a founding member of the Aluminium Stewardship Initiative (ASI), AMAG resolved at an early stage to actively respond to the challenges of ensuring a livable environment for future generations. Thanks to the company’s unique recycling capabilities at its integrated Ranshofen site, its access to low-CO₂ primary metal through its stake in the Alouette smelter in Canada (see “Primary aluminium at AMAG” on page 12) and the material cycle closed by the connections between AMAG rolling, AMAG components and AMAG casting, AMAG has since further consolidated its exemplary role as a leading aluminium producer in terms of sustainability. Additional confirmation comes from the long list of certifications and awards as well as positive customer feedback. This integrated value chain, which is structured with a clear focus on optimizing material use, has numerous benefits. Not only does it help to cut costs and reduce complexity, it also conserves resources, reduces transport volumes and thereby minimizes CO₂ emissions. The combination of a foundry, a rolling mill and a parts supplier represents a unique asset in the industry and makes it possible to close the aluminium cycle. The chips generated during parts production account for a significant proportion of total aluminium scrap. It is only logical, then, for these chips to be returned to the production process to improve the material balance and minimize demand for primary metal and alloying elements.

Industrial excellence and innovation

Responding to customers’ requirements and helping them to contend with ever-changing circumstances is part of the AMAG DNA. After all, long-term success is only possible when all stakeholders work together. This includes providing services that go beyond delivering flawless products and ensuring outstanding delivery reliability. Recent accolades from Airbus are emphatic proof of AMAG’s success in fulfilling this commitment, meeting customers’ needs and adapting to the challenges of an ever-changing landscape. These included the Airbus Accredited Supplier Award for the third year in succession, confirming AMAG’s outstanding performance in terms of quality and on-time delivery over an extended period. AMAG was also the only rolling mill in the Airbus supply chain to receive a special award in the "Innovation" category, recognizing the successful implementation of its Smart Factory for analysis of material samples for the aviation industry.The Smart Factory is capable of producing and analyzing up to 500,000 material samples per year in a fully automated process with the help of artificial intelligence. In addition, AMAG was the only company in the Airbus supply chain to receive a special sustainability award in acknowledgment of its wide-ranging commitment to the issue and the unparalleled transparency and quality of its sustainability reporting.

These awards consolidate AMAG’s position as a leading supplier of high-quality aviation materials and demonstrate its commitment to sustainable innovation.