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New Breakthrough Technologies Lower Cost, Weight and Production Risk of New Airplanes

June 9, 2011

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

Agenda

Introductions

Kevin Lowery

Alcoa Aerospace Portfolio – pgs 3-7

Eric Roegner, President Alcoa Forgings and Extrusions

New Technologies Provide Step-Change Improvements – pgs 8-14

Mick Wallis, President North American Rolled Products

Market Research Study -- The More You Know, The More Favorable Aluminum Is -- pgs 15-19

Eric Roegner, President Alcoa Forgings and Extrusions

Questions and Answers

Alcoa Aerospace is Comprised of 4 Units Totaling $2.9B in Sales

2010 Aero Revenues = $2.9B

4 Units Totaling $2.9B in Sales 2010 Aero Revenues = $2.9B Alcoa Power and Propulsion (aka

Alcoa Power and Propulsion

(aka Alcoa “Howmet”)

$1,024m 36% $868m $596m 30% 21% $376m 13%
$1,024m
36%
$868m
$596m
30%
21%
$376m
13%
$1,024m 36% $868m $596m 30% 21% $376m 13% Forgings & Extrusions Alcoa Fastening Systems Global

Forgings & Extrusions

Alcoa Fastening Systems

36% $868m $596m 30% 21% $376m 13% Forgings & Extrusions Alcoa Fastening Systems Global Rolled Products

Global

Rolled

Products

36% $868m $596m 30% 21% $376m 13% Forgings & Extrusions Alcoa Fastening Systems Global Rolled Products

Industry leading products and integrated solutions

Investment Large Press Large Press Rolling Fasteners Castings Extrusions Al Forgings Product Breadth
Investment
Large Press
Large Press
Rolling
Fasteners
Castings
Extrusions
Al Forgings
Product
Breadth

Global

Aerospace

Market

Position

#1

#1

#1

#1

#1

Breadth Global Aerospace Market Position #1 #1 #1 #1 #1 Global Footprint Aerostructures Fastening Systems 
Breadth Global Aerospace Market Position #1 #1 #1 #1 #1 Global Footprint Aerostructures Fastening Systems 

Global

Footprint

Aerostructures

Position #1 #1 #1 #1 #1 Global Footprint Aerostructures Fastening Systems  Understanding: Beyond

Fastening

Systems

Understanding: Beyond “materials” – we understand how materials together with structural and design innovations, can work in concert to provide optimal solutions

Global Footprint: We are where you need us to be – globally positioned to support global customer We are where you need us to be – globally positioned to support global customer growth

Proven Track Record: A long history working with aerospace customers to help new aircraft meet demanding new : A long history working with aerospace customers to help new aircraft meet demanding new missions

Fuselage: higher damage tolerance and corrosion resistance

Wings: enhanced fatigue life, higher strength and/or higher damage tolerance

Structures: enhanced stiffness, density, strength and /or corrosion resistance available

Advanced Fasteners: for metallic and CFRP structures

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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Alcoa’s content runs from nose to tail and from wing-tip to wing-tip

Fuselage Stringers

to tail and from wing-tip to wing-tip Fuselage Stringers Vertical Stabilizer Fasteners Wing Ribs (Plate) Hydraulic

Vertical

Stabilizer

Fasteners

Wing Ribs (Plate) Hydraulic Vessels Fuel Connectors Fuselage Skins Seat Tracks Floor Beams
Wing Ribs (Plate)
Hydraulic Vessels
Fuel Connectors
Fuselage Skins
Seat Tracks
Floor Beams
Fuel Connectors Fuselage Skins Seat Tracks Floor Beams Wing Gear Rib & Support Fittings Skins Lower
Fuel Connectors Fuselage Skins Seat Tracks Floor Beams Wing Gear Rib & Support Fittings Skins Lower

Wing Gear

Rib &

Support

Fittings

Skins
Skins

Lower Wing Skins

Wing Spars

(Plate)

Upper Wing

Skins Lower Wing Skins Wing Spars (Plate) Upper Wing Wing Flap Fasteners 95% of Alloys From
Skins Lower Wing Skins Wing Spars (Plate) Upper Wing Wing Flap Fasteners 95% of Alloys From

Wing Flap

Fasteners

95% of Alloys From Alcoa
95% of
Alloys From
Alcoa
Wing Box Fasteners Engine Pylon
Wing Box
Fasteners
Engine Pylon

Fasteners

Wing Spars

(Forgings)

Engine Pylon Support Structure

Turbine Engine

Airfoils

Fuselage to Wing Connection

Engine Pylon Support Structure Turbine Engine Airfoils Fuselage to Wing Connection Bay Landing & Support Forgings

Bay Landing & Support Forgings

An aerospace industry tradition: every new aircraft program includes new aluminum product innovations

Boeing 747-8

includes new aluminum product innovations Boeing 747-8 • Innovations include the application of advanced

Innovations include the application of advanced metallic material technology from the 777 family to the 747 platform.

A new generation of large twin aisles entering service in 2011 – extending the 747 well past 2020

• A new generation of large twin aisles entering service in 2011 – extending the 747
• A new generation of large twin aisles entering service in 2011 – extending the 747

Boeing 787

in 2011 – extending the 747 well past 2020 Boeing 787 • First Aluminum Lithium Large

First Aluminum Lithium Large Commercial Aircraft plate application

Alcoa’s newest plate product selected for multiple applications.

Aluminum continues to be a focus of Boeing teams targeting challenging weight goals

Airbus A380

Boeing teams targeting challenging weight goals Airbus A380 • New sheet & plate product inventions. •

New sheet & plate product inventions.

Aluminum lithium extruded floor structure.

World’s largest fuselage panels and largest wing skins.

Each A380 consumes 7X metal required by a single aisle Increasing build rate in 2011

Airbus

A350XWB
A350XWB

Aluminum lithium extruded floor structure as proven on A380

EIS 2015 Build rates forecasted to exceed 10 aircraft per month by 2016

• EIS 2015 • Build rates forecasted to exceed 10 aircraft per month by 2016
• EIS 2015 • Build rates forecasted to exceed 10 aircraft per month by 2016

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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Aluminum continues to be the material of choice when missions and performance are matched

Premature judgments about aluminum obsolescence?

are matched Premature judgments about aluminum obsolescence? Bombardier CSeries: Aluminum intensive airframe The

Bombardier CSeries: Aluminum intensive airframe Aluminum intensive airframe

The Mitsubishi Regional Jet:Bombardier CSeries: Aluminum intensive airframe  Initial Design: Composite wings  Sept 2009

Initial Design: Composite wings

Sept 2009 Redesign: Aluminum wings

AVIC ARJ-21: Aluminum intensive airframe Aluminum intensive airframe

Aluminum wings AVIC ARJ-21: Aluminum intensive airframe Gerson Lehrman Group Inc. concludes that new

Gerson Lehrman Group Inc. concludes that new aluminum-lithium alloys will be “the material of choice over composites” for narrow-body airliners, citing aluminum’s damage tolerance, manufacturability and recyclability”.

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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Our Value Proposition Our solutions span all four life-cycle phases

“The Performance You Need … With Lower Risk … for Today & Tomorrow”

When You Build It • Lower Manufacturing and Assembly Costs • Reduced Program Risk
When You Build It
• Lower Manufacturing
and Assembly Costs
• Reduced Program Risk
When It’s Time for Retirement • Recyclable
When It’s Time for
Retirement
• Recyclable
Risk When It’s Time for Retirement • Recyclable When Your Customers Fly It • Lightweight •
Risk When It’s Time for Retirement • Recyclable When Your Customers Fly It • Lightweight •
When Your Customers Fly It • Lightweight • Aerodynamic
When Your
Customers Fly It
• Lightweight
• Aerodynamic
Your Customers Fly It • Lightweight • Aerodynamic As They Maintain It • Corrosion Resistant •
As They Maintain It • Corrosion Resistant • Meet Emerging Inspection Interval Requirements
As They Maintain It
• Corrosion Resistant
• Meet Emerging Inspection
Interval Requirements

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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Performance

Our new technologies provide step-change improvements since the B787 design

10%-20% Lighter Structures Cabin Comfort Extended Inspection/MRO
10%-20% Lighter
Structures
Cabin Comfort
Extended
Inspection/MRO

Via New AL-Li Alloys in Combination with Advanced Structural Concepts & Other Supporting Technologies

Baseline (e.g., 777 or 737-NG) Conventional Metallic Structures 5%-10% Lighter Structures + Improved Corrosion
Baseline (e.g., 777 or 737-NG)
Baseline (e.g., 777
or 737-NG)

Conventional Metallic Structures

5%-10% Lighter Structures + Improved Corrosion Performance
5%-10% Lighter
Structures
+
Improved
Corrosion
Performance

Via New AL-Li Alloys

+

+

Conventional Metallic Structures 5%-10% Lighter Structures + Improved Corrosion Performance Via New AL-Li Alloys + +
Corrosion Performance Via New AL-Li Alloys + + Time 787 Design Freeze Ready Now Supports EIS
Corrosion Performance Via New AL-Li Alloys + + Time 787 Design Freeze Ready Now Supports EIS
Corrosion Performance Via New AL-Li Alloys + + Time 787 Design Freeze Ready Now Supports EIS

Time

787 Design Freeze

Ready Now

Supports EIS 2015 & Beyond

Material selection for the 787: right decision at the right time. BUT times have changed and a lot has happened between then and now.

Alcoa has developed completely new alloys that allow for:

- Up to 10% lighter than composite-intensive planes - Lower risk and 30% less expensive to manufacture, operate and repair than composite-intensive planes - Provide passenger comfort features that are equivalent to composite-intensive planes (such as large windows, higher humidity and higher cabin pressure)

Optimized Fuselage Structure options - using validated technologies - offer more than just advanced materials

Adv. Fuselage Concept
Adv. Fuselage Concept
Adv. Fuselage Concept Reinforced Laser Welded Panels Reinforced Frames or Stringers

Reinforced Laser Welded Panels

Adv. Fuselage Concept Reinforced Laser Welded Panels Reinforced Frames or Stringers

Reinforced Frames or Stringers

Selective Reinforcement:

What Is It? Can use bonded fiber-metal laminates instead of Al or Ti straps



What Do They Do? They save weight by allowing much thinner skins to meet damage tolerance goals



Used Elsewhere? Yes – already applied on A400M center fuselage frames



Readiness Level? Component level validation through Alcoa stiffened panel tests for fuselage and wing

Maturation Timeline 2011 2012 2013 2014 Manufacturing of Curved Fuselage Test Panel Curved Fuselage Panel
Maturation Timeline
2011
2012
2013
2014
Manufacturing of Curved
Fuselage Test Panel
Curved Fuselage
Panel or Barrel Test
Development of
Design Allowables
Inspection and Repair
Demonstration

Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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The combination of Alcoa solutions & new engines delivers new short range aircraft that meets or exceeds targets

Higher Aspect Ratio Wing Corrosion Resistant Advanced Alloys, Al-Li Tailored Products & Forms • Enabled
Higher Aspect Ratio
Wing
Corrosion Resistant
Advanced Alloys, Al-Li
Tailored Products &
Forms
• Enabled by Al-Li and
Advance Structural
Concepts
Alloys &
Product Forms
• Low Buy-to-Fly
Solutions
• 3% - 7% Lower Density
Improvements for a New
Single Aisle / Short Range
Aircraft (EIS >2020)
• Aerodynamic efficiency
improvements
• Significantly Improved
Corrosion Resistance
• Low Residual Stress
Products
22% – 27% more fuel
efficient (Assumes 15%
efficiency improvement from new
engines)
6% - 10% lower empty
weight
100% increase in structural
and corrosion inspection
intervals
Increased passenger
comfort
Larger windows
Advanced Structural Concepts
(Damage Tolerance Improvement of
Critical Areas)
Cabin pressure (to 6,000 ft. alt)
• Up to 10x Improved Damage
Tolerance Performance
More reliable design,
modeling and certification
processes
• Reduced inspection burden through
SHM
• Enables Increased Cabin
Pressurization

Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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Alcoa: the Al Li pioneer now rolls out a third generation of new corrosion resistant alloys for longer inspection intervals*

Exfoliation Corrosion: 3rd Gen Al-Li alloys are highly resistant to exfoliation corrosion

Al-Li alloys are highly resistant to exfoliation corrosion 7150-T6511 specimens fastened and coated -- severe

7150-T6511 specimens fastened and coated -- severe exfoliation propagated from coating defects after moderate seacoast exposure

from coating defects after moderate seacoast exposure Al-Li 2099-type specimens with no coating -- No

Al-Li 2099-type specimens with no coating -- No exfoliation occurred after prolonged seacoast exposure

Stress Corrosion: 3rd Gen Al-Li alloys have doubled their resistance to stress corrosion

ST SCC Threshold Stress, KSI
ST SCC Threshold Stress,
KSI

Conventional Aerospace Alloys (No Lithium)

3rd

Generation

AL-Li

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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In large scale testing our solutions validated substantially extended fatigue inspection intervals

The combination of these products and technologies …

Advanced Al-Li Alloys

•

Advanced Structural Concepts (Selective Reinforcement)

… have demonstrated these test results …

… in large panel tests… Example: Fuselage Crown Panel Constant Amplitude 3X Life at 20%
… in large panel tests…
Example: Fuselage Crown Panel Constant Amplitude
3X Life at
20% Lower
Weight
… that deliver such benefits as:
… that deliver such benefits as:

Doubled inspection intervals consistent with 12- year heavy-check cycles

>20% weight savings in damage tolerance-driven areas

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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Lets not forget some very important additional advantages of metallic designs (safety, weight, cost)

Metallic aircraft have intrinsic multi-functionality (including electromagnetic field and current return properties)

Eliminates the need for a metallic current return system “work around” (copper mesh, bus bar, etc)



Eliminates need for an estimated ~1,000 kgs for a twin aisle aircraft

need for an estimated ~1,000 kgs for a twin aisle aircraft “Alcoa Proprietary Information - These

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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We are confident our value proposition can be relevant across the industry

Our Confidence is buttressed from two sources:

We are receiving positive acceptance of our Value Proposition from other OEMs who have been wrestling with similar material choices

We have conducted a sizeable, market acceptance research study of our own that included many of your own customers and other members of the broader A&D community

research study of our own that included many of your own customers and other members of

Delivering on our solutions shifts the industry towards favoring metallic structures

“As of today, what’s your overall perception of aluminum and composites as a primary structural material for new aircraft?

More than two-thirds (68%) of industry wide professionals rated aluminum highly as a choice for primary structure applications.

•

In that same survey, aluminum outscored composites by almost 10% in favorability for primary structure

“How likely would you recommend Alcoa's "next gen" technology as the primary structural material on future aircraft if it can deliver:

Up to 10% lighter than composite-intensive planes Lower risk and 30% less expensive to manufacture, operate and repair than composite-intensive planes Able to provide passenger comfort features that are equivalent to composite-intensive planes (such as large windows, higher humidity and higher cabin pressure)

that are equivalent to composite-intensive planes (such as large windows, higher humidity and higher cabin pressure)

Designers and Technologists favored metals the most - The more you know – the more favorable metals looks to you

Favorable (4-5) Neutral (3) Unfavorable (1-2)
Favorable
(4-5)
Neutral
(3)
Unfavorable
(1-2)

Q1. As of today, what’s your overall perception of aluminum as a primary structural material for new aircraft?

Q2. and, what’s your overall perception of composites as the primary structural material for new aircraft?

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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The new scorecard: That was then…. THIS IS NOW

 

Advanced

 

Attribute

Metallics

CFRP

Weight

Weight  
 

MRO – Inspection

Draw

Draw

MRO – Repairability

MRO – Repairability  
 

Recurring Cost / Supply Chain

Recurring Cost / Supply Chain  
 

Non-Recurring Cost

Non-Recurring Cost  
 

Cabin Comfort

Draw

Draw

Sustainability

Sustainability  
 

Part Count

 
Part Count  

Customer Perception

Draw

Draw

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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Summary

The Material Selection for the 787: Right Decision at the Right Time.

The Material Selection for the 787: Right Decision at the Right Time.

BUT Times have Changed and a Lot has Happened Between Then and Now.

BUT Times have Changed and a Lot has Happened Between Then and Now.

Completely New Alcoa Aluminum Lithium Alloys Allow For:

Completely New Alcoa Aluminum Lithium Alloys Allow For:

- Up to 10% lighter than composite-intensive planes

- Lower risk and 30% less expensive to manufacture, operate and repair than composite-intensive planes

- Provide passenger comfort features that are equivalent to composite-intensive planes (such as large windows, higher humidity and higher cabin pressure)

Not Just Us – Industry Surveys Show The More You Know, The More Favorable Aluminum

Not Just Us – Industry Surveys Show The More You Know, The More Favorable Aluminum Is.

and higher cabin pressure) Not Just Us – Industry Surveys Show The More You Know, The

Thank You

Thank You “Alcoa Proprietary Information - These commodities and technology are exported from the United States

“Alcoa Proprietary Information - These commodities and technology are exported from the United States in accordance with Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Any reproduction or distribution of the contents of this presentation in whole or in part is prohibited unless authorized in writing by Alcoa.

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