Gas solution for industrial process in series manufacturing Japanese Market status of Heat treatment for Automotive & Fabrication Lyon, 18/10/2012 l Makoto, Tsuboi l Marketing Manager 1 Air Liquide, world leader in gases for industry, health and the environment
Summary ■ Air Liquide Japan ■ Market Trend and Forecast ■ Automotive Production and Evolution ■ ALJ Action Plan 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 2 2
Air Liquide Japan (ALJ) ■ Established since 1907 (France, 1902) ■ R&D center (Air Liquide Laboratories, ALL) created in 1986, located in Tsukuba: Group's technologies promotion and technical assistance to ⬜ customers in Japan and Asia Work in progress on: ✓ DLC ( Diamond Like Carbon ) coating ✓ Li Batteries It is organized around 3 sub-groups: ⬜ ■ Surface Science Solutions for new material ■ Process Development Solutions on customer site ■ Organometallic Synthesis 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 3 2
Market Trend 2011-2013 in Japan 2013 Segment Contents 2011 2012E 2013E Topics Growth Motor Vehicles & Cycles Shift to overseas production Automotive - 8.0% Module and Parts for Motor Expansion of demand for Vehicles compact cars and Eco cars - 13% + 8.0% - 8.0% Re-start Boeing 787 project Slowdown in China Land transports (Construction machine) Transport Aeronautics -10.0% Back-order quantity decrease Shipbuilding ( MHI Kobe stopped - 5.0% +20% -15% -10% shipbuilding operation in 2012 ) Boiler, Pressure Vessels Stable and Tanks Metal +1.0% Production increased by Fabrication Fabricated metal products automotive market HT/Laser workshop +1.0% +1.0% +1.0% Industrial Machinery Demand Expansion for rising Machineries (turbine, compressor, etc) +3.0% countries Li-ion battery +20.0% +6.0% +3.0% Create demand on the housing Construction, Maintenance Construction to anticipate a consumption due +20.0% and building dismantling to tax rise +5.0% +17.0% +20.0% 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 4 2
2013 Market Forecast (1/2) Transportation ■ Motorcycle * ⬜ 2012 market growth : - 9.7% 2013 market trend : - 8.0% ⬜ ■ Shift to overseas production ■ Aircraft ** 2012 market growth : + 8.0% ⬜ 2013 market trend : + 2.5% ⬜ ■ Re-start Boeing project (787) ■ Li-ion Battery *** ⬜ 2012 market growth : +30.0% 2013 market trend : +10.0% ⬜ ■ Expansion of eco-car production * Japan Automobile Manufactures Association ** The Society of Japanese Aerospace Companies *** Battery Association of Japan 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 5 2
2013 Market Forecast (2/2) ■ Construction machine * 2012 market growth : + 6.0% ⬜ ⬜ 2013 market trend : + 3.0% ■ Expansion for rising countries ■ Heat treatment workshop ** ⬜ 2012 market growth : + 7.6% 2013 market trend : - 8.0% ⬜ ■ Expansion on exports demand ■ Shift to overseas production • Technical trend for each market stays stable ** Japan Metal Heat Treatment Association * Japan Construction Equipment Manufactures 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 6 2
Automotive Production in Japan 2008R 2009R 2010R 2011R TOYOTA 4,012 2,792 3,283 2,760 NISSAN 1,293 895 1,134 1,113 HONDA 1,264 841 993 711 MAZDA 1,079 717 910 813 SUZUKI 1,218 908 1,078 950 DAIHATSU 793 684 665 610 MITSUBISHI 854 427 660 603 Others 1,063 641 904 839 TOTAL 11,576 7,905 9,627 8,399 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 7 2
Evolution on Automotive Production in Japan 9,626 9,400 9,200 9,000 9,000 8,300 s e m i t 6 + From ： Fuji Keizai, IRC 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 8 2
Compatibility for future automotive From TOYOTA HP Car Size Distance EV ： For short distance. Constraints on the range PHEV ： Evolved HEV and EV FCV ： Long distance and filling time for H 2 is short - Infrastructure is required EV: Electric Vehicle HEV: Hybrid Electric Vehicle PHEV: Plug in Hybrid Electric Vehicle FCV: Fuel Cell Vehicle 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 9 2
Production unit of Eco-car in Japan • Hybrid Electric Vehicles production is higher • Evolution of Hybrid and Electric Vehicles growth are similar From ： Fuji Keizai, IRC, FCCJ 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 10 2
Automotive Gas Market Parts (Modules) Main Parts Application Gas Body Combustion O 2 Raw Materials Glass Combustion O 2 , N 2 , H 2 Others Degassing Ar, N 2 For Eco-Cars: Piston, HT N 2 , H 2 Cylinder Engine Muffler Welding Ar, CO 2 Light Enclose Xe Transmission HT N 2 , H 2,, Parts (Modules) Main Parts Application Gas Brake, Suspension HT N 2 , H 2 Li Battery Inert O 2 Airbag Inert He, Ar FRP Inert O 2 , N 2 , H 2 Seat Welding Ar, CO 2 Body Component New Carbon Fuel tank Welding Ar, CO 2 Material/Parts Inert Ar, N 2 material Tire N 2 Poly HT N 2 , H 2 Inert N 2 , H 2 carbonate Air Conditioner Welding Ar, CO 2 Fuel Cell Test/ R&D H 2 , N 2 , O 2 Sensor, Car Inert N 2 Electronics Information Car • Hydrogen gas consumption for FCV Inert N 2 , SG Equipment navigation is very large Assembly (Car Welding Ar, CO 2 maker) Emission Control Analysis Cylinder 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 11 2
ALJ Action plan (1/4) ■ Key Actions Heat treatment Market status in Japan ⬜ ■ Less distortion on parts manufacturing (focus on Nitriding process, Sub zero, DLC coating) ■ Focus on electric power reduction due to nuclear power plant problem in North Japan ■ Quality and Environment = phase out NH 3 crackers and reduction of LPG use ■ Car parts Production shifting to Overseas (other Asian countries) Heat treatment Innovation ⬜ ■ Chilling system for salt bath process - Succeed in trial of chilling system with LIN - Business model development on chilling system for salt bath → less Distortion and Anti-oxidation Chilling system for salt bath ■ ALNAT-N - Launch ALNAT-N (N 2 +NH 3 +N 2 O) by using H 2 sensor for Gas Nitriding ■ ALNAT-HP - ALNAT-HP reference (He/CO 2 gas quenching) in cooperation with furnace maker and car manufacturer - 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 12 2
ALJ Action plan (2/4) ■ Key Actions “Eco-friendly HT process Development ” ⬜ - Conversion from existing generator (Endo Gas, NH 3 cracker) to ALNAT(N 2 base HT) ➢ To boost N 2 generators ➢ To promote the atmosphere control system & analyzing services for sintering, brazing - Focus on Vacuum HT process “For less distortion of industrial parts in HT process” ⬜ - Low temperature process → less distortion (tendency toward increasing) ➢ Gradually shift from carburizing to Nitriding process and DLC coating for car parts Carburizing (930°C, 4 hours) → Nitriding (560°C, 5 hours) - Alternative chromium plating due to environmental problem (reduce use of hexavalent chromium for Europe exports) “Gas Quenching Process: Ar/He recycling technology” ⬜ - Focus on He and He mixtures, Gas atomized process ⬜ Others ( include Li Batteries) 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 13 2
From Endo gas to N 2 -Base for sintering & ALJ HT technology Endo gas atmosphere for sintering process Endo gas De wax Gas flow Heating zone Cooling zone Gas flow Pre-heat N 2 base atmosphere technology for sintering process N 2 +H 2 Wet N 2 N 2 +H 2 N 2 +H 2 N 2 De-wax Gas flow Heating zone Cooling zone Gas flow Pre heat Gas injector Gas shield BOX ALNAT Advantages Reduction of atmospheres gas volume in the furnace ( ↘ 25% ): ● control & calculate of zoning atmospheres & gas shield (curtain) box ALNAT-Zone Improvement on working environment → N on-flame at cooling zone ● Easy to produce ● 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 14 2
Focus on Vacuum carburizing process for car parts Japan: Regulation limitation on the gas quenching pressure to 10 bar has been and remains a strong hurdle, both in the country itself and overseas production facilities Consumption gas list Acetylene : Carburizing gas Nitrogen : HP gas quenching under 10 bar He mixture gas : HP gas quenching under 10 bar Consumption Volume N 2 : 150 km 3 / month C 2 H 2 : 3 t / month He mixture : 270 km 3 / month ( gas recycling rate 85% ) Our objectives • To provide customers with efficient and competitive gas solutions adapted to the requirements of various Heat treatment process → based on the promotion of our ALNAT Solutions 00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 15 2
QUESTIONS? 16 Air Liquide, world leader in gases for industry, health and the environment
00/00/201 Doc title Air Liquide, world leader in gases for industry, health and the environment 17 2
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