Gas solution for industrial process in series manufacturing - - PowerPoint PPT Presentation

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Gas solution for industrial process in series manufacturing - - PowerPoint PPT Presentation

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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

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1 Air Liquide, world leader in gases for industry, health and the environment

Lyon, 18/10/2012 l Makoto, Tsuboi l Marketing Manager

Japanese Market status of Heat treatment for Automotive & Fabrication

Gas solution for industrial process in series manufacturing

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2 Air Liquide, world leader in gases for industry, health and the environment

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Summary ■ Air Liquide Japan ■ Market Trend and Forecast ■ Automotive Production and Evolution ■ ALJ Action Plan

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3 Air Liquide, world leader in gases for industry, health and the environment

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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 Solutions for new material Solutions on customer site

⬜

It is organized around 3 sub-groups: ■ Surface Science ■ Process Development ■ Organometallic Synthesis

Work in progress on: ✓ DLC (Diamond Like Carbon) coating ✓ Li Batteries

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4 Air Liquide, world leader in gases for industry, health and the environment

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Market Trend 2011-2013 in Japan

+3.0% Demand Expansion for rising countries +3.0% +6.0% +20.0% Industrial Machinery (turbine, compressor, etc) Li-ion battery Machineries +20.0% Create demand on the housing to anticipate a consumption due to tax rise +20.0% +17.0% +5.0% Construction, Maintenance and building dismantling Construction +1.0% Stable Production increased by automotive market +1.0% +1.0% +1.0% Boiler, Pressure Vessels and Tanks Fabricated metal products HT/Laser workshop Metal Fabrication

  • 10.0%

Re-start Boeing 787 project Slowdown in China (Construction machine) Back-order quantity decrease (MHI Kobe stopped shipbuilding operation in 2012)

  • 10%

+20% -15%

  • 5.0%

Land transports Aeronautics Shipbuilding Transport

  • 8.0%

Shift to overseas production Expansion of demand for compact cars and Eco cars

  • 8.0%

+ 8.0%

  • 13%

Motor Vehicles & Cycles Module and Parts for Motor Vehicles Automotive 2013 Growth Topics 2013E 2012E 2011 Contents Segment

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5 Air Liquide, world leader in gases for industry, health and the environment

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2013 Market Forecast (1/2)

■ Motorcycle *

⬜

2012 market growth : - 9.7%

⬜

2013 market trend : - 8.0% ■ Shift to overseas production

* Japan Automobile Manufactures Association ** The Society of Japanese Aerospace Companies *** Battery Association of Japan

Transportation ■ 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

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6 Air Liquide, world leader in gases for industry, health and the environment

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2013 Market Forecast (2/2)

■ Construction machine *

⬜

2012 market growth : + 6.0%

⬜

2013 market trend : + 3.0% ■ Expansion for rising countries

* Japan Construction Equipment Manufactures ** Japan Metal Heat Treatment Association

■ 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
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7 Air Liquide, world leader in gases for industry, health and the environment

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8,399 9,627 7,905 11,576 TOTAL 839 904 641 1,063 Others 603 660 427 854 MITSUBISHI 610 665 684 793 DAIHATSU 950 1,078 908 1,218 SUZUKI 813 910 717 1,079 MAZDA 711 993 841 1,264 HONDA 1,113 1,134 895 1,293 NISSAN 2,760 3,283 2,792 4,012 TOYOTA 2011R 2010R 2009R 2008R

Automotive Production in Japan

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8 Air Liquide, world leader in gases for industry, health and the environment

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Evolution on Automotive Production in Japan

9,626 8,300 9,000 9,400 9,200 9,000 From ： Fuji Keizai, IRC

+ 6 t i m e s

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9 Air Liquide, world leader in gases for industry, health and the environment

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EV ： For short distance. Constraints on the range PHEV ： Evolved HEV and EV FCV ： Long distance and filling time for H2 is short

  • Infrastructure is required

Compatibility for future automotive

From TOYOTA HP

Distance Car Size

EV: Electric Vehicle HEV: Hybrid Electric Vehicle PHEV: Plug in Hybrid Electric Vehicle FCV: Fuel Cell Vehicle

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10 Air Liquide, world leader in gases for industry, health and the environment

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Production unit of Eco-car in Japan

From ： Fuji Keizai, IRC, FCCJ

  • Hybrid Electric Vehicles production is higher
  • Evolution of Hybrid and Electric Vehicles growth are similar
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11 Air Liquide, world leader in gases for industry, health and the environment

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Automotive Gas Market

Ar, CO2 Welding Assembly (Car maker) Cylinder Analysis Emission Control N2 Inert Sensor, Car Electronics Ar, N2 Degassing Others O2, N2, H2 Combustion Glass O2 Combustion Body Raw Materials Ar, CO2 Welding N2, SG Inert Car navigation Information Equipment N2, H2 HT Air Conditioner N2 Tire Ar, CO2 Welding Fuel tank Ar, CO2 Welding Seat He, Ar Inert Airbag Body Component N2, H2 HT Brake, Suspension N2, H2,, HT Transmission Xe Enclose Light Ar, CO2 Welding Muffler N2, H2 HT Piston, Cylinder Engine Gas Application Main Parts Parts (Modules) Fuel Cell Ar, N2 Inert Carbon material O2, N2, H2 Inert FRP O2 Inert Li Battery New Material/Parts H2, N2, O2 Test/ R&D N2, H2 Inert Poly carbonate Gas Application Main Parts Parts (Modules)

For Eco-Cars:

  • Hydrogen gas consumption for FCV

is very large

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12 Air Liquide, world leader in gases for industry, health and the environment

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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 NH3 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 ■ ALNAT-N

  • Launch ALNAT-N (N2+NH3 +N2O) by using H2 sensor for Gas Nitriding

■ ALNAT-HP

  • ALNAT-HP reference (He/CO2 gas quenching) in cooperation with furnace maker and car

manufacturer

  • Chilling system for

salt bath

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13 Air Liquide, world leader in gases for industry, health and the environment

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■ Key Actions

⬜

“Eco-friendly HT process Development ”

  • Conversion from existing generator (Endo Gas, NH3 cracker) to ALNAT(N2 base HT)

➢ To boost N2 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)

ALJ Action plan (2/4)

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From Endo gas to N2-Base for sintering & ALJ HT technology

N2 base atmosphere technology for sintering process

De-wax Pre heat

Heating zone Cooling zone

Wet N2 N2+H2 N2

Gas flow Gas flow

Gas injector

N2+H2 N2+H2

Endo gas atmosphere for sintering process

De wax Pre-heat

Heating zone Cooling zone

Gas flow Gas flow

Endo gas

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 → Non-flame at cooling zone
  • Easy to produce

Gas shield BOX

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Focus on Vacuum carburizing process for car parts

Consumption gas list

Acetylene : Carburizing gas Nitrogen : HP gas quenching under 10 bar He mixture gas : HP gas quenching under 10 bar

Consumption Volume

N2 : 150 km3 / month C2H2 : 3 t / month He mixture : 270 km3 / 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

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

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16 Air Liquide, world leader in gases for industry, health and the environment

QUESTIONS?

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17 Air Liquide, world leader in gases for industry, health and the environment

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■ Key Actions

⬜

Market status

■ HT market needs less distortion for parts ( e.g. Nit riding process, sub-zero process increase） ■ Focus on “CO2 and electric power reduction” due to environment problem/nuclear power plant problem ■ Production of HT process is shifting to other Asian countries ■ Reduction of HT process with expansion electric-battery vehicles

⬜

Heat Treatment Innovation

■ Chilling system for salt bath

− Get successful in trial of chilling system with LIN at HEF

  • Launch chilling system with LIN into salt bath market.

■ ALNAT-N

− Do trial under “Open Air “ innovation(N2+NH3+N2O) ⇒ for reduce NH3 consumption and HT cycle time

  • Do trial under using H2 sensor for Nit riding process (tight up with analyzer

equip dept.)

■ ALNAT-HP

  • Install gas quenching system to Nissan aligning with Parker HT and Daido steel

technology in 2012

⬜

Training

■ Heat Treatment Special Training for young sales reps

Vacuum carburizing training with furnace make

A&F 2012 Action Plan (2)

?

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19 Air Liquide, world leader in gases for industry, health and the environment

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Automotive Value Chain

■ Automotive Gas Market

Ra w Mat eria ls Aut

  • Part

s Ma nuf act urer s Mo dul es Ass em bly Car Ma ker s Mai nte nan ce Sho p Car Use r 400 JPY/Unit 10% 200 JPY/Unit 5% 300 JPY/Unit 8% 3,000 JPY/Unit 77%

➢ Gas value per vehicle and rate.

・Gearbox ・Engine ・Airbag ・Air conditioner ・Car navigation ・Battery… ・Gear ・Shaft ・Tire ・Muffler ・LSI… ・Steel ・Aluminum ・Glass… ・Emission control ・assembly ・R&D… Small ・Sheet metal

■ Gas value per vehicle ： 3,900 JPY/Unit

・Asahi ・NSG ・Daido ・Sanyo Special ・Kobe Steel ・・・ ・Exedy ・Futaba ・TRAD ・Fine Sinter ・Aisin・A・W ・YUTAKA ・Jatco ・・・ ・Denso ・Aisin ・Daicel ・Panasonic ・RENESAS ・・・ ・TOYOTA ・Nissan ・HONDA ・Mitsubishi ・Daihatsu ・・・

※ ALJ user

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20 Air Liquide, world leader in gases for industry, health and the environment

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8,399 9,627 7,905 11,576 TOTAL 839 904 641 1,063 Others 603 660 427 854 MITSUBISHI 610 665 684 793 DAIHATSU 950 1,078 908 1,218 SUZUKI 813 910 717 1,079 MAZDA 711 993 841 1,264 HONDA 1,113 1,134 895 1,293 NISSAN 2,760 3,283 2,792 4,012 TOYOTA 2011R 2010R 2009R 2008R

Back up : Production unit of Automotive

■ Production unit in Japan

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21 Air Liquide, world leader in gases for industry, health and the environment

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Back up : A&F 2012 Market Forecast (1)

■ Heat treatment workshop

(Japan Metal Heat Treatment Association)

⬜

2011 market growth : + 7.6%

⬜

2012 market trend (economic) : +

⬜

2012 market trend (technical) : =

■ From endo / exo gas to N2 base ■ Focus on vacuum furnace

■ Automotive

(Japan Automobile Manufactures Association)

⬜

2011 market growth : - 13.8%

⬜

2012 market trend (economic) : +

■ Recovery from earthquake ■ Expansion of demand for eco-cars ■ Overseas transfer for parts makers

⬜

2012 market trend (technical) : =

■ Motorcycle

(Japan Automobile Manufactures Association)

⬜

2011 market growth : - 9.7%

⬜

2012 market trend (economic) : -

■ Transfer production abroad

⬜

2012 market trend (technical) : =

■ From endo gas to N2 base for HT

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22 Air Liquide, world leader in gases for industry, health and the environment

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Back up : A&F 2012 Market Forecast (2)

■ Construction machine

(Japan Construction Equipment Manufacturers Association)

⬜

2011 market growth : + 24.0%

⬜

2012 market trend (economic) : +

■ Recovery demand in Japan ■ Expansion for Asian countries

⬜

2012 market trend (technical) : =

■ Aircraft

(The Society of Japanese Aerospace Companies)

⬜

2011 market growth : + 2.0%

⬜

2012 market trend (economic) : +

⬜

2012 market trend (technical) : =

■ Shipbuilding

(The Shipbuilders’ Association of Japan)

⬜

2011 market growth : - 10.8%

⬜

2012 market trend (economic) : -

■ Backorder quantity decrease

⬜

2012 market trend (technical) : =

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23 Air Liquide, world leader in gases for industry, health and the environment

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Back up : A&F 2012 Market Forecast (3)

■ General machine

(Japan Machinery Federation)

⬜

2011 market growth : + 5.6%

⬜

2012 market trend (economic) : =

⬜

2012 market trend (technical) : =

■ Metal products

(Japan Machinery Federation)

⬜

2011 market growth : + 1.1%

⬜

2012 market trend (economic) : =

⬜

2012 market trend (technical) : =

■ Li-ion Battery

(Battery Association of Japan)

⬜

2011 market growth : - 3.7%

⬜

2012 market trend (economic) : +

■ Expansion of production for eco-car

⬜

2012 market trend (technical) : =

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24 Air Liquide, world leader in gases for industry, health and the environment

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A&F Sales Result & Estimation (Gas & Service)

■

Segment

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25 Air Liquide, world leader in gases for industry, health and the environment

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A&F Sales Result & Estimation (Gas & Service)

■

Products