University Masters really.

Worked with us here you

were.

Bigger and better

things.

Thanks Michael.

So is my mentioned a little bit on I've
done a lot of things in my career.

I like to say I went to school for
physics and woke up five years later with

a degree in music but what really happened
was I would just go the idea of good being

an engineer and at some point one of my
physics professors convinced me that if I

stuck with physics I could pretty much
do any kind of engineering I started off

with an internship at a nuclear power
plant in a structural Department.

And then I went on to grad school where I
joined the surface science department when

I know my Ph D. ended up leaving
after Katrina the wife decided she

didn't want to leave live in New Orleans
anymore so we relocated here and went back

to that structural engineering background
and worked in structural engineering for

a couple years before I came here and
was hired as an electrical engineer but

really kind of morphed into
more of a process engineer and

he'd be able full of Saga free and
all the things that Mikael mentioned and

now my life is kind of
come full circle where e

ended up getting an offer from Novellus
and a surface science department.

So I talk is beer cans to pick up trucks
it's really what everything you never

wanted to know about beer cans and
everything that goes into it so.

It's not working.

OK so just cook over the line I'd probably
get in trouble if I didn't give you

some sort of a corporate over you how many
of you have actually heard of novellas.

Several of you that's good.

Talk a little bit about what our flight
role that women in products because pretty

much when I joined over I knew about
ten foil which I now know do not call

it tinfoil but it's aluminum foil and
I mean it goes through the process of what

we do to go from an ingot to a can and
surfaces which is more my specialty

the issues we have with in challenges
that we have with our surfaces

touch a little bit on aluminum and
automobiles and the F one fifty.

Talk about recycling a little bit in not
just recycling from sustainability and

by mental.

Ave but also the fact that
it actually is necessary for

us to produce enough aluminum for
such a build is the F one fifty and

finally I'll touch on
what was mentioned in my.

My abstract about the call the call C.V.
process which is really what I was

hired to do and develop which I think
is a really cool technology and

I'm hoping that they're going to adopt it
it's still kind of in its infancy he was

a little want to be a little restrained
about how much I shared with you but

the overall process is there and
I hope I hope it's interesting to.

OK so a little bit in both Novellus
we have over eleven thousand.

Employees twenty five
operations in eleven countries.

Last year we did a little over
eleven billion in sales and

three million tons in shipments so.

The network.

So we're not a small company in fact with
the largest flat road aluminum company

in the world fourteen
percent of the market share.

Is next with nine percent we originally
were cans Rolled Products division would

respond off in two thousand and five and
two thousand and seven we were picked up

by him doco which is a mining
metals subsidiary from the India.

Conglomerated.

And just a little bit about our product
line so obviously beverage cans are our

main bread and butter represent a little
over sixty percent of our business.

We sell to all the big players Bowl Rex
and Crown automotive we've been heavily

involved with automotive dating back well
pretty much all the way back to really

starting in the ninety's where Jaguar Audi
and Ford started looking into light

weighting their automobiles with with
aluminum and that's actually the C.V.T.

process I'm going to talk about originally
came from and finally specialty products

so anything we can't group into beverage
cans or automotive gets into specialty so

here we do things such as for
chassis for flat screen T.V.'s.

Covers for
laptops suitcases appliances in stock for

radiators heat exchangers you name it it
just gets lumped into specialty products.

The overall trend for
growth in these areas is pretty small for

a beverage cans and specialty products but

automotive is predicted to grow above
twenty five percent over the next five

years which is which is huge and that's
what I'm talking touch on a little bit

later on the the recycling efforts that
we're going into and the fact that.

All of the products are aluminum companies
the world could not support Forbes

endeavor to build F one fifty and

I might mention this again later one of
the things one of the telltale signs is in

the past thirty years companies invested
started before two thousand and

twelve thirty years before then a company
invested in one dedicated automotive line

just to make out a motive sheet in the
past three years we've invested in five so

it's a huge growth for us and it's a huge
growth for the entire aluminum industry so

a little bit about where I come from the
both Global Research and Technology Center

is was moved to from Kingston Ontario
three years ago and the idea was.

To kind of realign with our customers
Kingston Ontario is extremely difficult to

get to and the weather is horrible so they
figured our headquarters in Atlanta so

we might as well move down there and
set up shop so

we've got a pretty beautiful facility and
I can if you ever want to visit come talk

to me because it's we've got everything
you could think of everything that touches

on our our process development from
lubrication to coatings we've got surface

characterization obviously mechanical
testing is huge corrosion testing

we've also got three pilot lines we've got
a camp line now one thing I want to stress

we don't actually make cans but we make
material that goes into making cans so

we've got a first not a first gale but
a scaled down version of A can

canning line so we can go from step
material to a final can we can fill cans

we can decorate them we've got a lot
of amateur beer makers that but

are trying to get management to let them
can their own beer hasn't happened yet

but it might so
customers will actually come to us and

say hey we've got a new design for a Canon
we've got a new design for a bottle and

we can rent them time on it change or
die set ups and everything it's pretty

versatile and they can run new new tests
and we have all the testing in-house that

they can help them develop new designs for
cans and bottles.

Also one of the neat things they
did about here here is they

they transitioned out a senior
management to the actual aren T.

center so we've got all of our global
directors for for each of our business

groups there we've got a global director
for R. and D. and R C two C.T.O. or

offices are in the house which is really
I think it's great because it brings

a lot of face time with senior management
they actually see what we're doing and

all the research and development where
we're working on and how difficult

it is to actually do failure analysis and
samples that are sent in from customers so

there's not as much of a fight
between hey we need to get this done

they actually have a better
understanding of what it is we do.

So on to the overview of what flat
rolled aluminum products are so.

Plate is thick sheet which is used to
aerospace armor for military it goes

from anywhere from two hundred millimeters
down to about six millimeters and

then in Europe they have something called
Shape which we don't really produce here

and really kind of falls
in between plate and.

And.

Sheet and so sheet is really what we

produce it's are six millimeters
down to two hundred microns further.

There's less than two hundred microns in
about two years ago we divested over for

oil operations in the U.S. and North
America we still retain some in Europe

but as far as North America goes we
pretty much just produce sheet for

automotive can and specialty products.

So how do we go from an end to a can and
back again so

I'm not going to go I'm not
going to talk too much or

anything about smelting because it's
not something we do it's nothing we

OK there's a competitor but
we also by the prime aluminum from them so

what we do is we do a lot of
recycling to get our material.

So the process steps to go from being good
to a can obviously melting in alloying

by casting to make the actual and
get hot rolling cold rolling to get down

to gauge what you want service
quality is something we need to check

the core processing which every everything
we make basically go through some sort of

core of the process and the trick here is
you can bring it you can engineer surface

to do whatever you want you can engineer
to be pretty you can engineer it to be

good to it he's here to you can
engineer to be spot welded easily but

it's has to be called The Call process
meaning we have to do it quickly so

we can go into a lab and do whatever we
want to a surface and make it work but

if it takes minutes or hours to do
it's not going to work for us so

we need to invest in and processing
that we can have a core of the core

literally unrolling a coil and one side
really rolling on the other side and

doing it very quickly and finally after
the processing you get to the beverage and

so one thing and if every.

One knows but can body stock and can and
stock are two different allies so

obviously you can buy the stock
you start with a flat sheet and

it needs to be drawn out to be called
deep draw ironed out need to be malleable

to be able to do this you need to
surface that that that is low friction

it can in stock on the other hand you want
to be slightly brittle because you want

to be able to form it so you need to be
malleable but it needs to be better so

that when you actually pull the tab
it opens the funny story about one of

the customers we developed an all
in one one aluminum alloy can and

we kind of touted it for
a little while we thought it was great but

when the customers got it and they opened
up the can they said it doesn't pop so

that cracking when they open the can
up and everything else was fine all

the properties worked but the fact that
it wasn't it was a little more malleable

when they opened it up in a peeled
instead of crack they didn't like that so

it's a lot of static Soko and
into these things.

So melting in our going so

basically is where we take our scrap
aluminum cans automotive sheet anything

we can find it we're going to melt it down
we do try to keep things separate but

obviously with the woman who can being two
different alloys in order to melt that

down we need to we need to then get the
metallurgy back to where it needs to be so

basically the main components we had are
typically magnesium agony silicon copper.

Magnesium and copper probably two most
common ones for making the material

hard so obviously if you driving a car
down the road you don't want soft on them

you want something that's stiff you can
do he treatments to strengthen it so

that brings you to the processing part of
it so the composition press the processing

the casting obviously scalping which is
just cleaning off the surface homogenizing

which is making sure all those components
are well distributed throughout the entire

material finally rolling in annealing
which is kneeling is the final step for

hardening the material and that all
gives you your microstructure which

really gives you material properties and
many to the properties is really what

the product performance is so
that's what we're.

Going to the customer.

And so the melting process basically
start with a heavy gauge shot and

you start melting it down.

And after you melt it down we take
we basically cast a tiny baby and

it's and we use spark Yes to measure
the different components and

we can add Allen components so we can add
more pure aluminum at this point to dilute

it if we need to finally once the molten
metal was is sitting in the mountain for

nothing for us we can move it into the
casting of the holding furnace and at this

point it might sit there for a little bit
they've got magnetic stairs in there to

make sure it's all mixed together and
that's a rust chance you have for actually

making sure your alloys are correct so
they'll do a final check at that point.

Now what happens you might think it
will OK I've got a can it's got paint

on it obviously we all know the inside
of a can is has some sort of coating

to prevent the acidic drinks that are in
it to from eating through the aluminum So

what happens to all of that well it
burns up so if you've got a sandwich and

you've got cheese all over your tin
foil and a woman in foil I'm sorry and

you throw it into the recycling bin and
what happens that all burns off and

becomes what we called draw so basically
comes the surface and you skim it off.

And it's about one to three percent of
the total metal that we melt down so

what happens with these impurities
will be we call them inclusions

they can cause pinhole So
on the top left here.

Is a cross-section I.C.M.
of Can body stock and you can

see it is actually virtually it's all the
way through the middle of that material so

obviously this is weaken the material
if you pressurized the can

you might end up having a blowout also you
have surface defects in the bottom image

is a cross-section it's a it's a higher
mag and you can see the actual

blister happening on the surface I
mean talk a little bit about surface.

What we call near surface micro structures
that occur and this is all this happens

because of inclusions and also hasn't
happened because of rolling practices.

So how do we get rid of them so
obviously that some of it comes out.

The dress right so you can scrape it
off but you're never going to get

everything out of it so there's a couple
processes we use to remove the rest of

the contaminants from the material so
this is just a typical physical

furthur it's typically
they use poor ceramics and

they literally just put
it in the middle of the.

Refractory vessel and they let
the molten aluminum flow through it

as you could expect you just look at a.

Close up of the filter media you
have larger particles represented

by the logical red lines and as they get
smaller they get further into the material

at this point most of them will get
removed but if you want to go even further

we have a process called inline fluxing
which is kind of neat basically what they

do is they have this Lancet they stick
down into the molten aluminum and

it rotates and as it rotates it it forces
bubbles out of the bottom of it typically

are gone in chlorine gas what this does
that removes hydrogen a lot of the alkali.

Groups that are that are in the well
actually will actually adhere to

the bubble and
be carried to the surface and

at that point you can remove
them I'm not a medal or

just so I stole the slide so
don't ask me too many questions on those.

After you get the everything
melted down we go to casting so

we direct chill casting and basically what
it what it is is exactly what it sounds

like you pull aluminum into into a mold
and you choose the sides of it so

the next slide actually has a pretty good
explanation of it so typically what you

have is a mold so this would be your first
line defense where it's actually going to

start dissipating heat from the side and
cooling the sides of the material and

then after you had a false bottom
on the top on the bottom of it and

that starts to drop down and as you drop
down you've got some some water spraying

on the side of it which is cooling
cooling and aluminum even for this.

So basically what you
have is a video of it.

It's a good start.

So this would be your You're holding for
on this.

And as the mouth aluminum comes
down it hits or it's your mold and

then it's cooled and you've got a sump
of molten and aluminum in the middle but

basically the false
bottom will drop down and

you can build your get as deep as your pit
is we go up to I think the longest and

gets we we cast about
thirty thirty feet ten

meters.

For now we've got this huge and it and
what are we going to do with these and

it's anyone's guess how many cans we
can make out of a single and get.

Anyone.

Close is about first standard in
get which is eight to ten tons

it's about seven hundred
fifty thousand cans.

You say we cast the green gets in that so

you can get well over a million cans
if you need to I think they say and

vice versa I think it's eighteen million
cans go into about a eighteen tonne and

get so when we're recycling
on the other end coming back.

I think this is going to freeze on me.

So now that we've got this being it.

With a video.

In there.

I had a video of it but
we're not going to be able to do that so

typical process route for
Cain and Sheen against Cain and

cheat who came by the sheet which is the
body of the can the bottom part of it they

can then cheat because the top part of it
there's a big difference between can and

cheat and can body she can body sheet
is it is a little thinner and it

can be drawn out right pretty easily can
and cheat there's two things One is it's.

The new material and it's also coded so

this is the only product that they
can that we actually coat and

we sell it coated and they form it
with the coating on it and then they

see it on top of the CAN body so the first
thing they do is we preheat the end it so

the ingots Obviously you think of aluminum
and we're going to read them down

from but a foot and
a half thick down to millimeters thick or

less so we need to heat them up a little
bit so depending on the alloy depending on

the final gauge they heat up between
three hundred five hundred degrees C..

First you go into the hot metal so
the first step is a hot reversing male

which is exactly what it sounds like
you lay down the the end get and

you wrote back and forth and
you just keep rolling it thinner and

thinner like you're rolling up pizza
dough after that it would go to a second

step which is basically a stand they
stand will to stand will one stand

well depending on the plant and
we were down to.

Two it's first gauge after and
depending on how many.

Passes you do so you might actually
rode through the one time one way and

back the other way and all this passing
affects the surface structure so

every single time you're rolling down
this on this aluminum just think about

growing up pizza don't what's going
on you're defining the green So

you've made this nice microstructure
in the within the material itself and

you have all these big aluminum grains and
you have all these inner metallics and

material spread throughout the material
and now you're going to bash all the.

So if the hot no going to
go to the cardinals so

called like it sounds it's just a little
it's a little cooler out of the cold

though you might go to like cold metal
which is basically just a final pass to

make sure that you get your final
gauge exactly where you need to.

After that you go to the fan fishing
line all this rolling a lot of times

it'll work the material a little bit so
you go through a tension level or

at this point you might you might cut it
up in the blanks so you get a nice flat

sheets Obviously if you roll up aluminum
if you unroll it you going to have

some sort of coral set in there so
it's going to be you know curved so

this allows us to actually spread
it out in level it after this and

then she'd go to a slit or so you think of
the top McCain It's about this this wide

Well you don't need too much material for
that so we split it into three inch wide

strips and all this is coated.

And then finally package packaging and
shipping so going back to what I was

talking about with what's going on with
the surface as you were bashing it and

rolling it down is basically the outer
outer skin of the material if you think of

burgers on this side of a beach and over
time they kind of get broken down into

finer and finer grained to become sand
all this similar thing happens here and

in the back microstructure you have these
big nice great grains of aluminum and

as as they go through this process they
start getting broken up and when they get

broken up they they get oxidized because
women of oxidized almost immediately and

next slide I'll show you a little bit but
the other thing this is kind of a neat So

these was basically try to depict
what's happening you're getting this

tearing action at the surface so
you think about these grains in the and

the in the bulk structure getting
torn apart near the surface.

Here's a pretty cool image this
is an actual optical image and

they basically just made a bunch of
square hash marks across the surface and

then they rarely into a into the bite
of a coal mill and you can see.

You know it's a long happens so
I was so wrong and

stretching near the surface is
happening as well but you're getting

pieces that are actually breaking off
I'll talk about that in a minute but

this is another step in the process where
I actually work hardening the material so

when you're actually stretching these
greens and you creating new greens

you're actually changing the middle
of Dickel properties of the material.

And what you end up with on
the surface if you just look quickly

it just looks like a very oriented surface
almost like someone just took a broom and

brushed it across the surface.

Typically we get surface references
range between half a micron up to

several microns.

And.

But not all surfaces are pretty so
what ends up happening during this

process is as I mentioned you start to
break up these big grains into smaller and

finer grains and as they get oxidized
you get mixed in oxidized magnesium

oxides aluminum oxide and
oxides are very brittle so

they tend to crack and when you're going
through these big red bites you actually

get what we call pick up so these if you
look at this image this is the biography

image the green surface would be your
nominal surface where it should be and

these blue surfaces are actually where
material has been ripped up and ripped off

the surface and then put down over here
with a red surface so it gets picked up on

to the these big rolls and then the as
they turn around they come back around and

they put it back down on the surface and
this repetitive process of doing this over

and over again eventually ends up building
up this near surface microstructure So

here you see all these nice big contrast
differences here these are your

bulk microstructure but up here near
the surface you have these fine grains and

so these are those oxide that I was
talking about not only oxide to get mixed

in there but also you're
lubricating this whole process so

you have the surface layer
that's that's contaminated with

all different kinds of oxides
which become more brittle so

they're easily easier to rip out and
also some oils and whatever else.

Might fall into the process because
rolling aluminum isn't exactly

a cleaner in process.

So.

This is just a schematic to try to show
that here you've got your bow cranes and

as you get closer and closer to
the surface your brains get smaller and

smaller and
the picture needs to be bigger.

So what happens with these services
is that they start forming transverse

cracks so we have here sample with
the left hand side is a smooth surface you

know it looks clean it's got some darker
material on it which is just residual

carbon on the right hand side for lack of
better term looks like crap I mean what

we call transverse cracks so this is what
happens when you have that brittle surface

you need depending on your own practices
you can you can create these cracks or

you can you can try to avert them if
you look closely there's a similarity

between these two samples and I just want
to point point out the processing issues

we have and challenges this is exact
same sample as the top of the sample and

in the bottom of the sample So not only do
we have to deal with surface issues from

the core of the coil but
also on the same coil if we.

If the the anger which the material
star enters into the red light

is off by a little bit we can end up with
a really horrible surface on one side and

a good surface on the other side.

Another thing so this is just a higher
mag image of these cracks and

at first glance you might look and

say OK it's a couple cracks What what's
the big deal I mean obviously it's going

to affect the lights a little bit
the lighting a little bit the reflection

it's going to absorb a little differently
but if you do a Fed cross-section of those

what you might find is that you actually
get dealing with nation of the surface so

again this brittle nature of this new
service microstructure can cause you to

have the lamination Now if you're trying
to if you're building a not immobile and

you want it you need to glue it together
you really want to be gluing it to

a surface that has a bunch of
these cracks that are complete.

The deal emanated from the book so this is
one of the issues that we deal with and

we try to fight back with a reading group
because people see production they see

the faster we roll the more production we
have the better you know the more money we

make which is fine but when you
start causing issues like this and

you start causing customers to send
material back it doesn't really matter I

was talking to someone the other day had
this conversation he's a global director

for specialties and he said he had this
issue in Asia where he went to them and

he said you know we need to
change our rolling practices and

they said OK production's up and
he said well that's great but

we need to change our own practices
you need to slow down and

this is why he went back six months
later and they hadn't done anything and

he asked him why he said well we've
doubled production and he said but

your return rate is triple it was in
those exact numbers but basically it was

literally OK we've we've gone from
fifty percent you know making fifty

corners a day to one hundred
calls a day we went from

getting ten returns a day to twenty
returned or sixty returns a day so

you're returning more you might be
doubling your production rate but

you are you getting more returns but
that's not always seen all the see is

the production more we can push through
the mill the more money we can make.

So called the core processing I just
have one slide kind of covering this but

this is I mention the beginning this is
something that we do the every single.

Every single piece of material
that goes through our process

this is kind of where I come into the game
is is developing new technologies and

like I said it's all about speed for us
we can engineer surface to do whatever we

want if we hit with the time we have but
when you're trying to do this in a very

fast paced environment you're talking up
to seven hundred metres per minute on can

lines so you know you might look at and
say well it's not that big of a deal but

when you're talking about putting down
a couple of micron layer thick coating

across a six foot strip
of metal moving at.

Seven hundred meters per minute and
you're doing it without any defects in.

It's pretty impressive.

So basically the call the call processes
can can vary anything from just a simple

degrees where you literally just washing
off any excess lube that might be on there

to edge cleans which you have to clean is
really what actually does an acid that's

on the near surface microstructure and
tries to remove some of that will

brittle material for
further processing this is a cache line

sematic where the cache line Sansar
can be continuous annealing insert and

solution heat treat So
basically you've got your unwind here and

you've got a stitch or so
you've got a second coil behind it and

as this as this code goes through you've
got it accumulators so they grow up and

you can actually stop the line in
the wind keep continuing over here and

you can stitch these two together so
you can have a continuous process and

you never have to stop the line and all.

These accumulators just go up and down.

And so the first step would be go
through your furnace and your quench So

that gives you material properties
the furnace lets you do some Anjan ization

making sure all your
intimate Tallackson your

your alloying components are well
dispersed the quench actually affects how

your strength of material how quickly you
quench then on to chemical treatment where

this is where you do your edge clean your
pretreatment your chemical conversion for

an Asian promotion if you need it
then you go on to living aging and

then you rewind at the end.

So this is just a quick schematic of
a can plant layout basically stuff so

this would be Can bodies instead of
the canons I talked about before

basically start with a full with sheet
you go in and it's a several step process

basically it goes to a cup or where
it almost looks like a bowl first and

then it goes through a couple
more steps to get down to get out

to a regular canned body which you'd
reckon what you'd recognise is a can body

it goes onto its washer the decorator
were to get painted then on to.

Baking oven to cure the pain and
neck or flange or and

then finally the pallets to be filled and
capped.

And so recycling obviously we're
the largest recycler of aluminum

beverage cans in the world as well I think
last year we did eighty eighty million or

something like that.

But anyway.

If you start from the very beginning you
have box like mining aluminum refining

smelting the bank that goes in and casting
sheep production all round back to casting

Can anyone guess how long it takes we
say as a came to cane so if you go

buy a can of the grocery store drink it in
the recycling bin it gets sent back melted

down produced into a can filled back in
the grocery store and the same shelf he

bought from the average lifetime of
cane in this recycling process is.

I would guess you know.

It's sixty days so it's I was
impressed with that I thought that was

a pretty short period of time to
go through that entire process.

So under cars so
we're going to back in and

he forwards time he had about a choice
of a three or four different alloys

Now there are hundreds and if you look
at the history of aluminum in cars it

actually started out with a pretty
significant chunk would being the most.

Important in the early twentieth century
but it would have had a pretty good

chunk of it and
low carbon steel was pretty low but by.

One thousand twelve or so the low carbon
steel really took over in the aluminum

pretty much had no business in it and over
time it's kind of grown a little bit and

as I mentioned with the advent of the.

Deploying of the F one fifty is
an aluminum intensive vehicles

really change the whole future
of the aluminum industry.

So.

Just walkthrough.

Case study for automotive sheet so
it's a very similar process to

can and I'll talk about the recycling
aspect of it a little bit but

we start with a coil under the coil would
go through early electrolytic cleaning so

this would be a process I mentioned before
an asset to cleaning but a lot of times

a lecture using a letter electrolytic
process to speed up the process

then it will go through its pretreatment
application which which may be anything

from an even promotion to a coating
drying oven other finishing probably

options depending on what the customer
wants it can be anything you can lube it

here you can you can pay to hear you can
do all kinds of things goes appreciate

a call that's cut to length so go through
a tension level like I mention for

the Canon saw and cut into flat sheets and
then it goes to lubrication.

After lubrication it will go into storage
until the company wants to form it

they'll form it into whatever part they
want and then go sit in storage again and

then they'll put the editor and.

They'll put some and he's of on it to
bonded together now what's the one step

that I mentioned before this that you
wouldn't think would make much sense if

you're if you're putting glue on it now.

We liberated so we go through all this
trouble of finding these process is

a critical process where we can educate
in a surface and we can you can make it

one of the better we can make it fun to
build and then we have to lube it and

the customers like forward do not want
to clean it all they want to do is buy

the material form it stick it in storage
when they want to build the truck they

just grab it out they have a good on it
glued together and out the door close.

So we have to actually
design systems that.

That work with that so basically what
we have done is not us but we work with

the chemical companies to design a bonding
system that we have our surface which is

pretreated with an Asian promoter then
we put a lubricate a lubricant on it and

then we bonded together we actually
design the lubricants so that it is most.

It will squeeze out but the stuff that
doesn't gets actually absorbed into the he

said so the piece of actually
gets down to your pretreatment So

it's what we call conflicting
surface requirements so

we're constantly trying to determine what
methods will work and how we can work with

chemical companies because a lot of these
processes a lot of these bonding systems

we have to work with we don't come
up with Hey we went to down and

they've got this bonding system that works
great with our material basically for

it comes to us and says this is what
you're going to use to figure it out.

And so after it's bonded together
we still have the spot while

the traditional vehicles obviously
are spot welded together.

Polonium is a little more difficult to
spot weld but at this point it's not cured

so we need to hear that together
somehow and there you can rivet it.

Causes issues too so we develop surfaces
that can be easily spot weld able.

And after it's spot welded
goes into subassembly and

finally into the thermal cure which
which we actually use two fold one

is it's used to cure the the adhesive
that we just put on it and

to this is the final stage of the car and
we've formed a lot of our hard

hardening materials but we haven't
actually cured the materials yet so

we actually cheat and use the thermal cure
for the paint bake in the subassembly bake

to finally cure to make the final
cure of our material and harden it.

So the recycling portion as I
mentioned is a pretty huge.

So one friend finally decided to go with
aluminum like I mentioned the entire room

and she could not provide as much material
as they needed you're talking we had

two or three Don't come any
factors that are making sixty or

seventy thousand cars a year
using aluminum intensive and

friend came along say well we're going
to make seven hundred fifty thousand and

there just wasn't enough for that so what
novellas did what Alcoa did they went and

sat down with Ford and said OK how
are we going to do this we've got to.

Five thousand series in a six
thousand series alleys and

we can't mix those together so we need
you to help us out so what they do is we

sell them a coil it goes to their stamping
department in the form department and all

this crap that gets the forms on the floor
there gets sorted so they serve it into

five thousand series six thousand series
they throw out on the truck and return it

to us and we melt it down and this process
goes twenty four seven constantly so

we're constantly shipping material out
constantly getting material back in and

melting it down in form and
forming new material out of it and so one

amazing thing about aluminum is that it's
one hundred percent recyclable I mean you

never actually lose anything it's you have
issues with impurities in inclusions and

things like that that I mentioned but
as far as the womb itself it's you don't

there's no loss in the recycling
process which is impressive fact.

So one of the so that's the business
side of it why we want to recycle

I mean it's cheaper obviously for
us to do that and

it's the only way we could actually
produce this much material and

the amount of time that we had but
the other thing is on the environment side

the amount of energy needed to recycle
them in them is about five percent of

the material the energy needed to actually
mine it from box so there's a huge mental

reason to go for this I recycle process
to it's completely closed loop so

well they tell us everything we
get back is our material and

everything else gets back is there
material I don't really believe in but.

So that brings me to my pet project
which is flame pyrolysis which is really

just a fancy name for a combustion
chemical vapor deposition process.

I think it's got all the buzz
words it's a disruptive technology

I mean you're talking about going going
into an industry that's been around for

ages they use what chemistry is they're
used to work on mysteries and they

you know they use what chemistry is for
etch cleaning these what chemistry is for

pretreatment And
what we're trying to do is show that

you know by using this flame technology
on a cold the core process we can.

You can avert a lot of that wet chemistry
and cut down on environmental factors as

well as a cost so the way it started
was actually in the ninety's.

And Jaguar they wanted to make aluminum
intensive vehicles and that's fine and

dandy we can treat the material we want
we can glue it together we can ship it

out but what happens when you get into
an accident you can't really go to

out of shop and have the other shop
guy make up a bath with all kinds

of different nasty ingredients in
your hand dip these materials and

pull them out dry them
correctly put the adhesive on.

And.

Fix the car so there was some
interest in using them or for

circuits as as pretreatment for
a heating promotion and what they

ended up it was a group between Alcan
at the time which is now Novellus and

yet a university and basically what
they figured out was they could mix.

T.M.'s and camping guess so I called the
crumble a torch because that's basically

what it is but it's for the canister
that's just got some touching metal silo.

And camping gas and what you do is you
grind of the ground the miller down so

you grind of anything that's any dirt
paint whatever and you take the torch and

you just spread it on apply it he
said include the parts together and

it works extremely well Jaguar has been
using it since the ninety's B.M.W.

uses it and so
then the process came out so

well we can do this in the plant I mean
it's seems to be pretty robust you know

you just had a guy a torch Intel and keep
it a couple inches away from the material

and it seems to work why can't we do
this in a call to call process so

that's kind of where we are now
is we we switched H M D A So

which you know is used here
is a as a promoter and

basically using the same process
we brought a little lab set up and

we can we can test this hypothesis so

the actual process we have are called
the call process we might have one.

A minimum of two one person but
made of two burners for Burns six

burners depending on what kind of film you
put down we can adjust the height we can

adjust all kinds of different parameters
we can put down thick films we can put

down thin films we can put down dense
films we can put down fluffy films.

All about varying our area gas mixture and

literally all it is is a it's like
your gas grill out back it's and

we've got air to get we use
methane natural gas mixture and

inject so vapor into it and as it goes
to the flame it actually combusts and

you can put down amorphous to
look at films in this way.

Pretty much you know what we're looking
for do is we can we can have a incredibly

fast product we can if we need to put down
more material we can always just add more

burners and we're also looking at it for
depositing.

Kind of like a dust.

To increase or
decrease friction I should say

we can know we're also looking at it from
putting if we put down different types of

films how that affects the corrosion
resistance and how that affects or.

Ability and I think that's pretty much
what I have here yes that's that's it

so.

I thought as I talk too fast I tend to.

Look.

We're going into it mainly because
the car companies are interested but

traditionally we haven't now.

Alcoa is really been the main player in

that.

Very.
But I'm aiming for

fifty two hundred nanometers.

Good question.

So characterization of it is interesting.

I use a C.M. to kind of get
a morphological idea of what it looks like

they'll tell me if I have a very
dense film or very fluffy film.

After they are I've been using pretty
extensively because that gives me more of

a chemical make up and it's you can really
change the type of film you're putting

down and how.

You know basically changing the chemistry
of it and how much silk and nothing.

You have and I want to silicon
carbon bonds and always bonds and

everything and
that's how I kind of determine.

What type of film I had and
then uniformity.

I'm putting it down in a pretty small for
size sheet film now and I can check pieces

here or there and it seems to be pretty
consistent but it's something that

we're going to have to develop a better
by the better method of characterizing

it.

Yeah.

Yeah.

Well there's a big push obviously
a lot of the chromate based and.

I think next year the year after a lot of
manufacturers are not allowed to use it so

from our perspective it's actually more
of a one off experiment so the way our

exploratory program works it's very much
like a lean innovation type of mindset so

you kind of go out there and
you just kind of ask a question and

do a couple quick experiments so
in those quick experiments we.

Don And we've done it.

Several times over the past few years and
we've noticed a consistency that we do get

some corrosion part and
how long it lasts and you know how well if

how well it works after it's been sitting
out on the you know in the environment for

a while that's something we're
not sure we need still need to

investigate.

I think from a standpoint of where.

Are you guys are.

The more characterization techniques you
can understand and how to do the better.

I think that's what helped me when I when
I started I was specifically hired for

this project and it immediately got
shelved and then they kind of looked

at me like you don't have to you
are before you've done around them

before you've done I.C.M. before you've
them before you've done so they just.

It was an approach it was in a time when
we were growing so when they moved us from

Kingston to here they they went from about
two hundred people down to twenty four.

And so the growth over the past
three years has been incredible and

it went from twenty four people moving
here to one hundred fifty plus now in

a pretty short period of time and so
within that I ended up running the.

Elemental characterization analysis lab.

Compound analysis lab and Iran that for
a while and then we hired a guy to run it

and I moved over to C.M.
because we were short handed there and so

the ability to just kind of jump from
one thing to another help me a lot and

now I come back and
actually you know was given money and

everything to run this project
now that it's relaunched.

So that I may be.

A little bit of an anomaly but.

I find and I appreciate when new
students come and they they're not only

willing to not only know all these
different characterization techniques but

willing to do it right so and that's my
biggest message is when you join a company

and you know even with a Ph D.
just willing to get there in the lab and

just run these one off experiments if
someone has a question he should be able

to go to a lab real quick run it if
someone's not there to help you just be

able to do it yourself and
that's what helps a lot.

Yes.

Yes so
there was a last recycling side were

where they do all that I mean once the
trucks off in the road and well not yet

because they haven't been
to many accidents yet but

yes they that's the idea is will
will get it back from junkyards and

buy back from them.

Yes yes.

Actually no tell you no telling aerospace
use a lot of seven thousand series and so

that's something we're.

Delving into now but it's not something
we've made in the past so it's Kevin's

question and so I said we're not really
we don't really sell in that sector but

now that Ford is pushing us into that you
know it's basically a stronger alloy.

Now that they're pushing us into it it
think in the future will probably try to

get some of the business.

That have a question of.

Crime crash member in
the frame is still steel but

body panels interior panels
crash panels those are all

aluminum.

Yes We've actually met with
them a little bit to talk about

some potential collaborate.

NS But their approach is
a little different from ours.

You know they have their
nozzles where it's not really

to get a uniform across a four metre.

You know from what I saw what
they were doing wasn't really

the exact application we were looking for.

And they said we're just using a very
simple you know barbecue burner basically

and injecting him via so into it and
we're getting good results with

it.

And it's around the same time that
Al can was developing it with

his When they they were
developing it too and.

Yeah I said to the current bill
a torch and it works it's it's on

the market now and that's what Audi and
B.M.W. Jaguar they all rely on for for

repairing vehicles.

And other questions.