A dynamic venture into a high-flying industry TotAl - FLY

Introduction to TotAl-Fly The following is a brief introduction to a network of companies named TotAl-Fly (fly~aircraft). TotAl-Fly is a sub network of the TotAl-Group (Toten Aluminium). The TotAl-Fly companies have taken on a joint effort in offering complete products and services to the military and civilian aeronautical industry. The presentation covers general information about the network, the companies involved, the services offered and contact information.

The participating companies in ”TotAl-Fly”  Nammo Raufoss AS  Raufoss Technology & Industrial Management AS (RTIM)  Engineering-Support AS  Varmpresse Metall AS  Alutech AS  Totenprodukter AS  Lena Metall AS  Hydro Aluminium Structures Raufoss AS Engineering-Support AS Lena Metall AS

The TotAl-Group  An industrial network based on: – 38 companies which are focusing on forming and machining of aluminium components – 10 large companies, while the rest are smaller companies with less than 50 employees – a total of about 2600 employees – the companies are typical sub suppliers, but do also have some own products. A few examples are:

Geographic location

The TotAl-Group  The TotAl-Group shall be a driving force in further development of the strong mechanical industrial tradition in the region by: – being a catalyst for cooperation between the companies – assisting local companies in entering new markets with own products or taking on sub supplies – being a meeting ground for exchanging experiences and building networks – securing existing and create new industrial companies in the region Examples of cooperation: projects product development manufacturing marketing profiling competence sourcing logistics

Industrial History – The Driving Force  The regional industrial development - – from production of ammunition for handguns to light weight components for the automotive industry – a culture for innovation and technological development stimulated by demanding customers worldwide – restructured from large companies to dedicated business units – a strong and dynamic industry region which has proven its ability to adapt to new market conditions

Industrial History – The Driving Force  A leading industrial site - – the industrial site of Raufoss houses about 40 companies with 3000 employees, of which 1000 engineers – based on metal forming manufacturing industry – industrial interaction – a large number of small spin-off companies are established in the region with own products or as sub suppliers

Demanding Global Customers  A few examples of existing products and sub supplies: – military ammunition, missiles – automotive industry steering coulombs wheel control/suspension arms – offshore industry helicopter landing decks – aerospace industry sub supplies to the Ariane-program – civilian aeronautical industry sub supplies to Airbus

Cooperation results in TotAl - solutions  Cooperation provides flexibility – core competence in several areas – effective use of resources – quick restructuring – a network which covers the whole process from raw material to final product in one geographic region  Solutions at any development stage – from design, prototyping and testing to mass production of any volume

The TotAl-Fly services  plastic forming  casting  machining  joining  surface treatment  heat treatment  design and engineering  prototyping  technical services and support

The focus – Quality management  Some of the companies have management systems that are certified according to: – ISO 9001 – ISO – AQAP 110  Other companies have, or are in the process of adapting, a management system according to ISO 9001

Plastic forming  Capacity: – 5 hydraulic presses: tons – 7 mechanical presses: tons work piece max 1000x1000x1000 mm.  Methods: – forging aluminium and copper alloys – impact extrusion aluminium and copper alloys, steels – profile and sheet forming for instance stretch bending aluminium and copper alloys

Machining  Turning capacity: – 29 lathes, which of 22 CNC machines Max Ø = 700 mm max L= 2000 mm  Milling capacity: – 19 milling machines, of which 15 CNC-machines largest total working area of one machine (WxHxL): 1700x800x800 mm largest W= 1700 mm, H= 1200 mm, L= mm.

Machining (2)  Boring capacity: – 23 machines, of which 20 automates max Ø = 100 mm  Grinding capacity: – 8 machines – face grinding, cylindrical grinding and tool grinding max diameter Ø 350 mm max (WxHxL) 200x400x200 mm  Cutting capacity: – 11 machines, of which 3 automates max length (automat): 500 mm max diameter (automat): Ø250 mm

Joining  Methods: – welding – MIG, TIG, MAG experience with: aluminium alloys, acid-resistant steel, stainless steel and tool steel – friction stir welding joining of 6xxx and 7xxx aluminium alloys flexible fixture with max width of each work piece limited to 300 mm, max L= 6200 mm joining geometries –butt welding –lap weld (plate/profile) –T-solutions – gluing and riveting experience with aluminium alloys

Surface treatment  Anodising – regular anodising of aluminium – chromium acid anodising of aluminium  Chromate coating – aluminium and zinc  Electroplating – zinc plating with subsequent chromate coating – copper plating – bright nickel plating – tin plating – hard and bright chromium coating

Surface treatment (2)  Painting – one and two component systems – powder coating  Phosphating – zinc phosphate as primer for paint or as lubrication layer  Other chemical processes – pickling of steel, copper and aluminium alloys – varnishing of brass – passivation of corrosion resistant steel  Carburisation  Nitriding

Heat treatment  Air circulation furnaces – 13 furnaces – temperature range: 60 – 750°C – largest chamber (WxHxL): 580 x 600 x 850 mm  Furnaces with controlled atmosphere – 6 furnaces – schielding gas and endo-gas with carbon censor – max. temperature: 1050°C – largest chamber (WxHxL): 580 x 600 x 850 mm  Vacuum furnaces – 2 furnaces – temperature range: 500 – 1300°C – gas: nitrogen and argon

Design and Engineering  The companies in TotAl-Fly have highly qualified and dedicated engineers. Their main tasks are: – design (CAD) – computational engineering – manufacturing technology – metallurgical aspects

Support and Testing services  Environmental testing – vibration – impact – temperature: 80 to 180°C – moist, salt – high pressure: up to 3000 bar (Proof, burst, cycle)  Metrologi – 4 CMM’s 1 Brown & Sharp Global –Size 900x150x800,PC-Dmis software, Accuracy: ISO

Support and Testing services (2)  Materials laboratory – mechanical testing (tensile, compression and impact testing) – hardness testing – metallography (mechanical and chemical preparation, optical and electron microscopy)

Support and Testing services (3)  Surface characterisation – layer thickness – testing of sub processed test of anodised aluminium – sticking tests – impact tests – salt spray corrosion tests  NDT-laboratory – radiography – magnaflux – penetrant – ultrasonic – eddy current

Other Services  Assembly – development and construction of equipment for assembly and mounting  Hire-out of trained personnel – hire-out of skilled branch personnel on all levels – from skilled labour to doctorates in all the previously defined fields

Extended network  Casting – sand cast aluminium – weights from 0,5 to 400 kg  Extrusion – the second largest European aluminium extrusion group  Network – NCE Raufoss (Norwegian Centres of Expertise) – SINTEF (The largest independent research organisation in Scandinavia ~1700 employees) – regional and national innovations centres

Summary: TotAl-Fly  A subnetwork of the TotAl-Group.  Complementary competence through ettective cooperation.  Highly flexible services, both in terms of competence and product development stages.  A part of the light metal cluster located around Raufoss in Norway. An industrial site with an international reputation for innovation and technology development.

Contact information  Contact person: Tor Holdø General Manager TotAl-gruppen P.O.Box 163 NO-2831 RAUFOSS, Norway Telephone: