P U R E A L F A R O M E O. Without heart we would be mere machines

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1 P U R E A L F A R O M E O Without heart we would be mere machines

2 straight to the heart of Alfa Romeo values

3 Accessible Dream F1 technology available

4 Pure and sensuous Design Engineered around Drivers Most sporty Bodystyle Uncompromising Handling High performance Agility Accessible Dream World-class Technology

5 Pure and sensuous Design Engineered around Drivers Most sporty Bodystyle Designed to be coupè and its evolution with the same dynamic characteristics Uncompromising Handling High performance Agility Accessible Dream World-class Technology

6 Most sporty body style Styling definition Vehicle Technical Dimensions Ergonomics

7 Styling definition

8 Styling definition

9 Styling definition

10 Styling definition

11 Vehicle Technical Dimensions

12 Ergonomics H5 H30-1 H61-1 L53-1 H5 A.R. 4C Coupé

13 Design Engineered around Pure and sensuous Style freedom with minimum bodywork shaping constraints, maximum reduction of parts and aerodynamic effectiveness Drivers Most sporty Bodystyle Uncompromising Handling High performance Agility Accessible Dream World-class Technology

14 Pure and sensuous design Styling definition and enabling technologies vs. aerodynamics Aerodynamics results

15 Best aerodynamics enabled by style development

16 Best aerodynamics enabled by style development

17 Under-cover development Flat underbody and covers to promote great downforce Rear diffuser Front under-covers Frontal louvers Tunnel cover

18 Innovative technology application: aluminum warm forming Al 6016 th.1.5mm Aluminum warm forming: to achieve specific and complex geometry, reduce the springback and guarantee weight saving

19 Aerodynamics results The lowest drag resistance (Cd=0,340) for vehicles with negative lift (down force Cz<0) Cx Cz Alfa 4C Comp1 Comp2 Comp3

20 Pure and sensuous Design Engineered around Drivers Accessible Dream Most sporty Bodystyle Uncompromising Handling The best mass distribution of a mid-engined layout with rear wheel drive traction World-class High performance Technology Agility Minimum weight and highest weight to power ratio, thanks to carbon fiber monocoque and light alloys extensive application

21 High performance agility & uncompromising handling Weight to power target definition Vehicle Performance Body in White development

22 WEIGTH TO POWER RATIO [Kg/CV] Position Vs Competitors Alfa Romeo 4C HIGH PERFORMANCES ACCESSIBLE PRICE LIST PRICE [k ]

23 Targets Setting BONDARY CONDITION Engine Power 240 CV WEIGHT-POWER RATIO < 4 Kg/CV ACCELERATION km/h < 5 MAX LATERAL ACCELERATION 1,1 g TOP SPEED > 250 km/h HIGH STIFFNESS AT THE SUSPENSION CONNECTIONS TOTAL WEIGHT <900 Kg CENTER OF GRAVITY OF CHASSIS LOWERED

24 Vehicle weight achievement Weight 895 kg Front axle weight 38% Rear axle weight 62%

25 Product Planning Project Alfa Romeo 4C 24 months Technical and Technological Development Tooling VP & PS Series Digital Phase h/cpu Simulation & Component Testing: Safety (incl. restraints system) Dynamics NVH Durability Aerodynamics Corrosion protection Construction feasibility Materials optimization Etc. Digital simulation to evaluate ergonomic requirements and accessibility constrains; Tooling development according with Pre-VP phase; Tooling review according with Product development. Reduced VPs & PSs vehicles Parts made of series production tools

26 Carbon Fiber Monocoque: main targets Light weight Structural efficiency

27 CFRP Monocoque: Material & technology selection Drivers: Light weight Structural efficiency Targeted production volume Autoclave-hand lay up technology: Very stringent weight and structural requirements reached Economical targets of the non recurring investment costs achieved Compression of the total program lead time Very challenging and successful extensive carbon look surfaces Adler Group

28 Aluminum frames : main targets Light weight Structural efficiency High energy absorption

29 Aluminum frames: design solutions and adopted technologies Front Frame Rear Frame Functions : Crash management Engine support Sospension support Requirements: Weight Low investments High modularity High performance Multi-technologies: Extrusion process Stretch bending process Die casting process CMT welding process Weight - 30 % Invest. Cost %

30 Hybrid windshield structure: targets and design solution Windshield structure was design through adoption of low investment technologies and mix material with the objective to: Minimize the cost and weight Maximize the performances (right material at the right place) WAGON COMPONENTS Al (6082 T6) Upper weight reduction vs. dynamic stiffness improvement Aesthetic SMC perimeter HSS (DP600) Design features: Structural stiffness node Assembling through stainless steel screws (after e-coat) SMC panel is made of 4 parts, glued to the structure No Internal inner panel (A pillar trim attached direct to structure first worldwide application)

31 Multifunctional Roll bar: targets and design solution Structure obtained by welding aluminum sheets and extrusions in order to guarantee: Minimum weight High structural strength (minimizing intrusions in roof test std. 216) Minimize cost through technologies selections and function integration (seat belt anchorage integration) Collapsible solution vs. head impact High strength for seat belt anchorage Alfa Romeo patented solution WAGON COMPONENTS

32 Exterior panels: main targets Light weight Styling requirements vs. cost issue (simplification)

33 Exterior panels: main technological features LOW DENSITY SMC USED FOR AR 4C BODY PANELS: CHARACTERISTICS >UP-(GF+MD)70< Lower density (1.45 g/cm³) than Standard SMC Low Profile (1.8 g/cm³) Very good surface/part quality Good mechanical properties: No corrosion problems Low shrinkage (-0.06%) and CLTE: dimensional stability, low warpage or distortions, Short tooling construction time Short production cycle time Possibility for variable thickness and integration of functions (inserts, ribs) Suitable for structural bonding reducing the number of mechanical fixations COMPETITIVENESS OF SMC SOLUTION Total Production Costs (1) (in $ per vehicle) SMC Composites are price competitive vs. Aluminum alloy for small/medium series of Class A Body Panel applications Volumes (series over total lifetime) (in units, log scale) (1) Raw material, labor, equipment, tooling, others «Source: JEC Group»

34 BIW Weight Nr. of components (277) % in weight BIW weight 168 kg

35 Hang on parts Weight Nr. of components (49)* % in weight* Hang on parts weight 39 kg* *w/o fenders

36 Body Weight Nr. of components (341)* % in weight* BIW with hang on parts weight 213 kg* *with fenders

37 Vehicle body material mix, including fascias

38 Static stiffness and Lightweight index Static torsional stiffness: Static bend stiffness: 14,150 Nm/ 8,200 N/mm AR 4C Ref. model - 6% 2,0 2,5 3,0 3,5 4C Lightweight index: m = Weight Ct = Static Torsional stiffness A proj = Projected area

39 Energy ~ 35% Front crash optimization Very limited deformation space available Polygonal section for maximizing efficiency Initial Energy IMMAGINE INVIATA Selection of optimal front rail section Displacement

40 Force Front crash optimization Process optimization to guarantee test repeatability Correlation to sub-structure level tests for crushable structures FILMATO INVIATO Physical experimental test on front structure and virtual validation Time

41 Front crash results High performance achieved (1 load path) High efficiency crash behavior through the involvement of body rockers and door beams

42 Side crash results Carbon fiber rocker deformation w/o rupture Load path distribution to body cross member and seat cross member Load distribution in door through beam

43 Pole crash results Numerical material characterization Numerical Physical

44 World wide safety compliant

45 Global dynamic stiffness FILMATI INVIATI 1st Bending frequency 1st Torsion frequency

46 Variant flexibility opportunity Very high carry over vs. eventual future body evolutions Underbody Changing / Adding parts Upperbody

47 Pure and sensuous Design Engineered around Drivers Most sporty Bodystyle Uncompromising Handling Dash structure and driver position creating the perfect cockpit Optimized ownership cost High performance Agility Accessible Dream World-class Technology

48 Magnesium I.P. beam and driver position Engine sound Cost of ownership

49 Magnesium I.P. Beam: main targets and design solution TARGETS: Low weight structure ; Crash protection ; NVH contribution ; Model flexibility ; Low investment for low volume and challenging price car Concept design 3,4 kg Symmetrical structure Exchangable die insert for LHD/RHD version Steel brackets for version diversification Models:

50 Driver position creating the perfect cockpit CFRP seat structures (completed seat weight: ~ 20 kg)

51 ENGINE RPM ENGINE RPM rpm giri motore (DT2) db(a) Pa ACOUSTIC PRESSURE [db(a)] ENGINE RPM rpm giri motore (DT2) db(a) Pa ACOUSTIC PRESSURE [db(a)] Engine Sound management «Sporty» sound feeling: Dedicated development to increase the richness in engine orders tailpipe Engine Orders Engine Orders Hz BOCCA SCAR 14cm dx:s (CH4) FREQUENCY [Hz] Hz BOCCA SCAR 14cm dx:s (CH4) FREQUENCY [Hz] FROM TO

52 Vehicle fuel consumption and CO 2 emissions Engine Power 240 CV Fuel consumption (NEDC cycle): 6,8 l/100 km CO 2 emissions: 157 g /km

53 Aluminum front structure reparability

54 Carbon fiber structure reparability Scarf Repair Insert Repair + Scarf Repair carf Perimetric Scarf Not damaged zone Precured insert Not damaged zone

55 SMC fiber panels reparability WINDOW REPAIR process Removing damaged area Flaring Adhesive application and SMC sheet Polymerization, resin application and sanding SMC repairing SMC CRACKING REPAIR process Area creation with cutter Filling areas with resin Polyester application Sanding of area

56 Maintenance intervals and operations Body related items Maintenance cost is aligned with high volume models

57 Pure and sensuous Design Engineered around Drivers Most sporty Bodystyle Uncompromising Handling Accessible Dream High performance Agility World-class Technology A modular body produced to be compliant with global homologative standard

58 An accessible Super Car Manufacturing Targets Mission Super Car ("S" segment) at a low volumes production and accessible final cost Targets Flexible Process/Modular product, for low volumes production; Product/Process Standardization; Simplified assembly process; Low investments.

59 An accessible Super Car How to achieve Targets Identification of an existing plant able to produce a High Quality/Low Volume car (a «Master Craftsman»); Definition of a Body deployment able to minimize investments and achieve the highest performances; Identification of smart solutions in order to standardize Product/Process; Strong Manufacturer/Supplier integration to reduce product development time and cost; Design of a simple, flexible, cost effective assembly line, using Digital Manufacturing tools.

60 Modena plant overview Maserati plant Modena: an excellence on sport cars 4C assembly process Global Overview HPV: 34.6h Automation level: less than 10% Production Volume: 12 car/d (up to 24 car/d) Work organization : 1 shift/d 5 shifts/w Takt Time: 2250 seconds (37.5 min.)

61 Plant layout Testing (Promiscuous with Maserati) Body Shop General assembly To Paint Shop 3 Finishing Line (Promiscuous with Maserati) 2 From Paint Shop Painted Body Warehouse (Promiscuous with Maserati)

62 Body shop overview Body Shop description Overall area: 600 m 2 Production line area: 230 m 2 Quality area: 50 m 2 Main Logistic area: 320 m 2 Secondary Logistic area: 80 m 2 Air Circulation Volume: m 3 /h Manpower: 1 Team Leader + 8 Blue Collars Body Shop HPV: 6.7h Process line description (12 Body/d) On-line stations: 8 (including Quality Areas) Off line stations: 3 Assembled body parts: 136 (incoming Parts) Screws/Bolts/Nuts: 296 Mechanization degree: 0% On-line logistic: manual carrier Main Applied Technologies Adhesive Joints (Overall length): 11095mm (Two components acrylic adhesive 7355mm One component Silyl Modified Polymers adhesive 3740mm) Fastener Systems: Torque & Tension Fasteners Standard Fasteners

63 OP.30 OP.20 OP.10 To Paint Shop OP.50 Body shop Layout Production Quality Areas Meas. Equipment design OP.60 BS CPA STRENGTHS: High flexibility line (all equipment suspended using balancers, except Op.10 screwed on floor); Short track line (with just 5 Geo Stations); Simplified and standardized equipment concept (Op.20/30/40/50 equipment aligned on same PLP's features). OP.40 OP.10 OP.20 OP.30 OP.40 OP.50 OP.60

64 Simplicity Body deployment and Process sequence OP.50 OP.30 OP.20 OP.10 Joining Percentage (Weld Spot Equivalent) Full Body 43% 57% OP.60 Adhesives Fastners

65 Manufacturer/Suppliers integration Carbon Monocoque forming process (co-cured technology) CO-CURE AUTOCLAVE PROCESS Adler Group X DIR. TYPICAL SECTION CO-CURED ASSEMBLY MONOCOQUE/FRONT TUB TECHNOLOGY: Co-cured vacuum bag for monolithic Monocoque; Dedicated vacuum bag for Front Tub; Molds: Primary tub, side box structure, front tub; Co-cured laminated inserts; CF/GF PREPREGS + Thermosetting resin (EPOXY). MOLD SIDE CO-LAMINATED PARTS MOLD SIDE silicone rubber CO-LAMINATED PARTS MOLD SIDE

66 Manufacturer/Suppliers integration Monocoque assembly process FRONT TUB MONOCOQUE Adler Group MONOCOQUE ASSEMBLY: Monocoque gluing (just front tub); Holes drilling and surfaces milling; Fasteners and inserts threading; Painting.

67 Manufacturer/Suppliers integration Added feature on Monocoque Adler Group INSERTS (AL ERGAL 7075) JOINED FASTNERS Big heads; Nutzers. REWORKED (MILLING) SURFACES JOINED (GLUED) BRACKETS Stainless steel Brackets; Aluminum Brackets. FILLERS Nomex; Rohacell; Fillcore.

68 Manufacturer/Suppliers integration Front & Rear Al. Frame multi-technology approach Front Frame Rear Frame Stretch bending process 3D forming process combined with other EMARC patented technologies; All aluminium profiles are obtained with this technology. Extrusion process Traditional extrusion process combined with a special cooling system to control heat reduction. CMT welding process CMT (Cold Metal Transfer) is an innovative welding process in which the wire movement is incorporated into the process control, whereby heat is inserted only very briefly.

69 An accessible Super Car How to let people live an emotion Strength results achieved: Application of advanced technologies to achieve design targets: highest performances, lowest weight; Design of specific technical solutions on body to optimize investments and achieve the highest value: Design of a short and simple Body Shop and General assembly line track; Simplification and standardization of equipment concept (lightweight suspended equipment, PLP's located on Monocoque); Design of smart solutions to prevent product dimensional variability due low production volumes.

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