aluminium as the lightweighting material of choice for oems

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Aluminium as the lightweighting material of choice for OEMs Catherine Athènes, Marketing Director, Packaging and Automotive Rolled Products at Constellium Maranello, 44 th FARO Meeting, March 10, 2016

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Page 1: Aluminium as the lightweighting material of choice for OEMs

Aluminium as the lightweighting

material of choice for OEMs

Catherine Athènes, Marketing Director, Packaging

and Automotive Rolled Products at Constellium

Maranello, 44th FARO Meeting, March 10, 2016

Page 2: Aluminium as the lightweighting material of choice for OEMs

Agenda

1. Constellium

2. Aluminium the lightweighting solution of choice

3. A strong product portfolio both rolled and extruded

4. An aluminium solution for every part

5. Aluminium, a sustainable material

210.03.2016

Page 3: Aluminium as the lightweighting material of choice for OEMs

Agenda

1. Constellium

2. Aluminium, the lightweighting solution of choice

3. A strong product portfolio both rolled and extruded

4. An aluminium solution for every part

5. Aluminium, a sustainable material

310.03.2016

Page 4: Aluminium as the lightweighting material of choice for OEMs

Constellium is a leader in innovative

aluminum-based solutions2014 pro forma figures including Wise Metals acquisition

* The combined unaudited pro forma revenue information for the year ended December 31st, 2014 presented gives effect to the acquisition of Wise as if it had occurred on January 1st, 2014.

This information is presented for information purposes only and does not purport to represent what Constellium actual revenues would have been had the acquisition occurred on the date indicated,

nor is it necessarily indicative of future results.

Over 10,000 employees*

€4.7 billion in sales

(incl. €997 million from Wise Metals)*

21 manufacturing sites

C-TEC, our world-class Technology Center

Headquartered in Amsterdam, The Netherlands.

Corporate offices in Paris, France, Zurich, Switzerland and New

York, USA

410.03.2016

Page 5: Aluminium as the lightweighting material of choice for OEMs

Constellium: a long and rich experience in aluminum

1855Pechiney

1888Alusuisse

1902Alcan

2000Alcan Aluminum Limited

merges with Algroup/

Alusuisse

2003Alcan Inc. acquires

Pechiney

2007Rio Tinto

acquires Alcan

More than a century of growth

May 2013Constellium commences

trading on the New York

Stock Exchange and NYSE

Euronext Paris

May 2011Alcan Engineered

Products is renamed

to Constellium

January 2011Rio Tinto sells 51%

of Alcan Engineered

Products to Apollo,

10% to FSI and keeps

the remaining 39% stake

January 2015Constellium acquires

Wise Metals

510.03.2016

Page 6: Aluminium as the lightweighting material of choice for OEMs

Structured into 3 Business Units

Aerospace and Transportation € 1,197 billion in revenues

#1 worldwide for aerospace plates

#1 in the USA for large coils

Packaging and Automotive Rolled Products € 2,573* billion in revenues

#1 worldwide in closure stock

#2 in Europe for can body stock and #2 in North America

Major player in auto body sheet: #4 worldwide

Automotive Structures and Industry € 921 million in revenues

#1 in Europe for large profiles

#1 in Europe for hard alloy extrusions

#2 worldwide in crash management systems

* The combined unaudited pro forma revenue information for the year ended December 31st, 2014 presented above gives effect to the acquisition of Wise as if it had occurred on January 1st, 2014.

This information is presented for information purposes only and does not purport to represent what Constellium actual revenues would have been had the acquisition occurred on the date indicated,

nor is it necessarily indicative of future results.

610.03.2016

Page 7: Aluminium as the lightweighting material of choice for OEMs

7

Aerospace

Automotive

Packaging

Our customers: market leaders in their industries

710.03.2016

Page 8: Aluminium as the lightweighting material of choice for OEMs

We believe aluminium has an

unrivaled “benefit/cost” position

Aluminium has an optimal position in terms of

lightweighting benefit vs cost

Material Cost

Potential

weight saving

vs. steel

Ease of

adoption

for OEMs

UHSS/AHSS

steels

0.8 – 1.5

€/kg10 – 20% ++++

Aluminium3 – 5

€/kg30 – 50% +++

Magnesium10 – 20

€/kg40 – 60% +

Carbon Fiber

Composites

40 – 80

€/kg60 – 70% +

810.03.2016

Page 9: Aluminium as the lightweighting material of choice for OEMs

5-fold Increase in global

Body in White (BiW) market

expected

This explains the impressive growth of aluminium

automotive body sheets…

400230

490

200

2020

2,100

700*

1,200

2015

92030

2012

315

70 15

~5×

Europe +15%

US +43%

Asia +38%

CAGR ’12 – ’20

Global FRP Al-BiW market forecast act. 2012 – 2020 (kt)

* Outlook excluding any major shift for a new high volume model

Source: Constellium internal analysis

910.03.2016

2012 2015 2020

Page 10: Aluminium as the lightweighting material of choice for OEMs

2942

72

115

14

32

45

125

0

50

100

150

200

250

300

2012 2015 2020 2025

…as well as the growth of aluminium automotive

structures

Aluminium Body

Structure market (kt)

Aluminium CMS

market (M units)

Plants on 3 continents to capture

global growth: Europe, U.S. and

China

Europe North America China

8,011,0

14,5

3,0

6,0

7,5

2,0

3,5

5,0

0

5

10

15

20

25

30

2012 2015 2020

CAGR +14%

CAGR +8%

Source: Automotive Structures CMS Data base (2014)

1010.03.2016

Page 11: Aluminium as the lightweighting material of choice for OEMs

Some pictures of our investments in progress

1110.03.2016

Neuf-Brisach (F) Neuf-Brisach (F)

Singen (D) Bowling Green (US)

Page 12: Aluminium as the lightweighting material of choice for OEMs

Agenda

1. Constellium

2. Aluminium the lightweighting solution of choice

3. A strong product portfolio both rolled and extruded

4. An aluminium solution for every part

5. Aluminium, a sustainable material

1210.03.2016

Page 13: Aluminium as the lightweighting material of choice for OEMs

Overview of our lightweighting solutions

BODY SHEETS & COILS EXTRUSIONS & COMPONENTS

For

Closures skin

For

Body-in-White

Body-in-White

Crash Management

System (CMS)

Chassis

& Cockpit

MASTER PREZ AUTO_March 2016 Conferences_for conf call 1310.03.2016

For

Closures inner

Page 14: Aluminium as the lightweighting material of choice for OEMs

Constellium – key supplier for premium as well as

volume oriented OEMs in body sheet

10.03.2016 14

Audi

BMW

Chrysler

Citroën

Mercedes Benz

Opel

Peugeot

Porsche

Renault

Tesla

Mercedes-Benz

A Class

Audi

A3

Audi

A8

Peugeot

308

Citroen

C4

Mercedes-Benz

B Class

Audi

A7

BMW

7er

Peugeot

3008

Citroen

DS4

Mercedes-Benz

C Class

Mercedes-Benz

SL

Porsche

Cayman

Tesla

Model S

Opel

Zafira

PROUD

TO SUPPLY

Page 15: Aluminium as the lightweighting material of choice for OEMs

Constellium – key supplier for premium as well as

volume oriented OEM in Extrusion based components

10.03.2016 15

Audi

BMW

Citroën

Ford

Jaguar

Jeep

Mercedes-Benz

Opel

Peugeot

Mercedes-Benz

A Class

Audi

A6

Audi

A8

Peugeot

308

Ford

F-150

Mercedes-Benz

E Class

Audi

Q3

Audi

Q7

BMW

1

BMW

X5

Mercedes-Benz

C Class

Mercedes-Benz

S

Mercedes-Benz

Actros

Jaguar

F-Type

Jeep

Cherokee

PROUD

TO SUPPLY

Mini

Clubman

Porsche

911

Page 16: Aluminium as the lightweighting material of choice for OEMs

Our automotive body sheet portfolio: key product and

process performance

10.03.2016 16

DOWNSTREAM PROCESS PERFORMANCE

Joining

& Welding

Strength/Mech.

Resistance Crash Design & Style

Surface

Aspect

Adapted forming

technologies

PRODUCT PERFORMANCE

Stiffness

Page 17: Aluminium as the lightweighting material of choice for OEMs

Our automotive body sheet portfolio with increasing

performance

10.03.2016 17

Strongalex®

Ultralex®

Securalex ®

Securalex ®HS

Surfalex ®

Surfalex® HS Formalex ® PLUS

Strength/Mech.

Resistance Crash Design & Style

Surface

Aspect Stiffness

PRODUCT PERFORMANCE

For replacement of high

strength steel parts

and further down gauging

For parts which

need energy

absorption

For all

visible parts

For parts with

complex design

Page 18: Aluminium as the lightweighting material of choice for OEMs

Automotive Structures Product Portfolio focused on

three categories of components

Crash Management

Systems

Side Impact Beams

and other safety

systems

Body In White

Structural Parts

1810.03.2016

Page 19: Aluminium as the lightweighting material of choice for OEMs

Our Crash Management System (CMS) portfolio

evolves to respond to the needs of OEMs

10.03.2016 19

Industrialization

Manufacturing processes:

extrusion, bending,

forming, welding,

bonding …

Scale Up – Prototypes,

process optimization

& qualification testing

Brunel University:

Constellium and

JLR Partnership

Rapid prototyping

route – Alloy/Process

Collaborative

partnerships with

Tier 1 & OEM’s

Develop downstream

fabrication & joining

technologies

Design and next

generation CMS

Unmatched

alloy portfolio

Str

ength

UT

S (

Mpa)

Alloy composition/

process optimization

350

7,003

7,108

Ultimate 6xxx

Strength capability?

New High Strength

6xxx Alloys – HSA6

Shape Complexity/

Strength Compromise

Conventional High Strength

6xxx Alloys

400

450

500

CMS System

Active CMS

Semi active/100% active

Crashbox System

Crashbox innovation

Low & Highspeed

CMS Beam

With integrated pedestrian

protection system (SMIF)

Beam System

Springback beam

(pedestrian optimized

2nd loadpath beam)

Pedestrian System

Pedestrian protection

honeycomb

Page 20: Aluminium as the lightweighting material of choice for OEMs

Agenda

1. Constellium

2. Aluminium the lightweighting solution of choice

3. A strong product portfolio both rolled and extruded

4. An aluminium solution for every part

5. Aluminium, a sustainable material

2010.03.2016

Page 21: Aluminium as the lightweighting material of choice for OEMs

An aluminium solution for every part

Automotive body structures are today made out of a range of steel grades

In Constellium, our long-term ambition is to offer aluminium solutions to

convert all steel grades, maintaining both an attractive weight reduction

as well as a reasonable overall cost

Volvo XC90 2015 body structure

2110.03.2016

Page 22: Aluminium as the lightweighting material of choice for OEMs

For automotive body sheet, development of alloys and

solutions

Customizing

our offer From simulation studies

in design phase

To specific alloy &

conversion developments

Providing

solutions

For better integration

with other materials

For better manufacturing

efficiency of OEMs

Pushing the limits

of aluminium

Ultra High Strength

Ultra High Formability

More Crash properties

Higher Stiffness

Metallurgy, corrosion,

Surface treatment

Expertise

Joining, Welding

Studies

Characterization, Simulation,

Prototyping, Design, CAD Tools

2210.03.2016

Page 23: Aluminium as the lightweighting material of choice for OEMs

Our technical development offer

R&T Center “C-TEC”

Network of international

collaborations

Prototyping & testing

Alloy development

Laboratory casting at all scales

Hot and cold rolling

Heat treatment and quenching

Surface treatment & lubrication

From beaker-scale to continuous

pilot line

Analysis and characterization

Fully range of corrosion

and durability tests

State-of-the-art electron microscopy

and surface characterization

Strong chemical analysis capability

Design, forming

& simulation

Design & forming feasibility

simulation

Support for alloy choice

Specific design studies for OEMs

FEM modeling

Formability & mechanical testing

Full scale hydraulic stamping press

State-of-the-art mechanical

and formability laboratories

Joining and welding

Adhesive bonding

and durability testing

Riveting and other

mechanical fastening

All relevant welding

technologies

2310.03.2016

Page 24: Aluminium as the lightweighting material of choice for OEMs

Agenda

1. Constellium

2. Aluminium the lightweighting solution of choice

3. A strong product portfolio both rolled and extruded

4. An aluminium solution for every part

5. Aluminium, a sustainable material

2410.03.2016

Page 25: Aluminium as the lightweighting material of choice for OEMs

Life Cycle Assessment (LCA) confirms the benefits of

aluminium in terms of Greenhouse Gas emissions

10.03.2016 25

This study respects ISO14040/44 standard for LCA and the resulting report

underwent a critical review by independent third parties (Quantis with a

contribution from French CETIM).

Page 26: Aluminium as the lightweighting material of choice for OEMs

Constellium is committed to sustainability

1 sustainability charter, 4 pillars,

9 commitments, 12 targets

1 materiality assessment process involving

external and internal stakeholders to guide

our sustainability approach

2 full Life Cycle Assessments(LCAs)

demonstrating significant advantages related

to the use of aluminium and our products for

car hoods and beverage cans

Development of aluminium products

with environmental benefits

Participation in recycling initiatives

Member of the Aluminium

Stewardship Initiative (ASI)

Multistakeholder process

First voluntary standard for aluminium

sustainably produced and used

2610.03.2016

Page 27: Aluminium as the lightweighting material of choice for OEMs

THANK YOU!