Modalex™, our new solution

bringing stiffness and lightweighting

to Automotive Body Sheets

Olivier Rebuffet, Dr. Christoph Seemüller, Markus Gehrig

Constellium

Insight Edition @BMW 2016

November 9, 2016

Dingolfing, Germany

Agenda

1. Constellium

2. Aluminium, the lightweighting solution

3. Stiffness improved aluminium alloy Modalex™

An introduction to Constellium 2015

Constellium is a leader in innovative aluminium-based

solutions

3

Over 10,000 full-time employees

€5.2 billion in sales

22 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

*2015 key figures

An introduction to Constellium 2015

Constellium serves blue-chip customers

Aerospace

Automotive

Packaging

October 18, 2016: Constellium to open a new

automotive aluminium sheet finishing line in

Neuf-Brisach, France

Constellium Automotive Body Sheet News

With a production capacity of 100,000 tons, the new 240 m

long finishing line features high-speed thermal treatment,

precise temperature control, highly efficient quenching

process as well as greater flexibility on the thickness of

processed alloys. This diverse range of innovative

technologies will enable Constellium to manufacture high-

quality aluminium products for automotive closure inners,

outers and Body-in-White. The new finishing line is in the

final stage of the qualification phase and has already

started commercial production.

Sept 14, 2016: Constellium and UACJ

Announce Opening of their Joint Venture’s

Automotive Body Sheet Plant in Bowling

Green, Kentucky

The strategically-located 225,000 square foot facility will

house an initial capacity of 100,000 metric tons. It has

secured its metal supply with both partners’ rolling mills.

With cutting-edge equipment and technologies, the facility

expects to offer a flat rolled product portfolio for a wide

range of applications including closure panels, as well as

body structures. The plant is currently in qualification

phase, with ramp-up planned over the next two years. As

of today, the line is essentially committed with orders from

leading automotive OEMs in North America.

Agenda

1. Constellium

2. Aluminium, the lightweighting solution

3. Stiffness improved aluminium alloy Modalex™

YS [MPa]

Formalex®Plus

Formalex®

6016-X

Securalex®HS

6xxx-series

5xxx-series

3xxx-series

… Aluminium for automotive will grow leveraging

on its unique properties: strength and ductility

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Steel equivalent

by density ratio

Strongalex®

Ultra High Strength

Ultralex®

Ultralex® V2

7xxx-series

Securalex®UHS

Ultra

Hig

h D

uctilit

y

Ultra High Strength Steel

Mild Steel

… Aluminium for automotive will grow leveraging

on its unique properties: stiffness and buckling

Material: Mild Steel Alloy: 5182-O Alloy:Surfalex®

Yield strength: 240 MPa Yield strength: 130 MPa Yield strength: 200 MPa

Gauge: 0.70 mm Gauge: 1.00 mm Gauge: 1.00 mm

Y-Modulus: 200000 MPa Y-Modulus: 69000 MPa Y-Modulus: 69000 MPa

At same bending stiffness, aluminum is up to 50 % lighter than steel, by up

to 70 % higher buckling strength

Steel

5182-O

Surfalex®

buckling strength [%]

Steel

5182-O

Surfalex®

bending stiffness [%]

Steel

5182-O

Surfalex®

weight [%]

Weight specific energy absorption during crash ~ material flow stress & density

Flow stress 𝜎 during folding can be approximated by (Rp0,2 + Rm)/2

Aluminium offers significantly higher specific energy absorption than steel alloys

E ~ ( 𝜎)· t 5/3

𝜎 = flow stress t = gauge

0 5 10 15 20 25

Steel ZSE450

AA5754 O

SecuralexHS®

SecuralexHS® T6

Specific Energy

Absorption [kJ/kg]

… Aluminium for automotive will grow leveraging

on its unique properties: energy absorption

Along with our extrusion alloy offer with the high

strength 6xxx alloy family HSA6

Alloy Composition & Processing Technology

Str

ength

UT

S -

MP

a

350 MPa

425 MPa

Conventional High

Strength 6xxx Alloys

New High Strength

6xxx Alloys – HSA6

Max. 6xxx Strength

450MPa Solids & 480MPa Forgings

440 MPa

Thermo-Mechanically

Aged HSA6HSA6 bumper

We believe aluminium has an

unrivalled “benefit/cost” position

… Aluminium for automotive will grow leveraging

on its unique properties: economics and market

Material Cost

Potential

weight

saving vs

steel

Ease of

adoption for

OEMs

UHSS/AHS

S steels

0.8 – 1.5

€/kg10 – 20 % ++++

Aluminium3 – 5

€/kg30 – 50 % +++

Magnesium10 – 20

€/kg40 – 60 % +

Carbon

Fiber

Composites

40 – 80

€/kg60 – 70 % +

Increase in global Automotive

Body Sheet market expected

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

Source: Constellium internal analysis

230400

490

1 200

200

~6,6x

15

2,100

700*

92030

315

70Europe +15 %

US +43 %

Asia +38 %

CAGR ’12-’20

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

Agenda

1. Constellium

2. Aluminium, the lightweighting solution

3. Stiffness improved aluminium alloy Modalex™

Stiffness improved aluminium alloy

Development targets

Specifically for automotive applications

At least 10 % higher specific stiffness than

current products

Density ≤ 2.7 g∙cm-3

Forming & strength properties comparable to

6xxx inners (AL6-STD)

Corrosion behaviour at the level of inner

application

With a focus on Al-Mg-Si alloy metallurgy

Stiffness improved aluminium alloy

The Young’s Modulus measurement: Impulse Excitation ASTM E1876

Resonant frequency more precise than

mechanical measurement

Usage of rectangular bar

geometry:

𝐸 = Young′s modulus

𝑚 = mass of the bar

𝑏 = width of the bar

𝐿 = length of the bar

𝑡 = thickness of the bar

𝑓f = fundamental resonant frequency

𝑇1 = correction factor for fundamental flexural mode

𝐸 = 0.9465𝑚 ⋅ 𝑓f𝑏

𝐿3

𝑡3𝑇1

Stiffness improved aluminium alloy Modalex™

Stiffness properties

SampleDensity ρ

[g/cm³]

Young’s

Modulus E

[GPa]

Ratio E/ρ Improvement

Reference

AL6-STD2.69 69.0 25.6 -

Modalex™ 2.65 78.5 29.6 +15.7 %

Modalex™ brings unique density improvement vs. incumbent

aluminium alloys

Stiffness improved aluminium alloy Modalex™

Mechanical properties

Modalex™ mechanical properties are isotropic in-plane and close to

meet AL6-STD (6xxx inners)

angle/

rolling

direction

Rp0.2

[MPa]

Rm

[MPa]

Ag

[%]

A80

[%]r10 n5

Rp0.2

[MPa]

Rm

[MPa]

A80

[%]

Temper T4 T4 + paint bake

AL6-STD

spec.90°

90-

140>200 >20 >23 >0.55 >0.26 >160 >220 >14

Modalex™ 0° 101 217 18.8 22.0 0.74 0.262

Modalex™ 45° 97 212 19.6 22.7 0.79 0.261

Modalex™ 90° 99 217 17.9 21.5 0.72 0.259 166 234 14.7

Stiffness improved aluminium alloy Modalex™

Formability

0,15

0,17

0,19

0,21

0,23

0,25

0,27

0,29

0,31

0,33

-0,1 0 0,1 0,2 0,3

ma

jor

str

ain

minor strain

6016X - t =1.5 mm 2009

5182 - t = 1.5 mm 2013

High Stiffness - t = 1.5 mm

Modalex™ formability is compatible with effective cold forming

AL6-STD

AL5-STD

Modalex™

Stiffness improved aluminium alloy Modalex™

Corrosion

Modalex™ is resistant to corrosion: max. corrosion attack after ISO 11846

test remains limited (<200 μm)

AL6-STD

Modalex™

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1,0

0 100 200 300

dis

trib

utio

n fu

nctio

n

penetration depth / μm

AL6-STD Modalex

Basics on stiffness sizing of a tube of modulus E, radius r & thickness t

Equations

1. Tensile stiffness = 𝐸 ⋅ 𝜋 ⋅ (𝑟2-(𝑟 − 𝑡)2) ~ 𝐸 ⋅ 𝑡

2. Bending stiffness = 𝐸 ⋅ 𝜋 ⋅ (𝑟4-(𝑟 − 𝑡)4)/4 ~ 𝐸 ⋅ 𝑡3

3. Torsional stiffness =𝐸

2(1+𝑣)⋅ 𝜋 ⋅ (𝑟4-(𝑟 − 𝑡)4)/2~ 𝐸 ⋅ 𝑡3

Improvement of 15 % of E/ρ brings:

15 % lightweighting in pure tension

4.8 % lightweighting in pure bending and in pure torsion

Combination of load cases (body structure torsional stiffness)

15 % of E/ρ improvement brings 12.5 % additional stiffness

15 % of E/ρ improvement brings 11.5 % lightweighting

Stiffness improved aluminium alloy Modalex™

Benefits of 15 % E/ρ improvement

𝒕 𝒓

Automotive Body Sheet portfolio

Strongalex®

Ultralex®

Securalex®

Securalex® HS

Securalex® UHS

Surfalex ®

Surfalex® HS

Surfalex® HF

Formalex®

Formalex® Plus

Strength/Mech.

Resistance Crash Design & Style

Surface

Aspect Stiffness

Modalex™