bringing aluminium in the car body design to support lightweighting

Bringing aluminium in the car body

design to support lightweighting

Frank Gensty, Laurent Laszczyk, Olivier Rebuffet

Bad Nauheim, March 16, 2016

Agenda

1. Constellium

2. Our solutions for car body lightweighting

3. Our innovation strategy and capabilities

Bringing aluminium in the car body design to support lightweighting 216.03.2016

Agenda

1. Constellium




Constellium is a leader in innovative

aluminium-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


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


http://upload.wikimedia.org/wikipedia/fr/b/b3/Alusuisse_logo.svg

http://upload.wikimedia.org/wikipedia/fr/b/b3/Alusuisse_logo.svg

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

A major player in automotive body sheet

#1 worldwide in closure stock

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

Automotive Structures and Industry € 921 million in revenues

#2 worldwide in crash management systems

#1 in Europe for large profiles

#1 in Europe for hard alloy extrusions

* 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.

618.03.2016Bringing aluminium in the car body design to support lightweighting

Agenda

1. Constellium




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

Bringing aluminium in the car body design to support lightweighting 8

For

Closures inner

16.03.2016

Constellium – key supplier for premium as well as

volume oriented OEM in body sheet

Lightweight Design Summit, March 14-15, 2016 18.03.2016 9

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

7 series

Peugeot

3008

Citroen

DS4

Mercedes-Benz

C-Class

Mercedes-Benz

SL-Class

Porsche

Cayman

Tesla

Model S

Opel

Zafira

PROUD

TO SUPPLY

Constellium – key supplier for premium as well as

volume oriented OEM in Extrusion based components

Lightweight Design Summit, March 14-15, 2016 18.03.2016 10

Audi

BMW

Citroën

Ford

Jaguar

Jeep

Mercedes-Benz

Opel

Peugeot

Porsche

PROUD

TO SUPPLY

Mercedes-Benz

A-Class

Audi

A8

Peugeot

308

Mercedes-Benz

C-Class

Audi

A6

Audi

Q3

Audi

Q7

BMW

1 Series

BMW

X5

Ford

F-150

Mercedes-Benz

E-Class

Mercedes-Benz

S-Class

Mercedes-Benz

Actros

Jaguar

F-Type

Jeep

Cherokee

Mini

Clubman

Porsche

911

Our automotive body sheet portfolio: key product but

also process performances


DOWNSTREAM PROCESS PERFORMANCE

Joining

Strength/Mech.

Resistance Crash Design & Style

Surface

Aspect

Forming

PRODUCT PERFORMANCE

Stiffness

16.03.2016

Our auto body sheet portfolio with increasing

performance


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

16.03.2016

Constellium new Ultralex® provides approx. 15% weight savings vs. UHSS

Ultralex® offers inter-granular, filiform and stress corrosion resistance best-

in-class among the 7xxx family

Ultralex® is formable using press hot forming & warm forming, and joinable

using adapted mechanical fasteners


A new Ultra High Strength Aluminum: Ultralex®

16.03.2016

Car body engineering challenge:

have a further lightweighting option vs. the best steel offer (ultra high

strength steel)

Press-quenched B-pillar reinforcement prototype part (C-TEC internal)

Ultralex®

Ultralex® strength properties depend of the final temper

lightweighting potential and enabling technique are investigated within

Constellium and with forming and joining partners

Ultralex®: performance and enabling technique

16.03.2016Bringing aluminium in the car body design to support lightweighting 14

YS @T7 YS @T6 Rm @T6 A80 @T6

Ultralex® 450 MPa 500 MPa 550 MPa 15% Industrial trials

Ultra high Strength Steel

Warm or Hot forming

Corrosion protection needed

Mechanical fastening

17% lighter (door side impact beam)

Hot forming

Corrosion protection needed

Welding & Mechanical fastening

…

Side impact beam

productYS (MPa) UTS (MPa) A80 (%)

gauge for iso crash

performance

% light-weighting

vs. UHSS

UHSS (e.g. 22MnB5) 1100 1500 6 1,2 -

Ultralex® 500 550 15 2,9 -17%

New developments to improve

OEM process performance

Bringing aluminium in the car body design to support lightweighting 16.03.2016 15

DOWNSTREAM PROCESS PERFORMANCE

Improved welding

cycle timeImproved forming

process

New Remote Laser weldable alloy

Remote laser welding for joining

complex part with

a single alloy solution.

New highly formable skin

High quality skin alloy with

improved formability

performance

New Remote Laser weldable alloy development


Constellium new Remote Laser

weldable alloy development is

an inner alloy targeting

mechanical properties needed for

closures inners matching VDA

239-100 AL6-STD requirements

This alloy is a uni alloy solution, that has been designed to be weldable

without filler wire

Remote-Laser Welding


weld light inners with improved cost

(reduced cycle time)

Best-in-class skin & improved formability development


Constellium new highly formable skin development proposes an

improved formability of ~20% vs. incumbent skin alloys, without

compromising any other requirement of outer skins (surface appearance

-roping free-, bake hardening response, corrosion resistance)


geometrical complex details of light

outer skins using a conventional

cold forming process

Challenging geometrical details in outer skin

Best-in-class skin & improved formability development

New highly formable skin gives clear formability improvement both in

simulation and in prototype stamping trials of complex parts.

Surfalex® New highly formable skin

16.03.2016Bringing aluminium in the car body design to support lightweighting 18

Solution T4 In service 2%; 185°C; 20'

Rp0,2[MPa]

Rm[MPa]

Ag[%]

A80[%] n5 r10

Rp0,2[MPa]

Rm[MPa]

A80[%]

VDA AL6-OUT 90-130 - ≥ 20 ≥ 24 ≥ 0.26 ≥ 0.60 ≥ 200 ≥ 260 ≥ 14

Surfalex® 110 225 22 25 0.28 0.63 220 280 17

Highly formable skin 110 225 26 29 0.29 0.63 220 280 16

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


Our Crash Management System (CMS) portfolio

evolves to answer OEMs needs

Bringing aluminium in the car body design to support lightweighting 16.03.2016 20

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

7003

7108

Ultimate extrusions

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

Agenda

1. Constellium




Our vision is “aluminium everywhere”

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


Volvo XC90 2015 body structure

Our vision is “aluminium everywhere”

Example of approach “the right solution at the right place” to optimize weight

and cost: steel door redesign (source: C-TEC CAE team)


Part Alloy % vs. optimised steel Solution % vs.optimized steel

Door inner 5182 17% Remote- Laser weldable 23%

Door frame stiffener 5182 41% High stiffness (dev.) 50%

Mirror reinforcement 5182 47% 5182 47%

Door panel 6016 48% Surfalex® 48%

Door inner stiffener 5182 35% 5182 35%

Door panel stiffener 5182 38% 5182 38%

Door hinge reinforcement 5182 38% Strongalex® Plus 49%

Side impact beam UHSS 0% Ultralex® 22%

Lock reinforcement 5182 47% 5182 47%

Total 30% lightweighting36% lightweighting &

reduced cycle time

Chosing the right material solution allows further

lightweighting and further cost savings

C-TEC: a world-class technology center fully dedicated

to innovation

Uniquerapid prototyping

capabilities, simulation tools

and advanced joining

technologies such as

friction stir welding

Over150 patent families and trademarks

22Nationalities

223Employees

58PhDs

93Engineers

including


For automotive body sheets 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


Our technical development offer

C-TEC: Constellium technology center Network of international

collaborations

Prototyping and 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

and simulation

Design and forming feasibility

simulation

Support for alloy choice

Specific design studies for OEMs

FEM modeling

Formability and 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


Virtual design and simulation

Component crash & correlation

Full vehicle crash & correlation

CMS design

Requirements, objectives, innovation strategy

CMS System

Active-CMS

Semi Active/100% Active Systems

Crashbox System

Crashbox Innovation

Low & Highspeed

Beam System

Springback Beam (Pedestrian

optimized 2nd Loadpath Beam)

CMS Beam

With Integrated Pedestrian

Protection System (SMIF)

Pedestrian System

Pedestrian Protection Honeycomb

Mit freundlicher Genehmigung: BMW AG

NEW DEVELOPMENTS


Automotive extrusion based components

alloy and process development

Re-Thinking Extrusion Alloy Design And Manufacturing Process

Define targets, (strength, crush, corrosion

resistance, etc.), alloy design and process

conditions

Undertake rapid prototyping experiments

– cast, extrude and test a full range

of potential alloys

Analyse data and select only

the few best candidates

Scale Up – Prototypes, process

optimization & qualification testing

Technology/Knowledge transfer

to the extrusion plants

In house

research

centre (c-tec)

& integrated

r&d network

36

6M

Pa

Advanced Die Design Models –

Shape, microstructure & extrudability

Lab scale DC

caster & 5MN

press

Full scale DC

casting centre

with MC & 6”

fully integrat-

ed extrusion

press line &

ageing oven*

* Government funding secured in partnership with JLR to establish a Constellium University Technology Centre at Brunel University


THANK YOU FOR YOUR

ATTENTION!