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Automotive Circle Conference: bmw insight edition 2016 - Constellium presentation

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Constellium presented the theme "Stiffness Improved Aluminium Alloys for Automotive Body Sheet Applications"

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Automotive Circle Conference: bmw insight edition 2016 - Constellium presentation

  1. 1. 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
  2. 2. Agenda 1. Constellium 2. Aluminium, the lightweighting solution 3. Stiffness improved aluminium alloy Modalex™
  3. 3. 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
  4. 4. An introduction to Constellium 2015 Constellium serves blue-chip customers Aerospace Automotive Packaging
  5. 5.  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.
  6. 6. Agenda 1. Constellium 2. Aluminium, the lightweighting solution 3. Stiffness improved aluminium alloy Modalex™
  7. 7. 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 UltraHighDuctility Ultra High Strength Steel Mild Steel
  8. 8. … 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 [%]
  9. 9.  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
  10. 10. Along with our extrusion alloy offer with the high strength 6xxx alloy family HSA6 Alloy Composition & Processing Technology StrengthUTS-MPa 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 HSA6 HSA6 bumper
  11. 11. 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 €/kg 10 – 20 % ++++ Aluminium 3 – 5 €/kg 30 – 50 % +++ Magnesium 10 – 20 €/kg 40 – 60 % + Carbon Fiber Composites 40 – 80 €/kg 60 – 70 % + Increase in global Automotive Body Sheet market expected * Outlook excluding any major shift for a new high volume model Source: Constellium internal analysis 230 400 490 1 200 200 ~6,6x 15 2,100 700* 920 30 315 70 Europe +15 % US +43 % Asia +38 % CAGR ’12-’20 Global FRP Al-ABS market forecast act. 2012 – 2020 (kt)
  12. 12. Agenda 1. Constellium 2. Aluminium, the lightweighting solution 3. Stiffness improved aluminium alloy Modalex™
  13. 13. 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
  14. 14. 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 = 0.9465 𝑚 ⋅ 𝑓f 𝑏 𝐿3 𝑡3 𝑇1
  15. 15. Stiffness improved aluminium alloy Modalex™ Stiffness properties Sample Density ρ [g/cm³] Young’s Modulus E [GPa] Ratio E/ρ Improvement Reference AL6-STD 2.69 69.0 25.6 - Modalex™ 2.65 78.5 29.6 +15.7 %  Modalex™ brings unique density improvement vs. incumbent aluminium alloys
  16. 16. 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
  17. 17. 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 majorstrain 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™
  18. 18. 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 distributionfunction penetration depth / μm AL6-STD Modalex
  19. 19.  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
  20. 20. 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™

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