“Formed extrusions & high strength sheets: latest aluminium innovations to meet passenger vehicle lightweight needs.” Presented at Automotive Circle’s Insight Edition @ Ford USA on September 24, 2015.

1. Formed extrusions & high strength sheets:
latest aluminium innovations to meet
passenger vehicle lightweight needs
Automotive Circle
Insight Edition @ Ford USA
September 24, 2015

2. Constellium
A leader in innovative aluminium-based solutions
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3. Design for weight savings with aluminium
 Stiffness dominated
Body-in-White
 Combination of
membrane and through-
thickness bending
 Increase through-
thickness bending
component
Cantilever bending
0
50
100
150
200
250
300
350
400
0.0 0.5 1.0 1.5 2.0 2.5 3.0
Thickness Multiplier
Displacement(mm)
 Steel
 Aluminum
3

4. Sheet or extrusions for Body-in-White structures?
Sheet and extruded components are complementary, allowing
the optimization of the performance/cost equation
4
Open/closed sections
Section type
Component thickness
Features & fasteners
Cycle time
 Closed; easy to
implement.
 Complex; multiple
chambers.
Constant along part.
 Variable
 Add cost
 2 – 10 spm
Extruded components
 Open; closed
sections require
assembly.
 Multi-piece sections
necessary.
Variable along part.
 Constant
 Easy to implement
 5 -25 spm
Sheet components

5. Constellium Automotive Structures
 Full range of alloys and processes to accommodate the OEM needs
 Major supplier of BiW structural parts in Europe and largest in North America
Crashboxes (CMS)
Bumper beams
Longitudinals
Engine cradle/Subframe
Cockpit carrier
Bumper beams (CMS) Add-on frames
Structural
components (BiW)
Ford F-150
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6. Design & manufacturing with extrusions
 Account for extrusion tolerances in component design
 Design tools for variable blank geometry and thickness !!!
 Sections length of line are constant
 Moving away from this paradigm
 Maximize the ability to pierce and trim for machining reduction
 Scrap removal during piercing of closed sections
 Intensive use of FE forming analysis tools
 Evaluate the influence of variations in input geometry
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7. Extrusion tolerances do not support BIW tolerances
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 Absorb extra tolerance in the assembly process
 Calibrate important sections

8. Windshield header development
8

9. Extrusion post-processing summary
 Product design w/ extrusion allows the use of closed, variable
thickness sections
 Maximize through thickness bending
 Several possibilities outside of hydroforming
 Forming simulation tools are readily available
 Forming tools to account for incoming cross section and thickness
variations
 Required aging treatment after forming, tailored to performance
requirements
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10. The right alloy for each application
Alloy
Strength
Shape
Complexity
C20
C22
C24
C28/
6082
HSA6
YS 200 6 YS 220 MPa YS 240 MPa YS 280 MPa YS 370 MPa (400 UTS)
Crush Strength
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11. High strength crash resistance alloy – C28
C28 extrude beam
Bender mandrel r=0.4 mm
Yield stress: 280 MPa
UTS: 310 MPa
End Forming of C28 extrusion
11

12. Ultra-high strength 6xxx extrusion- HSA6
Hollow
sections
YS
(MPa)
UTS
(MPa)
A50
(%)
Bending
(°)
HSA6 370-400 400-430 10 90
 Novel and proprietary high
strength 6xxx alloy
 With UTS  400 Mpa
 Excellent corrosion resistance
 Application to CMS: bumper
mass down by 15%
 Key advantages in recycling
compared to 7xxx alloy
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13. Constellium’s BiW sheet portfolio
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FORMALEX®
Forming optimized
SURFALEX®
Perfect surface with excellent hemming
SECURALEX®
Crash crushable alloy for
structural parts
STRONGALEX®
High Yield Strength
SECURALEX®P5/P6
Pedestrian Safety alloy
SECURALEX® HS
High Strength Crash Crushable
FORMALEX® PLUS
Extra formability for complex shapes
5754, 5182
SURFALEX ® HS
Perfect surface with High Strength.
SURFALEX ® HF
Perfect surface with High Formability.

14. Body-in-White sheet key driver: no compromises
SAFETY
LIGHTWEIGHTINGSTYLE
DESIGN
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Elongation
Isotropy
Strength
Work
hardening
Energy
absorption
Thermal
stability
Paint bake
response
Ductiliy
Corrosion
resistance
Hemming
Roping
Character
lines

15. Development of high strength structural alloys
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Standard Today High Strength Ultra High Strength
YS [MPa]
Formalex®Plus
Formalex®
6016-X
6016-DRX/RSX
Strongalex®
Ultralex®V1
Ultralex®V2
Strongalex®Plus
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Steel equivalent
by density ratio
7000-series
6000-series
5000-series
1000 /
3000 /
8000 -series

16. High strength 6xxx aluminium alloys
* 2% + 20’@185°C
 6xxx-alloys offer unmatched corrosion
resistance for cosmetic, intergranular- and
stress corrosion cracking
 They are formable and joinable by
conventional mechanical joining and welding
joining techniques
 They are ideally suited for uni-alloy concepts
and closed loop recycling
Strength Ductility Status
YS @T4 YS @PB* YS @T6 A80% @T4
Securalex® ~100 ~180 250 25 Serial
Strongalex® ~140 ~260 300 25 Serial
Strongalex®Plus ~160 ~300 330 23 Industrial trials
Strongalex®380 ~170 ~310 350 23 Industrial trials
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17. Ultra high strength 7xxx solutions: Ultralex®
 Ultralex® v1: complies to AA7075; long experience and reference
data (processing, corrosion) coming from aerospace applications.
 Ultralex® v2: still in development; target is highest strength with
excellent stress corrosion performance and easy implementation in
hot stamping lines
Strength Ductility Status
YS @T7 YS @T6 Rm @T6 A80 @T6
Ultralex® v1 480 MPa 530 MPa 580 MPa 15%
Industrial
available
Ultralex® v2 560 MPa 620 MPa 675 MPa 13% Lab trials
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18. Forming technologies for Ultralex®: hot forming
Part
Picture
 B-pillar trials at Constellium
 Blank heating during few minutes at SHT temperature
 Transfer
 Stamping in cold dies
 Press quenching (die closing maintained)
 Total forming cycle time ~20 seconds
 Heat-up time: 8 minutes per batch
Ultralex v1 & Ultralex v2
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19. Forming technologies for Ultralex®: hot forming
Thickness
white= experimental
red = numerical
1.94/
2.0
1.52/
1.72
1.62/
1.7
1.94/
1.91
1.62/
1.59
1.79/
1.81 1.81/
1.83
1.85/
1.891.97/
2.0
1.89/
1.95
1.84/
1.9 1.99/
2.0
1.66/
1.74
1.61/
1.54
1.67/
1.7
 Simulations of hot forming
B-pillar trials with Autoform
thermosolver
 Consistent with experimental
results
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20.  Main concern for 7xxx-series structural alloys is to be safe from
catastrophic stress corrosion cracking failure in service.
 We test materials under multiple stress loading modes beyond plastic
yield and in different corrosive environments to ensure immunity to SCC
or hydrogen embrittlement in service.
 Ultralex® copper containing 7xxx-series alloys in overaged tempers
provide robust resistance in these tests.
Ultra high strength 7xxx-series alloys: corrosion
U-bend test specimen,
2-3% plastic deformation
Ultralex®v1. No failure
ASTM G85-A2 640 hours
Reference Alloy. Fully cracked after
167 hours ASTM G85-A2
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21. New Constellium-UACJ plant in Bowling Green, KY
 Joint venture between Constellium and UACJ to meet the growing
demand for automotive body sheet in North America.
 Devoted to aluminum automotive body sheet
 240,000 square feet
 Full portfolio of 5xxx and 6xxx alloys
 In-line pretreatment and lubrication
 Maximum width: 2200mm
 Maximum gauge: 3.2mm
 Separate coil completion line
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22. Summary
 Sheet and extruded components will continue to share the car
design space in Body-in-White construction.
 Advancements are focused on extending the strength spectrum to
achieve further weight savings.
 Constellium has established a joint venture with UACJ for auto
body sheet in North America.
 A new greenfield plant in Bowling Green, Ky., will start
production in 2016.
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23. Thank you for your attention!