Constellium presented its new generation of high-strength Crash Management Systems at Automotive Engineering Expo 2015. Lionel Chapis, Managing Director of Automotive Structures at Constellium, and Frank Gensty, Director Engineering, Automotive Structures and Industry at Constellium, highlighted how the latest generation of aluminium Crash Management Systems is setting new industry standards.

1. High Strength Crash Management Systems
June, 9th - 10th
Lionel Chapis - Frank Gensty

2. High strength crash management systems
Introduction
 Constellium key figures
 Cross functional and integrated Constellium Innovation Process
RCAR Structure
 High strength crushable alloys (C28 and above)
Towing
 Correlation Simulation & Testing
 Constellium Innovation
RCAR Bumper
 High strength structural alloys (HSA6)
 Constellium Innovation
Conclusion
AEE 2015 Nürnberg
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3. Constellium is a leader in innovative aluminium-based
solutions
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10,000 employees*
€ 4.7 billion in sales*
23 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
*ThecombinedunauditedproformarevenueinformationfortheyearendedDecember31,2014presentedabovegiveseffecttotheacquisitionof
WiseasifithadoccurredonJanuary1,2014.Thisinformationispresentedforinformationpurposesonlyanddoesnotpurporttorepresentwhat
Constelliumactualrevenueswouldhavebeenhadtheacquisitionoccurredonthedateindicated,norisitnecessarilyindicativeoffutureresults.

4. Constellium is a market leader in Automotive Structural applications
Crash Management Systems
• ~ 55% of sales
Side Impact Beams, other
Safety Systems
• ~ 15% of sales
BIW Structural Parts
• ~ 30% of sales
Main products
Automotive Structures
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5. 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
optimisation & qualification testing
Technology / Knowledge transfer
to the extrusion plants
In house research
centre (C-TEC) &
Integrated R&D
Network
Lab scale DC
caster & 5MN press
Full scale DC casting
centre with MC & 6”
fully integrated
extrusion press line
& ageing oven (*)
(*) Government funding secured in partnership with JLR to establish a Constellium University Technology Centre at Brunel University
366MPa
Advanced Die Design Models – Shape,
microstructure & extrudability
Re-Thinking Extrusion Alloy Design And Manufacturing Process
Alloy & Process Development
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6. Re-thinking alloy design and manufacturing
process, permitted to combine upsides of
current 6xxx and 7xxx solutions to obtain
press-quenched high-strength 6xxx alloys
Re-thinking alloy design and manufacturing
process, permitted to combine upsides of
current 6xxx and 7xxx solutions to obtain
press-quenched high-strength 6xxx alloys
Focus on High Strength Alloys – 6xxx
Re-thinking manufacturing process and alloy design
Press quench, standard billet purity
(easy to recycle), excellent corrosion
resistance, homogeneous properties
 Standard billet purity (easy to recylce),
excellent corrosion resistance
 Separate quench, heterogeneous
properties
Current solutions with
Rm sup. to 400MPa
Future state with
Constellium HSA – 6xxx
 Press quench if no formability
requirements, homogeneous
properties
 High billet purity, Stress-corrosion
cracking risk, formability guaranteed
only with separate quench
6xxx alloys (e.g. AA 6056)
7xxx alloys (e.g. AA 7108A)
+
+
-
-
+
-
Constellium HSA – 6xxx
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7. High Strength 6xxx Versus High Strength 7xxx
Extrudability/Strength Compromise
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50
60
70
80
90
100
110
300
320
340
360
380
400
420
440
EXTRUDABILITY(%)
RM(MPA)
Strength potential Rm (MPa) Relative extrudability

8. Low Speed Insurance Test
9th - 10th June 8
RCAR Structure Test
Objective of Test
• Rigid barrier in steel
• Overlap 40% of the vehicle width w/o exterior
mirrors
• Impact velocity VF = 15,0 km/h ( +1/-0 km/h )
• At the moment of impact the vehicle shall be free of
the propulsion system
• Test vehicle weight = curb weight with full fuel tank
+ additional test devices and 75 kg ballast for the
driver
Objective of Development
• System with maximum efficiency of energy
absorption
• No damage of cooling system (front system)
• No damage on the longitudinals
• No side collapse during crash
Automotive Engineering Expo 2015 Nürnberg

9. New Alloys for light weight design
C28 crushable alloy
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0.00
0.10
0.20
0.30
0.40
0.50
0 0.1 0.2 0.3 0.4 0.5
True strain
Truestress(MPa)
EN 6060-T62
C28
 New Constellium C28 crushable alloy
 YS ≥280MPa vs. 200MPa for 6060
 Potential for weight savings on crush
boxes up to 20%, depending on
designs.
 Higher strength of Heat Affected
Zone of welded assemblies
 Excellent ductility
C28 solution: from a 1 fold only to a fully
crushable performance with high
resistance
C28 solution: from a 1 fold only to a fully
crushable performance with high
resistance
Microstructurally Engineered 6xxx with YS > 280MPa
Best crash index of 18 (Average: 15)
where same strength products gave an
initial best crash index of 12 (Average: 9)
Automotive Engineering Expo 2015 Nürnberg

10. RCAR Structure Test - Efficiency CB
Low Speed Insurance Test
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Typicall AL System
• Fmax = 120 kN
• smax = 170mm Intrusion
• Emax,theor. = 120KN x 0,170m = 20.700J
= 100%
• E System= 18.200J = 88%
Efficiency-rate =
Emax = Fmax x smax
= 100%
Fmax = Defined by
customer (Max force
of longitudinals)
smax = Defined by
customer and its
package
Automotive Engineering Expo 2015 Nürnberg

11. Correlation FEA & Testing
Towing loadcase
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Objective of test:
• No major plasticity's
• No damage of car backbone structure
• Towing cycle fulfilled
Objective of Development
• System with maximum stiffness
• No negative impact on all other
loadcases

12. #1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #12 #13 #14 #15
Hardware 0,00 0,00 0,00 0,10 0,10 0,10 0,10 0,10 0,30 0,50 0,50 0,60 0,60 0,70 0,50
FEM 0,06 0,05 0,06 0,12 0,13 0,20 0,27 0,32 0,38 0,61 0,65 0,65 0,62 0,81 0,60
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
PlasticDeformation[mm]
Towing Cycles
Towing Loadcase
Correlation FEA & Testing
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13. Benefits:
much more
mechanical
„guidance“
Optimised
deformation
performance
Optimised
load
sustainable
Towing Loadcase
Standard Concepts vs. Constellium Innovation
Standard towing concept:
Towing eye welded into beam
Standard towing concept:
Towing eye welded into beam
Patented Constellium innovation:
Towing eye extruded in CB
Patented Constellium innovation:
Towing eye extruded in CB
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14. Why RCAR Bumper?
Low Speed Insurance Test
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Bumpers don‘t Bump ! Component Simulation with Trolly
RCAR Bumper Test
 10 kph
 Central Impact
 Defined Barrier height
 No damage on BiW Structure
14

15. Objective : Min.Bumper Beam Mass with optimal Beam depth
Shape Optimization
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16. 60826082
HSA6HSA6
Low Speed Insurance Test
RCAR bumper advantages mass / performance HSA6/6082
Option #1:
Potential usable for weight reduction
 Intrusion-Performance:
 neutral @ 100mm
 Weight:
 290g (= 12,4%) weight saving through
HSA6
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17. 60826082
HSA6HSA6
Low Speed Insurance Test
RCAR bumper advantages mass / performance HSA6/6082
Option #2: Potential usable for
intrusion optimisation without weight-
increase
 Intrusion-Performance:
 9mm Intrusion optimisation through
HSA6
 Weight:
 neutral
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18. Innovation CMS-design 3D, overlap -optimisationRCAR-Bumper overlap QT / Barrier
poor constellation!
RCAR-Bumper-overlap QT / Barrier
with 3D-bended QT = optimised constellation!
Solution: 3D-bumper
RCAR bumper design optimisation 3D
Innovation for light weight design
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19. Lightweight Strategy
Lightweight Potential based on similar functions
LightweightPotential
basedonsimilarfunction
Steel Aluminium Magnesium
CFK quasi isotropic CFK unidirectional
- 20 % - 30 % - 55 %
- 10 + x %
 HSA6
 Package and Parameter study
 Analytical optimisation
- 30 %
Automotive Engineering Expo 2015 Nürnberg
The right design, with the right material, at the right place for
optimised lightweight, performance and costs!
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20. Requirements, objectives, innovation strategy
CMS design
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CMS System:
• Active-CMS
• Semi Active / 100% Active Systems
Crashbox System:
• Crashbox Innovation
• Low & Highspeed
Beam System:
• Springback Beam (Pedestrian
optimised 2nd Loadpath Beam)
CMS Beam
• With Integrated Pedestrian
Protection System (SMIF)
Pedestrian System
• Pedestrian Protection Honeycomb
Component crash & correlation
Full vehicle crash & correlation
Virtual design and simulation to be continued
Mit freundlicher Genehmigung: BMW AG