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

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. Agenda
1. Constellium
2. Aluminium, the lightweighting solution
3. Stiffness improved aluminium alloy Modalex™

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. An introduction to Constellium 2015
Constellium serves blue-chip customers
Aerospace
Automotive
Packaging

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. Agenda
1. Constellium
2. Aluminium, the lightweighting solution
3. Stiffness improved aluminium alloy Modalex™

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. … 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.  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. 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. 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. Agenda
1. Constellium
2. Aluminium, the lightweighting solution
3. Stiffness improved aluminium alloy Modalex™

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. 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. 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. 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. 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. 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.  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. 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™