Aluminium response to automotive OEMs challenges
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Transcript of Aluminium response to automotive OEMs challenges
Constellium’s automotive strategy
and response to the market
opportunities and challenges
Dr Carsten Rink, Technical Director Automotive
Würzburg, March 14, 2016
Agenda
1. Constellium
2. Developing the right products
3. Our innovation strategy and capabilities
4. Following the automotive growth
5. Sustainability opportunities
214.03.2016Lightweight Design Summit, March 14-15, 2016
Agenda
1. Constellium
2. Developing the right products
3. Our innovation strategy and capabilities
4. Following the automotive growth
5. Sustainability opportunities
314.03.2016Lightweight Design Summit, March 14-15, 2016
Constellium is a leader in innovative
aluminum-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
414.03.2016Lightweight Design Summit, March 14-15, 2016
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
514.03.2016Lightweight Design Summit, March 14-15, 2016
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.
614.03.2016Lightweight Design Summit, March 14-15, 2016
An introduction to Constellium 2015 7
Aerospace
Automotive
Packaging
Our customers: market leaders in their industries
Lightweight Design Summit, March 14-15, 2016
Agenda
1. Constellium
2. Developing the right products
3. Our innovation strategy and capabilities
4. Following the automotive growth
5. Sustainability opportunities
814.03.2016Lightweight Design Summit, March 14-15, 2016
Overview of our lightweighting solutions
BODY SHEETS & COILS
for
Closures skin
for
Body-in-White
EXTRUSIONS & COMPONENTS
Body-in-White
Crash Management
System (CMS)
Chassis
914.03.2016
for
Closures inner
Lightweight Design Summit, March 14-15, 2016
Constellium – key supplier for premium as well as
volume oriented OEM in body sheet
Lightweight Design Summit, March 14-15, 2016 14.03.2016 10
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
Our automotive body sheet portfolio: key product and
process performance
14.03.2016 11
PRODUCT PERFORMANCE
Crash Stiffness
Strength/Mech.
Resistance
Surface
Aspect
Joining
& Welding
DOWNSTREAM PROCESS PERFORMANCE
Adapted forming
technologies
Design & Style
Lightweight Design Summit, March 14-15, 2016
Our automotive body sheet portfolio with increasing
performance
14.03.2016 12
Strength/Mech.
Resistance Crash Design & Style
Surface
Aspect Stiffness
PRODUCT PERFORMANCE
Strongalex®
Ultralex®
For replacement of high
strength steel parts
and further down gauging
Formalex ® PLUS
For parts with
complex design
Securalex ®
Securalex ®HS
For parts which
need energy
absorption
Surfalex ®
Surfalex® HS
For all
visible parts
Lightweight Design Summit, March 14-15, 2016
The challenge
Offer further lightweighting vs. the best steel offer (ultra high- strength
steel)
Constellium new Ultralex® provides approx. 17% 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
Press-quenched B-pillar reinforcement prototype part (C-TEC internal)
13
A new ultra high-strength aluminum: Ultralex®
14.03.2016Lightweight Design Summit, March 14-15, 2016
Ultralex® strength properties depend on the final temper
Lightweighting potential and enabling technique are investigated within
Constellium and with forming and joining partners
Ultralex®: performance and enabling technique
14
YS @T7 YS @T6 Rm @T6 A80 @T6
Ultralex® 450 MPa 500 MPa 550 MPa 15% Industrial trials
Ultralex®
Warm or hot forming
Corrosion protection needed
Mechanical fastening
17% lighter
Ultra high-strength steel
Hot forming
Corrosion protection needed
Welding & mechanical fastening
…
Side impact beam
productYS (MPa) UTS (MPa) A80 (%)
Gauge for iso crash
performance
% lightweighting
vs. UHSS
UHSS (e.g. 22MnB5) 1100 1500 6 1,2 -
Ultralex® 500 550 15 2,9 -17%
14.03.2016Lightweight Design Summit, March 14-15, 2016
New developments to improve OEM process
performance
15
DOWNSTREAM PROCESS PERFORMANCE
Improved welding
cycle timeImproved forming
process
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
14.03.2016Lightweight Design Summit, March 14-15, 2016
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
1614.03.2016Lightweight Design Summit, March 14-15, 2016
Constellium – key supplier for premium as well as
volume oriented OEM in Extrusion based components
14.03.2016 17
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
Lightweight Design Summit, March 14-15, 2016
Our Crash Management System (CMS) portfolio
evolves to respond to the needs of OEMs
14.03.2016 18
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
Unmatched
alloy portfolio
Str
ength
UT
S (
Mpa)
Alloy composition/
process optimization
350
7,003
7,108
Ultimate 6xxx
Strength capability?
New High Strength
6xxx Alloys – HSA6
Shape Complexity/
Strength Compromise
Conventional High Strength
6xxx Alloys
400
450
500
Design and next
generation CMS
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
Lightweight Design Summit, March 14-15, 2016
Agenda
1. Constellium
2. Developing the right products
3. Our innovation strategy and capabilities
4. Following the automotive growth
5. Sustainability opportunities
1914.03.2016Lightweight Design Summit, March 14-15, 2016
An aluminium solution for every part
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
2014.03.2016Lightweight Design Summit, March 14-15, 2016
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
2114.03.2016Lightweight Design Summit, March 14-15, 2016
For automotive body sheet, development of alloys and
solutions
Pushing the limits
of aluminium
Ultra High Strength
Ultra High Formability
More Crash properties
Higher Stiffness
Metallurgy, corrosion,
Surface treatment
Expertise
Providing
solutions
For better integration
with other materials
For better manufacturing
efficiency of OEMs
Joining, Welding
Studies
Customizing
our offer From simulation studies
in design phase
To specific alloy &
conversion developments
Characterization, Simulation,
Prototyping, Design, CAD Tools
2214.03.2016Lightweight Design Summit, March 14-15, 2016
Our technical development offer
R&T Center “C-TEC”
Prototyping & 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
& simulation
Design & forming feasibility simulation
Support for alloy choice
Specific design studies for OEMs
FEM modeling
Formability & 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
Network of international
collaborations
2314.03.2016Lightweight Design Summit, March 14-15, 2016
Virtual design and simulation
CMS design:
requirements, objectives, innovation strategy
Component crash & correlation
Full vehicle crash & correlation
Mit freundlicher Genehmigung: BMW AG
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
NEW DEVELOPMENTS
2414.03.2016Lightweight Design Summit, March 14-15, 2016
Automotive extrusion-based components:
alloy & 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
2516.03.2016Lightweight Design Summit, March 14-15, 2016
Agenda
1. Constellium
2. Developing the right products
3. Our innovation strategy and capabilities
4. Following the automotive growth
5. Sustainability opportunities
2614.03.2016Lightweight Design Summit, March 14-15, 2016
We believe aluminium has an
unrivaled “benefit/cost” position
5-fold Increase in global
Body-in-White market expected
Sheet based aluminium solutions are growing strongly
400230
490
200
2020
2,100
700*
1,200
2015
92030
2012
315
70 15
~5×
Europe +15%
US +43%
Asia +38%
CAGR ’12 – ’20
Global FRP Al-BiW market forecast act. 2012 – 2020 (kt)
* Outlook excluding any major shift for a new high volume model
Source: Constellium internal analysis
2714.03.2016
2012 2015 2020
Lightweight Design Summit, March 14-15, 2016
Constellium automotive rolled product footprint
Second largest-volume, fully
integrated rolling mill in Europe
World-class recycling center
Integrated hot/cold-rolling line
NEUF-BRISACH, F SINGEN, D
Joint Venture with UACJ (Japan),
majority owned by Constellium
Bowling Green, KY (under construction)
To respond to this challenge, we are expanding the
rolled products capacity
14.03.2016 28Lightweight Design Summit, March 14-15, 2016
Some pictures of our investments in progress
2914.03.2016
Neuf-Brisach (F)Neuf-Brisach (F)
Singen (D) Bowling Green (USA)
Lightweight Design Summit, March 14-15, 2016
2942
72
115
14
32
45
125
0
50
100
150
200
250
300
2012 2015 2020 2025
Extrusion based solutions show impressive growth as
well
Aluminium Body
Structure market (kt)
Aluminium CMS
market (M units)
Plants on 3 continents to capture
global growth: Europe, U.S. and
China
Europe North America China
8,011,0
14,5
3,0
6,0
7,5
2,0
3,5
5,0
0
5
10
15
20
25
30
2012 2015 2020
CAGR +14%
CAGR +8%
Source: Automotive Structures CMS Data base (2014)
3014.03.2016Lightweight Design Summit, March 14-15, 2016
Automotive Structures also
14.03.2016 31
Constellium automotive structures footprint
Production
of extrusions
for automotive
structures and
crash manage-
ment systems
Design and development
of automotive structures and crash
management systems, including
production processes, prototyping
and testing
Production of automotive structures
and crash management systems
Dahenfeld, D Gottmadingen, D
Design and development of auto-
motive structures and crash manage-
ment systems, including production
processes, prototyping and testing
Production of automotive structures
and crash management systems
Production of automotive
structures and crash
management systems
(start of production in 2017)
Van Buren, MIWhite, GA
Production of
integrated crash
management systems
Changchun, China
Lightweight Design Summit, March 14-15, 2016
Agenda
1. Constellium
2. Developing the right products
3. Our innovation strategy and capabilities
4. Following the automotive growth
5. Sustainability opportunities
3214.03.2016Lightweight Design Summit, March 14-15, 2016
Constellium is committed to sustainability
1 sustainability charter, 4 pillars,
9 commitments, 12 targets
1 materiality assessment process involving
external and internal stakeholders to guide
our sustainability approach
2 full Life Cycle Assessments(LCAs)
demonstrating significant advantages related
to the use of aluminium and our products for
car hoodsand beverage cans
Development of aluminium products
with environmental benefits
Member of the Aluminium
Stewardship Initiative (ASI)
Multistakeholder process
First voluntary standard for aluminium
sustainably produced and used
3314.03.2016Lightweight Design Summit, March 14-15, 2016
At Constellium, we strive to make
infinite aluminum recycling a reality
Committed to maximize recycling of
all scraps, from process scrap to end-of-life
Focus on increasing end-of-life recycling
and on designing new products with this
perspective
Engaged in industry initiatives to increase
end-of-life recycling and to improve the
measurement and the quality of end
of life scrap
Our recycling partnerships
3414.03.2016Lightweight Design Summit, March 14-15, 2016
THANK YOU FOR YOUR
ATTENTION!