Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design &...

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Implementation of Aluminum in High Volume Car Body Design & Manufacturing GALM, August 20, 2015

Transcript of Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design &...

Page 1: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

Implementation of Aluminum in

High Volume Car Body Design & Manufacturing

GALM, August 20, 2015

Page 2: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

Constellium: Three Business Units

8/21/2015 2

Aerospace and Transportation� € 1.197 billion in revenues� #1 worldwide for aerospace plates� #1 in the USA for large coils� #2 worldwide in general engineering plates

Packaging and Automotive Rolled Products� € 2.573* billion in revenues� #1 worldwide in closure stock� #2 in Europe for can body stock and #3 in North America� Major player in auto body sheet: #4 worldwide

Automotive Structures and Industry� € 921 million in revenues� #1 in Europe for large profiles� #1 in Europe for hard alloy extrusions� #2 worldwide in crash management systems

* The combined unaudited pro forma revenue information for the year ended December 31, 2014 presented above gives effect to the acquisition of Wise as if it had occurred on January 1, 2014. Thisinformation 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 itnecessarily indicative of future results.

Page 3: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

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

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Mercedes SL

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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© 2015 UACJ Corporation. All rights reserved. 4

Japanese BIW Market - UACJ Position

Customers: Toyota, Nissan, Honda, Mitsubishi, Subaru, MazdaApplications: Skins, Panels, Reinforcements, Door Panels, etc.

Main Models: Skyline

SAIPrius

Leaf Fuga Fairlady Z

Lexus Lexus Lexus Lexus

Roadstar

UACJ market share in Japan: 60%

Page 5: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

Response to the US BiW sheet demand:Constellium – UACJ Joint Venture

8/21/2015 5

51% 49%

 Combined customer portfolio

Page 6: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

New Constellium-UACJ plant in Bowling Green, KY

 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

Page 7: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

Continuous Annealing Line with Pre-Treatment

C. Annealing/SHT

Quenching

Ti/ZrConversion

Pre-DegreasingAlcoa 951 Pretreatment

BH Oven

Rinsing

Rinsing

Cleaning

Tension Leveling

Page 8: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

Key development driver: No compromises

SAFETY

LIGHTWEIGHTING

Elongation

Isotropy

Strength

Work hardening

Energy absorption

Thermalstability

Paint bake response

Ductiliy

Corrosion resistance

STYLE

Hemming

Roping

Character lines

DESIGN

Page 9: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

Design for weight savings: Stiffness Stiffness dominated BIW Combination of

membrane and through-thickness bending

  Increase through-thickness bending component f Strategic placement of

reinforcementsf Limit buckling modes

Cantilever bending

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0.0 0.5 1.0 1.5 2.0 2.5 3.0

Thickness Multiplier

Dis

plac

emen

t (m

m)

� Steel� Aluminum

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Sheet or extrusions for BIW structures?

Open/Closed sections � Easy to implement closed sections

� Open. Close sections need assembly

Section type � Complex, multiple chambers

� Multi-piece sections necessary

Constant along part Variable along part

Component thickness � Variable � Constant

Features & fasteners � Cost adder � Easy to implement

Cycle time � 2-6 spm � 5-20 spm

Extruded components Sheet components

Sheet and extruded components are complementary, allowing the optimization of the performance/cost equation

Page 11: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

  Request from OEMs: skin alloys that allow very sharp character-lines

  Combination of high work hardening @ high strains, coupled with bendability

Formability: Current designs require sharp lines

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Outer skin alloys requirements

In-service strength(dent resistance)

Corrosion resistance

Roping

Orange peel

Stretch forming & Stretch bending (sharp lines)

Deep drawing

Hemming

Hole expansion

Ability to form the partIn-service performance

Constellium-UACJ development strategy for exterior BIW:Stretching boundaries w/o sacrificing established design envelope

Current offer

HF variant

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� All the formability criteria improved in reference with the incumbent Surfalex£

� Æ Forming limit curve is improved, particularly in plane strain, which helps form sharper character lines

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maj

or s

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minor strain

+ 15%

Highly formable skin alloys for complex outer panels

Current

HF variant

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Bendability meeting highest OEM requirements Prestrain // RD Prestrain // TD

back

Page 15: Implementation of Aluminum in High Volume Car Body Design ... · High Volume Car Body Design & Manufacturing GALM, August 20, 2015. ... Devoted to aluminum automotive body sheet 240,000

Summary

 Sheet and extruded components will continue to share the car design space in BIW construction.

 Constellium and UACJ, established sheet suppliers in EU and Japan, are expanding in the NA market.

 Greenfield SHT facility in Bowling Green, KY, will start production in 2016, supplied by Constellium and UACJ mills.

 Shared technological advancements focus on extending the range of designs that can be achieved with high production methods.

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Thank you for your attention!

Please visit Constellium-UACJ at booth #23.