Aluminium Light-weighting for transportation Les alliages d’aluminium pour l’automobile et l’aéronautique: performances et prespectives Bruno CHENAL Nancy, 8 Juin 2016 Constellium: a long and rich experience in aluminium More than a century of growth 1855 January 2011 Pechiney Rio Tinto sells 51% of Alcan Engineered 2000 Products to Apollo, Alcan Aluminium Limited 10% to FSI and keeps the merges with Algroup/ remaining 39% stake Alusuisse May 2011 1888 2007 Alcan Engineered Alusuisse Rio Tinto Products is renamed acquires Alcan to Constellium 2003 Alcan Inc. acquires May 2013 Pechiney Constellium commences trading on the New York Stock Exchange and NYSE Euronext 1902 Paris Alcan January 2015 Constellium acquires Wise Metals 2 Constellium is a leader in innovative aluminium-based solutions 2015 key figures 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 3 Constellium serves blue-chip customers Aerospace Packaging Automotive 4 Agenda Requirements for new materials in transportation Recent and ongoing developments of aluminium in automotive applications Recent and ongoing developments of aluminium in aerospace applications 5 Summary Requirements for new materials in transportation Recent and ongoing developments of aluminium in automotive applications Recent and ongoing developments of aluminium in aerospace applications 6 Global market for flat rolled sheet in BiW Key drivers for growth in aluminium FRP in BiW worldwide 1. Steel to all-aluminium conversion of big volume US OEMs. 2. Incremental conversion steel to aluminium in hang-on parts, then structures at all OEMs. 3. Geographic expansion of European Premium Brand OEMs using aluminium. Constellium Global BiW Market Forecast Data 10 Aluminium in the Body-in-White Incremental change Step-change Closures and hang-on parts first, then All-Aluminium / Aluminium Intensive parts in body structure Vehicle Design 2015 Ford F-150 Moderate weight saving Big weight savings Moderate CapEx Large CapEx & manufacturing changes Low risk, reversible decisions Step-change in supplier volumes Need for multi-material joining Need for high-productivity, all-Al & assembly assembly line solutions 11 Constellium Aluminium in Automotive BiW We supply key OEMs the full range of aluminium sheet and extruded products. A A3 A8 F-150 Model S B A7 5 GT 3008 DS4 C SL Cayman 5008 Zafira Some of the vehicles where we supply Constellium aluminium for structural parts, closure inners and/or outer skin panels. 12 Constellium’s BiW Portfolio is based on Cu-free 6xxx (AlMgSi) and 5xxx (AlMg) alloys SURFALEX® STRONGALEX® Uniform Paint bake No compromise with response ® Aesthetics! surface & ULTRALEX No compromise with Strength Light-weighting! Roping Corrosion Hemming resistance Energy Work absorption FORMALEX® hardening SECURALEX® No compromise with Crash crushable alloy for Design! Thermal structural parts Isotropy stability Ductiliy Elongation 10 Higher strength alloy families exist but in general imply lower ductility (formability) Standard Today High Strength Ultra High Strength Al Al-Mn Al-Fe 5182-O Al-Mg Al-Mg-Si 6016-T4 Al-Mg-Si-Cu Al-Cu-Mg-(Li) 6016-T64 2024-T3 Al-Zn-Mg 6082-T6 7020-T6 Al-Zn-Mg-Cu 2198-T8 6065-T6 7046-T6 7075-T6 3003 – H18 7449-T79 5182-H19 11 Summary Requirements for new materials in transportation: weight/cost benefits Recent and ongoing developments of aluminium in automotive applications Recent and ongoing developments of aluminium in aerospace applications 17/06/2016 12 AEROSPACE Today, aerostructures are more hybrid. The proportions of the different materials are re-assesed for each new aircraft. Historical reminder of main aircraft programs % Composite Airbus A350 XWB 53% Airbus A380 Boeing 787 25% Airbus A330 Bombardier CSeries New Single Aisle COMAC C919 15% Boeing / Airbus 11% Boeing 777 Airbus A320 NEO 1994 1997 2005 2009 2011 2013 2016 > 2025 Date of first flight Challenge for new material solutions : Proposal of AIRWARE® solution 17/06/2016 13 Depending on %Cu, Li content, different strengthening precipitates can be obtained. δ’ (Al3Li) spheres Al-xCu-yLi at 500°C (-) + metastable at 155°C (-) 3 T1 (Al2CuLi) plates; hexagonal on {111}Al plans 2.5 (Al) T2 T. J. Langan, & J. R. : Li Pickens. (1989).. Li wt% Li 2 : Cu : Al T + Al Li 1.5 1 3 (Al) Al2CuLi_T1 T1 Following Van-Smaalen 1 et al, 1990 T + J' 1 (Al) P. Donnadieu, Y. Shao, F. De Geuser, G. θ’ (Al Cu) plates; tetragonal on plane Al15Cu8Li2_TB 2 0.5 A. Botton, S. Lazar, M. Cheynet, M. de J' Boissieu, & A. Deschamps. (2011). {100}Al (if no Ag in alloy) (Al) (AlLi)2Cu 0 1.5 2 2.5 3 3.5 4 4.5 5 Cu wt% Phase diagram source: Constellium Software ProPhase – C. Sigli J. M. Silcock. (1959-60). 17/06/2016 Constellium preferred target consists in exploiting the full potential of T1: AIRWARE® • Multi-phase precipitation systems based on main elements as Al-Li-Cu-Ag-Mg Al-xCu-yLi at 500°C (-) + metastable at 155°C (-) 3 High damage 2.5 2090 (Al) T2 tolerant 1980's Al-Li alloys 2091(2090,2091) dominated wt% Li area 2 AIRWARE® 1.5 2196 platform (Al) Al2CuLi_T1 Strength- Toughness ® AIRWARE balanced 1 2050 platform property High strength AIRWARE® (Al) 2x95 platformAl15Cu8Li2_TB dominated 0.5 area (Al) (AlLi)2Cu 0 1.5 2 2.5 3 3.5 4 4.5 5 Cu wt% Eurocorr 2013 – Estoril – Plenary Lecture - Challenges and recent development in aluminium corrosion resistant alloys for transport applications 21 AIRWARE ® alloys outperform current aluminum solutions. AIRWARE ® 2198 T851 Fuselage Sheet AIRWARE ® 2050 T84 Plate * Compared to 2024 T351 * Compared to 7050 T7451 AIRWARE® permit to gain weight (acc. to. airframer and internal calculations) 3-6% weight from density alone (no skin thickness reductions) 5-10% weight for replacement at iso-design (optimized local thicknesses) 15-25% weight for redesign with Al-Cu-Li alloys Eurocorr 2013 – Estoril – Plenary Lecture - Challenges and recent development in aluminium corrosion resistant alloys for transport applications 22 AIRWARE ® technology achieves exceptional balance of properties to meet the specifications of all structures of civil aircrafts. Spars, ibs and stringers 2050 Fuselage skin Stringers for fuselage 2098, 2198 2195, 2196 Upper wing skin 2195 Frames, Internal structure 2098, 2198, 2050 Floor beams, seat tracks 2196 Central wing box 2050 Lower wing skin Stringers for wing 2196, 2050 2195, 2296 Eurocorr 2013 – Estoril – Plenary Lecture - Challenges and recent development in aluminium corrosion resistant alloys for transport applications 17 Summary For lightweighting, materials developments for transportation must meet performance and cost requirements. But step change can be achieved via co-optimization of design, material, manufacturing. Driven by the evolution of regulation towards reducing CO2 emissions of cars, and by the competition with other materials in aerostructures, Aluminium has a fantastic but challenging growth opportunity. CONSTELLIUM has defined automotive and aerospace as one of his key strategic segments, and is actively addressing those challenges through strong R&D capabilities: Developing an appropriate portfolio of alloys along key technical drivers and pursuing with more step-change concepts Partnering with OEMs to develop affordable solutions All this with sustainability in mind 17/06/2016 18.