Bringing aluminium in the car body design to support lightweighting Frank Gensty, Laurent Laszczyk, Olivier Rebuffet Bad Nauheim, March 16, 2016

1. Bringing aluminium in the car body
design to support lightweighting
Frank Gensty, Laurent Laszczyk, Olivier Rebuffet
Bad Nauheim, March 16, 2016

2. Agenda
1. Constellium
2. Our solutions for car body lightweighting
3. Our innovation strategy and capabilities
Bringing aluminium in the car body design to support lightweighting 216.03.2016

3. Agenda
1. Constellium
2. Our solutions for car body lightweighting
3. Our innovation strategy and capabilities
Bringing aluminium in the car body design to support lightweighting 316.03.2016

4. Constellium is a leader in innovative
aluminium-based solutions
2014 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
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5. Constellium: a long and rich experience in aluminum
1855
Pechiney
1888
Alusuisse
1902
Alcan
2000
Alcan Aluminum Limited
merges with Algroup/
Alusuisse
2003
Alcan Inc. acquires
Pechiney
2007
Rio Tinto
acquires Alcan
More than a century of growth
May 2013
Constellium commences
trading on the New York
Stock Exchange and NYSE
Euronext Paris
May 2011
Alcan Engineered
Products is renamed
to Constellium
January 2011
Rio Tinto sells 51%
of Alcan Engineered
Products to Apollo,
10% to FSI and keeps
the remaining 39% stake
January 2015
Constellium acquires
Wise Metals
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6. 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.
618.03.2016Bringing aluminium in the car body design to support lightweighting

7. Agenda
1. Constellium
2. Our solutions for car body lightweighting
3. Our innovation strategy and capabilities
Bringing aluminium in the car body design to support lightweighting 716.03.2016

8. Overview of our lightweighting solutions
BODY SHEETS & COILS EXTRUSIONS & COMPONENTS
For
Closures skin
For
Body-in-White
Body-in-White
Crash Management
System (CMS)
Chassis
Bringing aluminium in the car body design to support lightweighting 8
For
Closures inner
16.03.2016

9. Constellium – key supplier for premium as well as
volume oriented OEM in body sheet
Lightweight Design Summit, March 14-15, 2016 18.03.2016 9
 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

10. Constellium – key supplier for premium as well as
volume oriented OEM in Extrusion based components
Lightweight Design Summit, March 14-15, 2016 18.03.2016 10
 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

11. Our automotive body sheet portfolio: key product but
also process performances
Bringing aluminium in the car body design to support lightweighting 11
DOWNSTREAM PROCESS PERFORMANCE
Joining
Strength/Mech.
Resistance Crash Design & Style
Surface
Aspect
Forming
PRODUCT PERFORMANCE
Stiffness
16.03.2016

12. Our auto body sheet portfolio with increasing
performance
Bringing aluminium in the car body design to support lightweighting 12
Strongalex®
Ultralex®
Securalex®
Securalex®HS
Surfalex®
Surfalex®HS
Formalex®Plus
Strength/Mech.
Resistance Crash Design & Style
Surface
Aspect Stiffness
PRODUCT PERFORMANCE
For replacement of high
strength steel parts
and further down gauging
For parts which
need energy
absorption
For all
visible parts
For parts with
complex design
16.03.2016

13.  Constellium new Ultralex® provides approx. 15% 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
Bringing aluminium in the car body design to support lightweighting 13
A new Ultra High Strength Aluminum: Ultralex®
16.03.2016
Car body engineering challenge:
have a further lightweighting option vs. the best steel offer (ultra high
strength steel)
Press-quenched B-pillar reinforcement prototype part (C-TEC internal)

14. Ultralex®
 Ultralex® strength properties depend of the final temper
 lightweighting potential and enabling technique are investigated within
Constellium and with forming and joining partners
Ultralex®: performance and enabling technique
16.03.2016Bringing aluminium in the car body design to support lightweighting 14
YS @T7 YS @T6 Rm @T6 A80 @T6
Ultralex® 450 MPa 500 MPa 550 MPa 15% Industrial trials
Ultra high Strength Steel
 Warm or Hot forming
 Corrosion protection needed
 Mechanical fastening
 17% lighter (door side impact beam)
 Hot forming
 Corrosion protection needed
 Welding & Mechanical fastening
 …
Side impact beam
product
YS (MPa) UTS (MPa) A80 (%)
gauge for iso crash
performance
% light-weighting
vs. UHSS
UHSS (e.g. 22MnB5) 1100 1500 6 1,2 -
Ultralex® 500 550 15 2,9 -17%

15. New developments to improve
OEM process performance
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DOWNSTREAM PROCESS PERFORMANCE
Improved welding
cycle time
Improved forming
process
New 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

16. New Remote Laser weldable alloy development
Bringing aluminium in the car body design to support lightweighting 1616.03.2016
 Constellium new Remote Laser
weldable alloy development is
an inner alloy targeting
mechanical properties needed for
closures inners matching VDA
239-100 AL6-STD requirements
 This alloy is a uni alloy solution, that has been designed to be weldable
without filler wire
Remote-Laser Welding
Car body engineering challenge:
weld light inners with improved cost
(reduced cycle time)

17. Best-in-class skin & improved formability development
Bringing aluminium in the car body design to support lightweighting 1716.03.2016
 Constellium new highly formable skin development proposes an
improved formability of ~20% vs. incumbent skin alloys, without
compromising any other requirement of outer skins (surface appearance
-roping free-, bake hardening response, corrosion resistance)
Car body engineering challenge:
geometrical complex details of light
outer skins using a conventional
cold forming process
Challenging geometrical details in outer skin

18. Best-in-class skin & improved formability development
 New highly formable skin gives clear formability improvement both in
simulation and in prototype stamping trials of complex parts.
Surfalex® New highly formable skin
16.03.2016Bringing aluminium in the car body design to support lightweighting 18
Solution T4 In service 2%; 185°C; 20'
Rp0,2
[MPa]
Rm
[MPa]
Ag
[%]
A80
[%] n5 r10
Rp0,2
[MPa]
Rm
[MPa]
A80
[%]
VDA AL6-OUT 90-130 - ≥ 20 ≥ 24 ≥ 0.26 ≥ 0.60 ≥ 200 ≥ 260 ≥ 14
Surfalex® 110 225 22 25 0.28 0.63 220 280 17
Highly formable skin 110 225 26 29 0.29 0.63 220 280 16

19. 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
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20. Our Crash Management System (CMS) portfolio
evolves to answer OEMs needs
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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
Design and next
generation CMS
Unmatched
alloy portfolio
StrengthUTS(Mpa)
Alloy composition/
process optimization
350
7003
7108
Ultimate extrusions
Strength capability?
New High Strength
6xxx Alloys – HSA6
Shape Complexity/
Strength Compromise
Conventional High Strength
6xxx Alloys
400
450
500
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

21. Agenda
1. Constellium
2. Our solutions for car body lightweighting
3. Our innovation strategy and capabilities
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22. Our vision is “aluminium everywhere”
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
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23. Volvo XC90 2015 body structure
Our vision is “aluminium everywhere”
Example of approach “the right solution at the right place” to optimize weight
and cost: steel door redesign (source: C-TEC CAE team)
Bringing aluminium in the car body design to support lightweighting 2316.03.2016
Part Alloy % vs. optimised steel Solution % vs.optimized steel
Door inner 5182 17% Remote- Laser weldable 23%
Door frame stiffener 5182 41% High stiffness (dev.) 50%
Mirror reinforcement 5182 47% 5182 47%
Door panel 6016 48% Surfalex® 48%
Door inner stiffener 5182 35% 5182 35%
Door panel stiffener 5182 38% 5182 38%
Door hinge reinforcement 5182 38% Strongalex® Plus 49%
Side impact beam UHSS 0% Ultralex® 22%
Lock reinforcement 5182 47% 5182 47%
Total 30% lightweighting
36% lightweighting &
reduced cycle time
Chosing the right material solution allows further
lightweighting and further cost savings

24. C-TEC: a world-class technology center fully dedicated
to innovation
Unique
rapid prototyping
capabilities, simulation tools
and advanced joining
technologies such as
friction stir welding
Over 150patent families and trademarks
22Nationalities
223Employees
58PhDs
93Engineers
including
Bringing aluminium in the car body design to support lightweighting 2416.03.2016

25. For automotive body sheets development of alloys and
solutions
Customizing
our offer
 From simulation studies
in design phase
 To specific alloy &
conversion developments
Providing
solutions
 For better integration
with other materials
 For better manufacturing
efficiency of OEMs
Pushing the limits
of aluminium
 Ultra High Strength
 Ultra High Formability
 More Crash properties
 Higher Stiffness
Metallurgy, corrosion,
Surface treatment
Expertise
Joining, Welding
Studies
Characterization, Simulation,
Prototyping, Design, CAD Tools
Bringing aluminium in the car body design to support lightweighting 2516.03.2016

26. Our technical development offer
C-TEC: Constellium technology center Network of international
collaborations
Prototyping and 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
and simulation
Design and forming feasibility
simulation
 Support for alloy choice
 Specific design studies for OEMs
 FEM modeling
Formability and 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
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27. Virtual design and simulation
Component crash & correlation
Full vehicle crash & correlation
CMS design
Requirements, objectives, innovation strategy
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
Mit freundlicher Genehmigung: BMW AG
NEW DEVELOPMENTS
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28. Automotive extrusion based components
alloy and 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
366MPa
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
Bringing aluminium in the car body design to support lightweighting 2816.03.2016

29. THANK YOU FOR YOUR
ATTENTION!