Why Quality Matters for Constellium – and Its Automotive Body Sheet Customers

Quality is a core value at Constellium and a critical expectation for our automotive customers. We must ensure that every product we deliver is safe, reliable, and high-performing, especially when produced at industrial scale and destined for vehicle end users.

Just two decades ago, aluminum was rarely used in cars. But today, OEMs are under increasing pressure to comply with evolving environmental regulations and reduce vehicle weight while maintaining or improving performance. Aluminum is the ideal solution: it’s lightweight, strong, corrosion-resistant, and allows for creative, aerodynamic design.

In the automotive sector, certain parts – such as crash-resistant structures – are classified as safety-critical components. For these, we archive full production documentation for up to 30 years to guarantee traceability and compliance.

Constellium has developed strong expertise in this space, working closely with virtually every major OEM worldwide. Our role is to help them select the most sustainable and technically suitable aluminum solution for their application, whether it’s for inner body parts, outer panels, or structural components.

We work hand-in-hand with our two R&D centers, one in Europe and one in the U.S., to support this process with cutting-edge science and innovation.

How Do We Guarantee That Every Coil Meets Customer Specifications?

Quality Starts with Product Development

Before production even begins, quality is already at the core of the process. When a customer submits a new request, we analyze their needs and propose the most suitable material and design based on performance, safety, and sustainability criteria.

Our R&D centers can run detailed simulations to predict material behavior under real conditions and confirm that the chosen alloy meets all mechanical and structural requirements.

Once the solution is validated, we move into the industrialization phase. Here, we apply a methodology called FMEA (Failure Modes and Effects Analysis) to evaluate every potential risk along the production line. This helps us:

• Identify Key Quality Characteristics (KQC)
• Link them to Key Process Parameters (KPP)
• Define preventive measures to avoid defects

Quality in Production

KQCs and KPPs identified during development are formalized in a Control Plan, which outlines the rules and responsibilities for everyone involved in the manufacturing process – not just the Quality team, but also Production, Process Engineering, and Maintenance.

All of Constellium’s automotive sites are certified to the latest international standards, including IATF 16949, a global benchmark for automotive quality management systems.

Step-by-Step: Quality at Every Stage

1. Casting

It all starts with chemical composition – the “recipe” that defines the alloy. We select aluminum-compatible scrap for melting and conduct tests to verify the composition.

A technician takes a sample of molten aluminum at over 700°C, molds it, cools it, and sends it to the lab for analysis.

[Insert video of molten aluminum sampling]

2. Rolling

Hot and cold rolling is where the metal reaches its final mechanical properties. Our mills are equipped with real-time sensors to monitor quality continuously, ensuring precise thickness and thermal treatment.

The final cold rolling stage sets the coil's exact thickness, which is continuously measured and adjusted by automated systems.

3. Finishing

The strip is cleaned, treated thermally and chemically, and visually inspected. Surface flatness and cleanliness are verified using high-precision laser and camera systems.

Each coil is only released once it passes all quality checks.

Did you know?
We’ve created “Quality Schools” within our sites – dedicated training spaces where employees can interact with real product samples to better understand quality standards and expectations.

Before any coil leaves our plant, it must be certified by our lab. A final sample is taken and tested for mechanical properties. Only then is it packed and cleared for delivery.

And After Production?

Quality doesn’t stop at the shipping dock.

Consistency throughout the year is crucial: whether a coil is made in March or November, its performance must be identical. Our Control Plan includes daily, weekly, and annual checks to ensure repeatability and compliance.

We also conduct annual internal audits to verify product integrity and ensure continuous improvement. Real-time monitoring of KQCs allows us to quickly detect and address deviations, reinforcing our path to operational excellence.

Conclusion

Quality starts at the very beginning of a project, continues through every production step, and extends into the product’s life in the field. It’s a team effort, requiring close collaboration between our customers and every Constellium department.

Our commitment to quality has been recognized by customers across the industry. In 2022, for example, Toyota awarded us a “Certificate of Recognition”, a proud moment that reflects the trust placed in our products and people.