Car Body Closures

Car Body Closures

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Constellium has developed a full range of automotive body sheet solutions for closure inners and outers.

Surfalex®

Thanks to its roping and hemming performance, the Surfalex® family is particularly well-suited to the outers of hoods, doors, and trunks, as well as fenders and roofs.

  • Surfalex® HF, our newest development, is an extremely formable version of Surfalex® adapted to deep-stamped visible inners like side panels.
  • Surfalex® HS retains all the surface qualities of Surfalex® but with higher strength.

 

Constellium is the primary supplier of automotive body sheets for the closures and inner parts of the Fiat Chrysler Automotive Group’s showcase SUV, the new Alfa Romeo Stelvio. We provide Surfalex® for the hood outer and the tailgate outer upper and lower, since its high surface quality and hemming and roping properties are particularly well-suited to the Stelvio’s design. And because our high performing 5182 alloy provides the required strength and formability for complex inner parts, the Stelvio uses it for the hood inner, front and rear door inner, and tailgate inner.

 

 

Formalex®

The Formalex® family answers the needs of deep-stamped complex, parts such as door inners.

  • Formalex® REMOTE is a uni-alloy with good formability and mechanical resistance, designed to be weldable without filler wire.
  • Formalex® PLUS has been designed to optimize work hardening, isotropy, and elongation, which all enhance formability.

 

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Automotive Body-in-White

Body in White

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Crash Management Systems

Crash Management Systems (CMS)

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For automakers, enhancing the safety of drivers, passengers, and pedestrians is a top priority.  Constellium’s superior design capabilities mean we can offer the most innovative Crash Management Systems to our customers. Aluminium is the ideal material for CMS components thanks to its superior energy absorption and crash behavior.

The CMS improves vehicle safety in the event of a collision, protecting not only the occupants, but the vehicle itself, which helps to minimize the cost of repairs.

Crash Management Systems are located in the front and rear of an automobile. They feature one (or two) aluminium bumper beams and two (or four) crash boxes.

Thanks to our new Constellium HSA6TM family of high-strength 6xxx alloys, we can reduce the bumper’s weight by 15-30% compared to traditional aluminium solutions. At the same time, our solutions provide high levels of formability, corrosion resistance and recyclability.

Constellium also provides safety components such as radiator supports and U-struts.

Crash can for Design for crash banner

 

Constellium supplies aluminium Crash Management Systems and Automotive Body Sheets for the new PEUGEOT 3008.

Constellium supplies the aluminium front Crash Management System for the vehicle, including a lower beam for enhanced pedestrian safety, and also provides aluminium coils and sheets for the inner and outer hood panels and for the fenders.

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BAttery enclosures

Battery Enclosures

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Constellium specializes in designing and producing battery enclosures that meet automakers’ goals for performance and cost.

Providing Lightweight Protection

Battery enclosure assemblies safeguard the batteries in electric and hybrid vehicles from puncture or intrusion, thereby protecting passengers and others, as well as the environment, from potentially hazardous conditions. Structural battery enclosures must meet lightweight targets to achieve overall vehicle dynamics.

Advanced Aluminium Solutions

We supply complete battery enclosure assemblies for Plug-in Hybrid Electric Vehicles and Battery Electric Vehicles. These are designed, rapidly prototyped, and produced from superior aluminium alloys. Our aluminum battery enclosures are engineered to resist crash and intrusion and to cool individual modules using innovative materials, design and joining technologies.

  • Feature superior materials such as high-strength Constellium HSA6TM and crushable Constellium HCA6TM, as well as our 3xxx, 5xxx and 6xxx alloy sheets.
  • Can integrate CALD Solutions, Constellium’s integrated cooling structures, to manage temperature and optimize battery life and performance
  • Offer the latest joining technologies, such as Friction Stir Welding, adhesive bonding and self-piercing rivets
  • Provide full structural integration

 

 

 

 

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Chassis and Mechanical Parts

Chassis and Mechanical Parts

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Constellium supplies customized profiles, tubes, and bars for chassis and mechanical parts, including:

  • Anti-lock braking system (ABS) housings
  • Anti-vibration systems
  • Shock absorbers
  • Other custom vehicle components

We design cut-to-length extrusions to meet the performance requirements of individual customers in terms of strength, precision tolerance, fatigue, and laser marking.

Constellium’s Děčín plant in the Czech Republic is the largest integrated hard alloy facility in Europe. In May 2017, the plant signed a multi-year contract with Robert Bosch to supply Anti-lock Braking System (ABS) profiles for the automotive industry. We will supply additional long-term solutions to Bosch plants worldwide and expect the overall volume at the Děčín plant to double, subject to market demand.

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Heat Exchangers

Heat Exchangers

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With extensive expertise in thermal applications, Constellium is one of Europe’s leading suppliers of aluminium rolled products for heat exchangers (engine cooling and climate-control systems).

Original equipment manufacturers increasingly use high-performance aluminium alloys for thermal management. In addition to being cost-effective and efficient to produce, rolled aluminium products are ideal for thermal transfer applications.

We have designed aluminium alloys for the following applications:

  • Tubestock for radiators, charge air coolers, condensers, and heater cores
  • Plates for evaporators, water charge air coolers, and oil coolers
  • Headers and side plates for any brazing application

Our new Kool X™ solution is ideal for demanding heat exchanger applications, such as water charge air coolers (WCACs) and evaporators. It provides excellent brazability and resistance to fatigue and corrosion.

Download our brochure 'Constellium's Aluminium Solutions for Heat Exchangers'

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Decorative Parts and Equipment

Decorative Parts and Equipment

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Constellium is a global leader in the production and supply of aluminium functional-surface products that are increasingly used in automotive decorative display. Our bright or structured surfaces meet the high surface quality and shine required for inner and outer automotive applications.

Our range of aluminium rolled products includes various surface finishes that contribute to interior and exterior decoration for inner and outer parts, including doors, cockpit, center console, still plates, nameplates, pedals, speaker grille, buttons, window trims and hood ornaments.

  • Staybright™

Staybright™ is a long-lasting, brilliant aluminium product used in exterior decorative trims for cars. With Staybright, cars can be washed repeatedly with high pH products without losing their trim brilliance and if anodized, require no additional layer of coating.

Download our brochure 'Constellium Automotive Decorative Surfaces'

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Aluminium Powders for Additive Manufacturing

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Consistent performance under challenging operating conditions is critical for motor sport components. Keeping this in mind, Constellium has developed novel additive manufacturing aluminium alloys, specifically designed for powder bed AM. The products are not blends or composite materials, and the absence of critical raw materials makes these alloys a sustainable choice for rapid prototyping, small series production and future scale-up.

Aheadd® HT1

Aheadd® HT1 is the most suitable additive manufacturing alloy for applications which need high strength and service temperatures up to around 250°C. The high thermal stability of Aheadd® HT1 makes it as an ideal choice to replace selected titanium or steel AM applications to reduce the component weight and cost. The higher thermal conductivity of aluminium over titanium may bring additional advantages.

Aheadd® CP1

Aheadd® CP1 is an additive manufacturing alloy packed with many features. High strength & ductility, excellent surface finishing characteristics, thermal and electrical conductivity approaching that of pure aluminium, very high printing speed and simplified post-processing make Aheadd® CP1 the solution of choice for wide range of aluminium AM applications. Aluminium AM heat exchangers are ideally suited to Aheadd® CP1.

For both alloys, component properties can be adjusted by tuning the post-build stress-relief treatment. This simplifies post-processing by eliminating the need to solution treat, quench and age, and also minimizes the risk of distortion of printed components during post processing.

Targeted Market, Application & Value drivers

Motorsport / Automotive

 

 

Target Segment 

Aheadd® HT1

Aheadd® CP1

Application areas

Values

Application areas

Values

Motorsports

→ Cars

→ Motorbikes

→ Acrobatics

 

Engine and structure manufacturers

 

Extreme-performance cars

 

High ends cars

• Engine components  with service temperatures above 150°C, replacing selected titanium AM applications.

 

• Complex structural components

• High strength at low and elevated temperatures;

 

• High thermal stability;

 

• Good corrosion resistance;

 

• Robust AM process window with good productivity;

 

• Geometric control: simplified post-processing with no quench requirement.

• Heat exchangers with complex geometries (including service temperatures above 150°C);

 

• Components or housings which need good thermal or electrical conductivity e.g. in hybrid/electric vehicles;

 

• Rapid Prototyping;

 

• Components for wind tunnel testing;

 

• Large & complex components;

 

• Visible parts (aesthetics);

 

• Cost-effective improvement of existing aluminium AM solutions in Al-Si alloys/

• High thermal stability;

 

• High thermal and electrical conductivity;

 

• High strength and ductility;

 

• Ability to print highly complex & large parts without cracking;

 

• Geometric control: low residual stresses, simplified post-processing with no quench requirement;

 

• Excellent surface finishing capabilities (polishing/anodizing);

 

• Cost reduction: high printing productivity and reduced need for support structures (no quench).

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