Constellium introduces its new PAVIM lightweight extrusion technology and streamlined CNC-machining capabilities at Inno

Constellium N.V. announced today at InnoTrans 2014 its new streamlined CNC-machining capability for producing customized parts ready for assembly. The Company will feature an interactive cross-section model composed of its PAVIM structural extrusions based on the Warsaw Metro’s body shell, and will present its broad portfolio of light-weight materials and sustainable engineering solutions.

Constellium is continuously focused on optimized alloys, die design, process and extrusion technologies to further reduce weight for the next generation of supplies to the global railway markets. A step-change in extrusion linear weight has been achieved with the newly developed and innovative extrusion product family PAVIM, allowing production of large structural extrusions with thin inner-webs, ensuring constant structure stiffness and material properties. The new PAVIM structural extrusions will be on display for the first time at Innotrans 2014 through a full-scale cross-section model.

CNC-machining streamlines the production of finished and semi-finished components and extrusions, offering reduced lead time, optimized inventory, and improved quality. “Our new CNC capability significantly reduces costs for customers by enabling them to buy finished or semi-finished components as well as fabricated extrusions without having to involve additional suppliers,” said Patrick Wahl, Constellium, Rail&Bus Extrusions, Segment Manager Components. “We can now provide aluminium extrusions as well as in-house produced parts ready for assembly to our customers.”

Constellium’s highlights at the fair include:

•PAVIM structural extrusions: The light-weighting capabilities of PAVIM structural extrusions are immediately beneficial for structures such as railcars, for which reducing life cycle cost and greenhouse gas emissions are of uttermost concern. This innovative product family distinguishes itself by displaying inner-web thicknesses down to 1.50 mm on profiles extruded with standard structural alloys according to EN 13981-1.

•Light-weight design cross-section model: Constellium’s booth at Innotrans 2014 will feature a 1.5m long 1:1 model of Warsaw Metro’s body shell cross-section. This new technology and lightweight design offers significant weight saving benefits through the combination of classical large structural aluminium extrusions and PAVIM structural extrusions as main structural elements.

• Structural and non-structural components: Constellium’s technological leadership is particularly visible in its new in-house CNC-machining capability, targeting a broader customer base as demand shifts from semi-products to parts ready for assembly. The 5-axis CNC-machine is capable of producing competitive customized parts up to 21m length. In-house CNC-machining complements Constellium’s portfolio of completely welded, bent and machined sub-assemblies such as structural pillars, floors, roofs, side walls as well as interior floors for all types of rail vehicles.

• Co-extruded conductor rails: The co-extruded conductor rails supply electrical power from substations to train vehicles. The Company has developed a co-extruded aluminium/stainless steel power rail – a unique and first-of-its-kind technology for this type of application – offering a range of increased customer benefits.

Constellium’s booth, located in hall 8.2, stand 203, will showcase its leading light weight solutions that address customer business challenges in a cost-efficient and innovative way.

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