Aluminum Extrusions From Start to Finish Presentation to MARTS – October 1, 2013
Presented by Randy Thomure Sapa Extrusions Roberto Mocchi – February 08
Why Aluminium? • • • • • • • • •
Light Strong Good corrosion properties Very good conductor High reflectivity Non magnetic Non toxic Formability Machinability
Advantages Of Aluminum Extrusions
Welded
Extruded
Crimped
Fastened
Extruded
Cast
Extruded
Extruded
Joined
Cast
Extruded
Extruded
Machined
Roll Formed
Aluminum Association
• Aluminum extrusions are utilized by customers to save final assembly time and reduce fabrication costs
Extruded
Extruded
How Extrusions are Produced
Dies – Solid & Hollows
Die Types
Extrusion Dies
Solid or Flat-Face Dies
Solid Die
Hollow Die
Hollow Die
Bearing Surfaces
Control material flow
Die Stack
Billets/Logs
Billet Sizes 13.75” 9”
2.5” (TDA)
35” 214.5 lbs
6.49 lbs 6”
27”
10”
48.4”
73.3 lbs 371 lbs 7”
30”
21” (Cressona)
114 lbs 8”
33” 157.7 lbs
60” Over 2000 lbs
Billet Process Efficiency Buttend Scrap ~4%
Hot Shear Scrap ~1%
One billet = gross weight
Stretcher ~11%
75% of billet will be customer length
4.5% Downstream scrap handling, fabrication, cutback, start ups
4.5% Extra process scrap pressline, start-ups, die trials, blisters, scratches
Extrusions Process
Process Flow
Pre-Extrusion • Billet Casting • Homogenization • Billet Prep & Inspection
Press Operations • Billet Reheat • Die to the Press • Extrude • Quench • Stretch • Saw Cut-toLength • Extrusion Inspection
Post Extrusion • Age • Testing • Fabrication • Pack • Ship
Die Furnace
Portland, OR
Extrusion Billet Heating
Gas Heating Furnace
Direct Extrusion
Most common type extrusion press.
Die is stationery
Ram presses the billet through container
Metal flows through die opening.
Can produce larger extrusions Extrusion Ram
Billet Die
The Direct Extrusion Press
Butt shear
front platen tie rods
Press Operation
Billet Change
Portland, OR
Heat Distribution 620°C
1150°F
350°C
660°F
Extrusion Puller
Guides extrusion out of press – Pulls through quench process – Maintains tension on extrusion – Improved straightness – Improved twist
Extrusion
Portland, OR
Quench Process
Quench (rapidly cool) – Air – Water – Spray Quench
Quench methods depend on – Alloy – Temper – Profile geometry Critical step in press heat treatment process to retaining hardening elements in solid solution (T1, T4)
Optimized Cooling - Air
Optimized Cooling - Water
Hot Saw
Connersville, IN
Stretching
Straightens the profile
Stress Relieves the profile
Stretching
Portland, OR
Finish Sawing
Process Scrap
Recycled to form new logs
Extrusion butts
Front & rear scrap from full extruded length
Artificial Aging
Most alloys are age hardened to optimize properties – T5 & T6 Tempers
Can Also anneal – fully soften – O Temper
Exterior Packaging Protection
Exterior protection during transit and handling – Paper – Cardboard – Plastic – Stretch wrap – Wood
Interior Packaging Protection
Separating profiles to protect critical surfaces
Interleaving, individual wrap, separate by layers
Paper, foam, plastic, chipboard, cardboard
Logs to Extrusion
Aluminum in Transportation
Commercial Transportation Market Drivers Desire for productivity to gain share when market returns Pressure to lower manufacturing costs Struggle to reduce inventory and WIP Fuel volatility driving lighter weight Need for increased payloads
Freight
Sapa Solutions Aligned with Market 3rd
Rail
Bus/Van
Design solution resources Expanded fabrication capabilities Wide multi-void panels Friction stir welding CVM expertise
Marine
Passenger/Transit
Aluminum Coal Cars
Extrusions including Top Chords, Side Sills and Side & End Posts
Pre-Drill and Cut to Length, if requested
Mass Transit Sapa’s leading edge technology serves virtually every brand across North America and around the world with an extensive range of components and systems. Application engineering, design, and manufacturing services: • Extrusion, fabrication and finishing • Friction Stir Welding • Energy absorption technology
Transit Car Assemblies
Double Sided, Hollow Sections
Friction Stir Welded Both Sides
Delivered Ready to Install
Sapa Profile Academy Sapa Profile Academy
Customer Education
15 subjects – Comprehensive course agenda covering all subjects of aluminum extrusion and fabrication taught by experts from Sapa and the aluminum industry
4 manufacturing tours – Extrusion, Fabrication, Coatings, Die Manufacturing
Design Workshop – Sapa experts help customers develop their own products using aluminum extrusion
Sapa presentation updated March 2011
Questions?
Randy Thomure Sapa Extrusions
[email protected] 815-412-0542
Shaping the future
Sapa is environmentally conscious with regenerative equipment and reduced solvent and waste components. Sapa products meet or exceed AAMA specifications.
