aluminium use in architectural industry
DESCRIPTION
Brief history of Aluminium and the process before it is converted to Architectural use.TRANSCRIPT
Reynaers AluminiumWE BRING ALUMINIUM TO LIFE
31 mei 20111Els Fonteyne
Reynaers gives added value to aluminium
Long lifespan in buildingSustainable Long lifespan in buildingLarge designfreedom by extrusionConstruction possibilities / transportStrength by design
Sustainable Low melting temperature
Light metalStrength by alloys Strength by design
Insulation of profilesLow maintenance
Strength by alloysElectrical conductivity
No corrosion / coating possibilities
31 mei 20112
Contents
Introduction
Production of aluminiumProduction of aluminium
Recycling of aluminium
Properties of aluminium
Aluminium alloysAluminium alloys
Processing techniques for aluminium
Extruded aluminium profiles
Reynaers’ systemsReynaers systems
31 mei 20113
Introduction
Old material / new material?Basic material alum
Discovery of aluminium
Discovery of the metal aluminium: 1825-1888
Production starts to increase:
World production in 1900: 6700 tonnes
World production in 2006: more than 35 million tonnes (source: EAA)World production in 2006: more than 35 million tonnes (source: EAA)
31 mei 20114
Production of aluminium
Starting material: Bauxite: Ore with a high aluminium oxide content
Production of aluminium: 2 stepsChemical process: Winning of aluminium oxide
Electrolytic process: Production of aluminium
31 mei 20115
Production of aluminium
Chemical process: Winning of aluminium oxide
Electrolytic process: Production of aluminium
31 mei 201164 ton bauxite
2 ton alumina
0.5 ton electrolyte
20-15000 kW/h = 50% production cost
1 ton aluminium
Recycling of aluminium
Recycling of aluminium saves 95% of energy needed for primary production
⇒ Closed recycling loop Al i E t i PA⇒ Closed recycling loop
%)
90100
Alumina Billets
Extrusion
Isolation
PA Extrusion
y re
quire
d (%
405060708090
primary
ecyc
led
5%Recyclage
Ene
rgy
Various applications010203040 re
use
Surface treatement
FabricationVarious applications
31 mei 20117
Properties of aluminiumGeneral
Atomic number: 13
Light: Density = 2702 kg/m³ (= 1/3 of steel)Light: Density 2702 kg/m ( 1/3 of steel)
StrengthUnalloyed aluminium: No high strength
Addition of relatively small percentages of other metals: Alloys with strength significantly higher th th t f l t t l t lthan that of normal structural steel
Rigidity: Modulus of elasticity = 7200 kg/mm² (= 1/3 of steel)
Elasticity (3x steel)
Cond cts electricit and heatConducts electricity and heat
Low melting temperature: 660°CVery easily worked, hence large number of forming techniques
Easily recycled
Corrosion resistance: Stable in air due to thin and closed oxide skin
Non-magnetic
Low coefficient of thermal expansion: 1.19 mm per m with 50° temperature difference
31 mei 20118
p p p
Aluminium alloys
Alloys to improve: Mechanical properties
Castability
31 mei 20119
Aluminium alloysAddition of other elements
31 mei 201110
Aluminium alloysTypes of alloy
1000 Al
2000 Al + Cu
3000 Al + Mn
4000 Al + Si
5000 Al + Mg
6000 Al + Mg + Si g
7000 Al + Mg + Zn
31 mei 201111
Aluminium alloysReynaers alloy
Silicon: Increases tensile strength
DIN 6060 Reynaers
Si 0 30 0 60 % 0 30 0 55 %
Improves castability and corrosion resistance
Copper: Increases tensile strength and hardness
All i h d bl Si 0.30 – 0.60 % 0.30 – 0.55 %
Fe 0.10 – 0.30 % 0.10 – 0.30 %
Cu 0.1 % 0.02 %
Mn 0.1% 0.1 %
Alloy is hardenable
Corrosion resistance decreases slightly
Electrical conductivity increases
Manganese:
Mg 0.35 – 0.60 % 0.35 – 0.60 %
Cr 0.05 % 0.05 %
Zn 0.15 % 0.15 %
Improves corrosion resistance
Thermal and electrical conductivity decrease slightly
MagnesiumIncreases tensile strength and hardness Ti 0.1 % 0.1 %
Other single 0.05 % 0.05 %
Other total 0.15 % 0.15 %
Increases tensile strength and hardness
Thermal and electrical conductivity decrease slightly
→ Avoidance of filiform corrosion: Pickling 2 gr/m² before painting remains most important
31 mei 201112
Avoidance of filiform corrosion: Pickling 2 gr/m before painting remains most important
Processing techniques for aluminium
Rolling
SpinningSpinning
Bending
Bending and setting
Deep drawingDeep drawing
Roll forming
Cold extrusion
ForgingForging
Superplastic forming
Hydroforming
CastingCasting
Friction Stir Welding
Machining
Extrusion
31 mei 201113
Extrusion
Processing techniques for aluminium
Rolling
SpinningSpinning
Bending
31 mei 201114
Processing techniques for aluminium
Bending and setting
Deep drawing
Roll forming
31 mei 201115
Processing techniques for aluminium
Cold extrusion
Forging
Superplastic formingSuperplastic forming
31 mei 201116
Processing techniques for aluminium
Hydroforming
Casting
Friction stir weldingFriction stir welding
31 mei 201117
Extruded aluminium profiles
1) Preheating of billet to +/- 450°C (melting at 600°C)
2) Extrusion of billet through die under high pressure (40 to 70 kg/mm²)
3) Rapid cooling of profile at 1°C/sec
4) Straightening of profile at room temperature
5) Sawing to the desired length
6) Hardening/ageing: 6 to 15 hours at 150°-200°
31 mei 201118
Extruded aluminium profiles
31 mei 201119
Extruded aluminium profiles
31 mei 201120
Extruded aluminium profilesInsulation process
31 mei 201121
Extruded aluminium profiles
2 processes:
P d i d l kk
Surface treatement
- Powder coatingoederlakken
- Anodisation
1.
2.
33.
31 mei 201122
Reynaers’ systems
AdvantagesAdvantages
Long lifespan (30-40 year)
Large glass surfaces with slim profiles
Low maintenance
31 mei 201123
Low maintenance
Insulation levels: large choice depending on location and orientation
Reynaers’ systems
Problem: Global warming due to greenhouse gasesG h itt d b b i f lGreenhouse gases are emitted by burning fuels 40% of CO2 production in Europe is emitted from buildings: heating and
use of equipment
⇒ Solution with Reynaers’ systems = development of sustainable systems which contribute to sustainable buildings
31 mei 201124
Reynaers’ systems
⇒ Reduce energy losses through building
Reducing heat loss by insulation
Reducing heat loss by air tightness of building⇒ ventilation required
Heat gain by use of passive solar energy
G l t d f l b ildi
31 mei 201125
⇒ General trend for low energy building⇒ High insulation windows required: Uw < 1.5 W/m²K
Reynaers’ systems
⇒ Reynaers’ high insulation systems
CS 86 HI: av. Uf 1.5 W/m²K
CS 104: av. Uf 1.0 W/m²K
Passiv Haus
CP 155 HI-Minergie: av. Uf 2 W/m²K
CW 50 HI: av. Uf 0.9W/m²K
31 mei 201126
Reynaers’ systems
⇒ Reynaers’ green energy systems
CW 60 solar: BIPV
BS solar
BS 100: sun shading
31 mei 201127
⇒ Large glass surfaces for passive heating of buildings
Reynaers’ systems
⇒ Reynaconnect: solution for building connections
Airtight
Acoustic insulation
Simple Installation
Thermal insulation
Acoustic insulation
Watertight
Damp regulation
31 mei 201128