extruded aluminium alloys and their...
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E. Hoch Hannover Messe, 12.04.2013 1
Extruded aluminium alloys and their applications
Picture: FWB
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Content
Company FWB
Aluminum market
Application examples in industry
Outlook and Future
Aluminium alloys, Extrusion and machining
Typical applications in the automotive
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Divisions
Automotive 50 %Construction 25 %Industry 25 %
Who is F.W. Brökelmann ?
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E. Hoch Hannover Messe, 12.04.2013
Process chain
FWB as a system supplier for complex products
Engineering• products
• materials
• processes
Prototyping• In-House
• as GU
Extrusion• Semis
• cut
• autom. cut
Processing• mech. proc.
• transform
• surface
Assembly• components
• modules
• systems
4
Who is F.W. Brökelmann ?
Ense Dortmund Opole / PL
Production network
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EUROPEAN MARKET FOR EXTRUDED PRODUCTS? DELIVERY VOLUME BY COUNTRY
Source: EAA, GDA
European deliveries in tons EU27: 2.771.325 tons
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EUROPEAN DELIVERIES OF EXTRUDED PRODUCTS DELIVERIES BY CONSUMER GROUPS
Source: EAA, GDA
EU27in Tonnen
5165
58
3205
67 137517
1159
753
146689
3950
72
95169
Transport Maschinenbau Elektrotechnik BauwesenHaus- & Büroausstattung Händler andereTransportation MerchantHome and Office EquipmentConstructionElectricalEngineering Other
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E. Hoch Hannover Messe, 12.04.2013
ALUMINIUM – ALLOY - TYPES
natural hard alloys
curablealloys
Zn
Mg
Cu
Mn
Fe
SiAlFe(Si)
AlMn
AlMg(Mn)
AlMgSi(Cu)
AlCuMg
AlZnMg(Cu)
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Al - Alloys
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ALLOY – STRENGTH - APPLICATION
Construction Industrie, Fittings, Moldings, Automotive, mech. Engineering
Vehicle constuction; Roads,
railways; water
Engineering, Defense
Aerospace; Defense
700
600
500
400
300
200
150
Rm
AlMgSi
AlMgSi, AlZnMg,AlMg(Mn)
AlCuMg
AlZnMgCu
Al - Alloys
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Production of aluminum extrusions
A single series of dependent steps
Casting
Homogenization
Billet heating
Extrusion
Cooling
Aging
Aluminum smelteror
smelting and refining
Mastery of the process chain
Processing
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Aluminium Extrusionpresses
Aluminium Billets
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Quelle: Ames, Strangpressen
Building a Extrusionpresses with toolkit
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Materialflow in the Container
Quelle: Ames, Strangpressen
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A selection of aluminum - extruded profiles
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Machining of extruded profiles
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5-axis machining center
5-axis CNC – BAZ Chiron Mill 2000
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7-axis CNC stretch bending
BENDING TECHNOLOGY
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BENDING TECHNOLOGY
roll bending
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Flexbending
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BENDING TECHNOLOGY
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Press bending
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BENDING TECHNOLOGY
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- Polishing- Gloss anodizing- Anodizing- Painting- Powder coating- KTL coating
Surface finishing
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Construction Profiles
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Examples use aluminum industry
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Alloy EN AW- 6060
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Examples use aluminum industry
Quelle:
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Alloy EN AW - 6082
Picture: Fa. PERI
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Examples use aluminum industry
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Alloy EN AW - 6060 / 6063
Picture Koralle
Picture Miele
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Examples use aluminum industry
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Picture Schaeffler INA
Examples use aluminum industry
Linear Guides
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E. Hoch Hannover Messe, 12.04.2013
Picture Rittal
Picture Loewe
Alloy EN AW - 6060
26
Examples use aluminum industry
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Bicycle rim
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Examples use aluminum industry
Heald frame profile
Alloy EN AW - 6060
Alloy EN AW – 6063 and 6082
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BACKREST PROFILE
Airbus (u.a. A380)
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Alloy EN AW - 6082
Examples use aluminum industry
Picture Recaro Aircraft
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Pisten – Raupen Stege
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Examples use aluminum industry
Alloy EN AW - 6082 / EN AW- 7020
Picture Prinot Leitner
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Manual wheelchairs
Alloy EN AW – 7020 and 6082
Examples use aluminum industry
SCOOTER
REHA + CARE
Power wheelchairs
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Heat Exchanger Systems Alloy: EN AW 3003 / 3103
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Examples use aluminum industry
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Examples use aluminum industry
Heatsinks for high-speed Rotors
Alloy EN AW - 6060
Picture FWB
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Requirement Al-Profil for a 50-MW-Solarpowerstation:
15 Vol-% von 20.000 to NaNO3-Solution
=> 15% von 10.000 m³ => 1.500 m³
=> 4.000 to Aluminiumprofils
33
Examples use aluminum industry
Latent heat storage for solar power stations (DLR)
Alloy: EN AW 3003 / 3103
Picture FWB
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1,5 m Length
20 Bends
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Aluminum Examples use automotiv industry
Heat and coolingsystem for gear Alloy: EN AW 3003 / 3103
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Pictures: Alcan/Audi
Why Aluminium in Automotiv?
Motivation for the use of aluminum
Wight reduction
Crash requirements
Improvedperformenc
Increased economy
Full Reciceling
Emissionreduction
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Si Fe Cu Mn Mg Cr Zn Ti VSonstig
eEinzeln
Sonstige
GesamtAI
Requirements ≤ 1,30 ≤ 0,4 ≤ 0,30 ≤ 1,00 ≤ 0,9 ≤ 0,30 ≤ 0,50 ≤ 0,25 ≤ 0,25 ≤ 0,05 ≤ 0,15 Rest
Tolranzbereich Duktal®
0,68-
0,77
0,16-
0,24
0,2-
0,25
0,68-
0,77
0,58-
0,67
< 0,04 < 0,01 < 0,01 < 0,04 0,05 0,15 Rest
Materialspecification: AA 6XXX, Alloyssystem AlMgSi
Chemical composition (to Mass- %, according to DIN EN 573-3) maximum values
EN AW-6060 EN AW-6063 EN EN AW-6082
AlMgSi 0,3 – 0,6 AlMgSi 0,5 – 0,7 AlMgSi 0,7 – 1,3
Requirements of automotive manufacturers
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• Body structure's profile
• sunroof components
• Door frame profiles
• Suspension Components
• Profiles for cooling and air conditioning
• airbag housing
• Steering system profiles
• Charging System Profiles
• trim
• Seat guide rail
• Cartridges cover blinds
37
Automotive - Examples
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WIND DEFLECTOR PROFILE
VW Eos, Porsche 911, Audi A3, A4, A5
38
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Automotive - Examples
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Roof frame profile
Automotive - Examples
Alloy EN AW - 6401
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E. Hoch Hannover Messe, 12.04.2013
Daimler
SLS
AUDI R8
Referenzen
Artega GT
40
Automotive - Examples
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Increase the strength requirementsof aluminum profiles for body structure components
1994 - 2004
Rp0,2
200 – 240 [MPa]
2005 - 2008 2008 - 2010
Rp0,2
230 – 280 [MPa]
Rp0,2
281 – 310 [MPa]
N + C
N + CN + C
+
+
Rp0,2
320 – 330 [Mpa]
ab 2010
N + C +
Development of body components during
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CrashfähigkeitQuasi-static compression testing of aluminum components in the axial direction
Requirements of automotive manufacturers
Part o.k. Part not o.k.
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Upsetting behavior: compression samples after short-term thermal stability test
o.k. o.k.
3 - Chamber hollow profile 4 - Chamber hollow profile
Requirements of automotive manufacturers
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Examples range
Mercedes SLS
F360 Modena
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Original Design (Steel) Aluminium Conzept
Krafteinleitung Steifigkeitssteigerung
Lastfall 1 +87%
Lastfall 2 +75%
Lastfall 3 +46%
Modalanalyse Frequenzerhöhung
Mode 1 +56%
Mode 2 +56%
Mode 3 +63%
Mode 4 +62%
Mode 5 +52%
Mode 6 +52%
Mode 7 +51%
Mode 8 +37%
Mode 9 +41%
Mode 10 +15%
Gewicht -52%
Example Frondend
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Aluminum use in the future ! ?
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Future
The right material at the right place !!!
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E. Hoch Hannover Messe, 12.04.2013
Soure: www.auto-motor-sport.de
Development projects in the area of commercial vehicles
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Future
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Future Electromobilität
BMW i8
Renault Zoe
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Future
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For more Information from FWB:
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Thank you for your attention