Aluminum Extrusions From Start to Finish

Transcription

1 Aluminum Extrusions From Start to Finish Presentation to MARTS October 1, 2013 Presented by Randy Thomure Sapa Extrusions Roberto Mocchi February 08

2 Why Aluminium? Light Strong Good corrosion properties Very good conductor High reflectivity Non magnetic Non toxic Formability Machinability

3 Advantages Of Aluminum Extrusions Welded Extruded Crimped Extruded Joined Extruded Machined Extruded Fastened Extruded Cast Extruded Cast Extruded Roll Formed Extruded Aluminum Association Aluminum extrusions are utilized by customers to save final assembly time and reduce fabrication costs

4 How Extrusions are Produced

5 Dies Solid & Hollows

6 Die Types

7 Extrusion Dies Solid or Flat-Face Dies

8 Solid Die

9 Hollow Die

10 Hollow Die

11 Bearing Surfaces Control material flow

12 Die Stack

13 Billets/Logs

14 Billet Sizes 2.5 (TDA) lbs lbs lbs (Cressona) 371 lbs 114 lbs lbs 60 Over 2000 lbs

15 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

16 Extrusions Process

17 Process Flow Pre-Extrusion Billet Casting Homogenization Billet Prep & Inspection Press Operations Billet Reheat Die to the Press Extrude Quench Stretch Saw Cut-to- Length Extrusion Inspection Post Extrusion Age Testing Fabrication Pack Ship

18 Die Furnace Portland, OR

19 Extrusion Billet Heating Gas Heating Furnace

20 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 Die Billet

21 The Direct Extrusion Press Butt shear front platen tie rods

22 Press Operation

23 Billet Change Portland, OR

24 Heat Distribution 620 C 1150 F 350 C 660 F

25 Extrusion Puller Guides extrusion out of press Pulls through quench process Maintains tension on extrusion Improved straightness Improved twist

26 Extrusion Portland, OR

27 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)

28 Optimized Cooling -Air

29 Optimized Cooling -Water

30 Hot Saw Connersville, IN

31 Stretching Straightens the profile Stress Relieves the profile

32 Stretching Portland, OR

33 Finish Sawing

34 Process Scrap Recycled to form new logs Extrusion butts Front & rear scrap from full extruded length

35 Artificial Aging Most alloys are age hardened to optimize properties T5 & T6 Tempers Can Also anneal fully soften O Temper

36 Exterior Packaging Protection Exterior protection during transit and handling Paper Cardboard Plastic Stretch wrap Wood

37 Interior Packaging Protection Separating profiles to protect critical surfaces Interleaving, individual wrap, separate by layers Paper, foam, plastic, chipboard, cardboard

38 Logs to Extrusion

39 Aluminum in Transportation

40 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 3 rd Rail Sapa Solutions Aligned with Market Design solution resources Expanded fabrication capabilities Wide multi-void panels Friction stir welding CVM expertise Marine Bus/Van Passenger/Transit

41 Aluminum Coal Cars Extrusions including Top Chords, Side Sills and Side & End Posts Pre-Drill and Cut to Length, if requested

42 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

43 Transit Car Assemblies Double Sided, Hollow Sections Friction Stir Welded Both Sides Delivered Ready to Install

44 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 DesignWorkshop Sapa experts help customers develop their own products using aluminum extrusion Sapa presentation updated March 2011

45 Questions?

46 Randy Thomure Sapa Extrusions

47 Shaping the future Sapa is environmentally conscious with regenerative equipment and reduced solvent and waste components. Sapa products meet or exceed AAMA specifications.