AluCluster. Knowledge Centre and Innovation Network

Transcription

1 AluCluster Knowledge Centre and Innovation Network

2 ALUCLUSTER INNOVATION NETWORK FOR ALUMINIUM Fonden AluCluster - Startet as a project in Foundation founded in 2002 by - Hydro Aluminium - SAPA Profiler - Mærsk Container Industry - Danfoss Drives Today - International oriented national aluminium cluster - Knowledge centre within aluminium Facts: - 7 employees - Financed by: - Danish Agency for Science, Technology and Innovation - EU - Consultancy, courses and projects

3 ALUCLUSTER INNOVATION NETWORK FOR ALUMINIUM Increase use of aluminium to the benefit of danish industry Wind and Offshore Automotive and Aerospace Innovation and R&D projects Technology transfer Education Technical consultancy Internationalisation New market development Welfare Technology Internationalisation Foodprocessing industry

4 ALUCLUSTER INNOVATION NETWORK FOR ALUMINIUM A network based on: Aluminium knowledge and competences Innovative and flexible companies International mindset Strong cooperation within universities, technical institutes and clusters

5 ALUCLUSTER INNOVATION NETWORK FOR ALUMINIUM Excellent corrosion properties Total Cost of Ownership High strength to weigth ratio Excellent conductor of heat 100 % recyclable Unique design possibilities Superb formability

6 Aluminium as construction material Advantages High strength to weight relation Excellent corrosion properties Low maintanence costs Easy formable smart solutions 100% recyclable Total Cost of Ownership High thermal conductivity Disadvantages Los of strength in HAZ when welded Low E-module Low melting point Attention when joined with other materials

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8 An Introduction to Alloys and basic Properties

9 From electrolysis to semi-finished products

10 A few physical properties Properties Aluminium Iron Copper Density g/cm 3 2,7 7,9 8,9 Melting point C Thermalconductivity W/(m C) Coefficient of linear expansion x10-6 / C Electric resistance x10-9 Wm 27, ,3 Elastic modulus GPa

11 Mechanical Properties The Classic Paradoks

12 The EN-Alloy-System

13 The Alloy System Aluminium Alloy Designation System (CEN) Major alloying element Atoms in solution Work hardening Precipitation hardening WROUGHT ALLOYS*) EN AW- 1XXX 3XXX 4XXX 5XXX 2XXX 6XXX 7XXX 8XXX None (min % Al) Mn Si Mg Cu Mg + Si Zn Other X X X X X X X X X X X (X) (X) (X) (X) X X X X Non-heat treatable alloys Heat treatable alloys CASTING ALLOYS*) EN AB- EN AC- EN AM- 1XXX0 2XXX0 4XXX0 5XXX0 7XXX0 8XXX0 9XXX0 None (min % Al) Cu Si Mg Zn Sn Master Alloys *) letters preceding the alloy numbers have the following meaning EN = European Standard A = Aluminium B = Ingot C = Cast Alloy M = Master Alloy W = Wrought Alloy Sources: according to EN 573; pren 1780 Source: TALAT Aluminium Alloy Designation System alu Training in Aluminium Application Technologies

14 Variation in properties

15 Strength & Tempers

16 Strenght affecting mechanisms Alloying/Solution treatment Agening Mechanical deformation

17 Dislocations 1 m 1 mm 1 µm 1 nm TALAT Atoms in Solid Solution

18 Grains deformation hardening Temper H18 Temper O/W

19 Grains affected by annealing

20 Temper non heat treatable F O H1 H2 H3 As fabricated non specified Annealed - recrystalised Cold worked no further treatment Cold worked and partly annealed Cold worked and stabilyzed HX2 HX4 HX6 HX8 ¼ hard ½ hard ¾ hard Full hard

21 Alloying/Solution Treatment

22 Alloying-elements affecting the crystal

23 The alloying elements create tensions in the crystal grid. In addition this counteracts the movement of dislocations.

24 Phase diagrams

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26 Agening

27 Agening

28 Solution treatment Quench Agening Stabilized

29 Temper heat treatable O / W Annealed, C, 1-5 hours T1 Cooled from extrusion and naturally aged (20 C) T4 Solution heated and naturally aged (20 C) T5 Cooled from extrusion and artificial aged, C / 3-10 hours T6 T7 Solution heated and artificial aged Solution heated and overaged

30 Natural agening vs. heat treatment An solution treated item will age over time This proces will also take place in workshop temperature. The strenght will increase approximately 3-7% The higher alloying the longer the proces to full agening EN AW 6082 EN AW 6005

31 Typical alloys offshore/construction Alloy! Temper! Tensile Strength (MPa)! Yield Strength (MPa)! Application! EN AW 5083! O! 275! 125! Sheet material. H12! 305! 250! Shipbuilding and offshore applications. H34! 340! 250! Excellent corrosion resistence! EN AW 5754! O! 190! 80! Structural sections. H14! 240! 190! High strength, good corrosion resistence! H34! 240! 160! EN AW 6082! T4! 205! 110! Structural sections. T6! 310! 260! High strength, good corrosion resistence! EN AW 6060! T4! 120! 60! Lighter structures! T6! 190! 150! EN AW 6063! T4! 130! 65! Lighter structures! T6! 215! 170!

32 Extrusion Aluminium a few processes Increased stiffnes Integrated functions Flexibility Profiles and sheets can be bend, cut, formed, machined etc.

33 Start your imagination SAPA fantasy profile

34 Aluminium - a few processes Joining techniqes Mechanical fastening Adhesive bonding Welding * Friction Stir Welding * Brazing Casting Low melting point Sand, Gravity, High & Low pressure die casting etc.

35 MIG TIG CMT Laser Friction Stir Welding Electromagnetic Impulse Explosion Welding Aluminium Welding

36 A few things to have in mind Be aware and talk to the designer/customer Simple vs. complicated welds Post treatment anodising (colour) Strength & corrosion resistance Alloys and temper Consumeables Welding method

37 Weldable alloys Weldable alloys All pure aluminium alloys Most Deformation hardening alloys (grp. 22) EN-AW (not limited to) 1050 A Heat treatable alloys (grp. 23) Many aluminium alloys are welable, however in generel the 2xxx and 7xxx series are considered difficult to weld. OBS on EN AW 7008/7020 natural agening

38 Heat Affected Zone Styrke MPa Temperatur C

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40 niversity, University of Sheffield, 17 July 2003, Uncontrolled Copy, (c) BSI Softening factor - HAZ

41 Design for welding Limit number of welds Place your weld in optimum places Design for welding?

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43 Friction Stir Welding

44 Trends and focus areas

45 Primary Aluminium Production

46 New hospitals 40 mia DKK Welfare Technology Light weight (HSE) Design Smart surfaces - Sterilius - Julius - AMAS

47 Automotive & Aerospace Driver for technology development - Alloy development Adhesive&bonding&seems&to&be&the&topic&of&the&day&among&European& automoive&manufacturers.&in&reality,&they&are&addressing&the&subject& welding/bonding,&in&which&the&adhesive&applicaion&is&followed&by&spo welding&to&posiion&and&fixture&the&parts&together&accurately&before&th heatncuring&adhesives&harden&to&full&strength&during&the&paint&process - Forming and joining processes Export opportunities - Innovative, flexible, HQ on time Strong collaboration with Bayern Innovativ

48 til maskiner og udstyr m Foodprocessing Industry Automatisation & Productivity - High speed robots - Price fødevarekontakt Challenge: - Cleaning agents corrosion - Wear 1 - Surface treatments

49 Surface Technologies På forskningsniveau er det i dag også muligt at tilføre overfladen forskellige funktionelle egenskaber f.eks. Antibacterial properties AMAS Wear resistance Keronite (kommerciel) Acid/alkaline corrosion resistance PECVD Optical properties ODAAS aluminium (B&O)

50 Wind and Offshore Huge potential market in DK and in foreign markets Knowledge and experience exists - Total Cost of Ownership $$$ - Need for weight reduction - Long term best practice exists However, it is still not done over night

51 Udfordringen Vægtreduktion! Ønsket vægtreduktion tons eller min. 50 %! Udgangspunkt i kendskab til aluminiums svagheder! Behov for at tænke utraditionelt ift. design! Hvorfor?! Lettere installation! Dimensionering af monotower! Vedligehold! TOTAL COSTS

52 Changing the mindset

53 Korrosionsforhold Generel rigtig god korrosionsbestandighed Vigtigste korrosionstyper Galvanisk korrosion Spændingskorrosion Pitting korrosion Viden og løsninger på området er tilgængelig Bi-metal Rustfri stål 316 Hårdanodiserede plader Neopren

54 Design- og konstruktionsforslag

55 Living Quarters & Helidecks

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58 WinWinD 3, nacelle cover

59 Leitwind cooling for direct drive

60 Standards and Guidelines Eurocode 9 (Dansk Standard) SAPA Design Manual Norsok:C-002, C-004, M-001, M-102, M-121, M DNV: OS-B101, OS-C401, OS-E401 SASAK håndbogen (DK) PDF 60