aluminum extrusion

Introduction This PowerPoint presentation uses information current as of June 21, 2011. 2011. You will note that some of the key slides in the economics area are marked “Preliminary”. Please visit the following to obtain the most up-to-date version of this and other presentations: www.ae www.aec.org/ c.org /exapps/Cust xapps/Custom ome erOutre rOutr each. ch .html ht ml

Introduction The Aluminum Aluminum Association Association (AA), Aluminum Extruders Council (AEC), the authors and contributors of this overview provide information and resources about aluminum products and aluminum-related technology as a service to interested parties. Information provided by them is generally intended for users with a technical background and may be inappropriate for use by lay persons. While the AA, AEC, authors and contributors make every effort to disseminate the most reliable and current information available, they do not warrant that the use of such information as appropriate for any particular purpose. In all cases, users should not rely on this information without consulting original source material and/or undertaking a thorough t horough scientific analysis.

Tabl ble e of Con ontents tents

• Introduction • Economi con omic c Advanta Advantage ges s of Aluminum Alumi num Extrusi xtr usions ons • Ad  A d v ant an t ages ag es o f Al Aluminum • Ad  A d v ant an t ages ag es o f Al A l u m i n u m Ext Ex t r u s i o n s • Overv vervie iew w of o f the t he Ext Extru rusi sion on Proce ro cess ss • Corro or rosi sion on Re Resist si sta ance nc e • Finishi ini shing ng / Fabrica bri cating ting Alumin Alu minum um Extrusi xtr usions ons • Ad  A d d i t i o n al Inf In f o r m ati at i o n , Edu Ed u c ati at i o n and an d Tr ain ai n i n g

Introduction

Courtesy of Light Metal Age magazine

Introduction Extrusi xtr usion: on: ofte o ften n the most cost co st effective effective and and quic q uicke kest st path path be b etween tween conc c once ept and produc pro ductt aluminum um extrusio n proc ess is • The alumin incredibl inc redibly y versatile and and capable of conve conv erting rtin g idea id eas s to reality reality quickly quic kly,, accurately and inexpensively

• Designers can utilize a near-net shape process to c lose los e tolera tol erances, nces, coupled with a list of superior physical phys ical characteristics characteristics to optimize op timize their design designs s This presentation presentation pr ovi ovides des both a conceptual con ceptual and and a practic al understanding understa nding of how best to design with aluminu aluminum m extrus extrusions ions

Introduction Exampl xample e of Alumi Al uminum num Extrusi xtr usions ons used in the Nev ada Sol Sola ar One Co Co ncentr nc entra ated Solar Sol ar Pow Powe er Plant

Introduction  Al  A l u m i n u m ext ex t r u s i o n s are ar e st s t r o n g and an d eff ef f i c i ent en t f o r crea creating long lasting lasting structure struct ures, s, critical to our ou r future fu ture

Photos courtesy of Hydro Aluminum

Introduction Extrusi xtr usion: on: often o ften the most mos t cost cos t effective effective and and quic q uicke kest st path path be b etwee tween conc c once ept and produc pro ductt  A l u m i n u m ext ex t r u s i o n s o f f er a lo long • Al list of adva advantage ntages s – both those inherent inherent in alumin um as well as those thos e gained gained from fro m the extrus extrus ion process

• Combin ing aluminum and the extrusion pro cess yields yields results which are second-to-none second-to-none re r egarding form, for m, fit, func tion, tio n, appeara appearance nce and and cost, cost , produ cing amazing, mazing, attractive parts and advantages  All u m i n u m ex extt r u s i o n s ar are e gr g r een een,, • A providing strong, lightweight lightweight designs whic h are fully recyclable Photo courtesy of Hydro Aluminum

Introduction Ideas deas taking takin g sha sh ape  A n i d ea tak t akes es s h ape ap e in in the • An designer’s mind and then takes takes shape as a final final produ p roduct ct hrou gh the flexibil flexibility ity o f the • Through alumin um extrus extrus ion process, pro cess, profil pro files es can can be creatively fine-tuned fine-tuned to spe sp ecific ally fit f it the th e design requirements requirements or o r to be specifically branded with your yo ur details  A l l t h ank an k s t o t h e amazi am azin ng • Al versatilit versatility y of alumin aluminum um extru extrusion sion

Introduction Th e Shape Shape is the th e Id Id ea  A l m o s t any an y s h ape ap e can c an b e pr p r o d u c ed • Al through aluminum extrusion high ly workable wo rkable material material can • The highly create a shape that th at can th en be enhanced and and perfected perfected th rough roug h additional ddit ional machin machining, ing, finishin g and and fabrication

2008 Transportation Category Winner  Electric motorcycle frame

Introduction The Shape hape becom become es more m ore than an an end end in i n itse it self  lf  Shape can be design desi gned ed • The Shape and extru extruded ded to b e more than the base base for a useful useful p roduct rodu ct

• Simplify maintenance and repairs for the final user of the product

fo rmed to : • It can be formed

• “Build in” an attractive appearance that can make the product easier to sell

• Reduce piece count / provide complex integral features • Facilitate manufacturing and assembly • Reduce costs and lead times for materials and production • Increase product reliability and durability

Photo courtesy of Light Metal Age magazine

Introduction Consi on sider der the Adva Adv anta nt ages: s imple household hou sehold appliances appliances to exotic space and electron electron ics • From simple applications, product s made from aluminum extrus ions are superior in:

 –  Design Flexibility  –  Performance  –  Efficiency  –  Reliability  –  Cost

Photo courtesy of NASA

Introduction  Al  A l u m i n u m ext ex t r u s i o n s r emai em ain n t h e bes b estt c h o i c e fo for many many applications ppl ications  A d v anc an c i n g t ech ec h n i q u es i n • Ad manufacturi manufacturing ng and assembly can extend alum aluminu inum’s m’s use to even even more applic applic ations, tion s, inclu ding th ose in which wh ich other o ther materia materials ls ha h ave long been been employed employ ed t he basic basic • The combination of the prope prop erties of alumin alumin um and its alloys , plus the th e infinite infi nite variety variety of of shapes shapes possible poss ible in the extrus extrusion ion process give aluminum extrusion its many m any advantages advantages over other materials materials and and methods method s of formin f orming g

The alumin alumin um extrusi on pro cess is flexible and has has both extremely extremely low t ooli ng cost s and shor t l ea ead d t imes, enabling enabling ef efficient ficient produ ction of near net shape, shape, compl ex integral inte gral parts parts – allowing exce xceptional ptional reductions to part coun ts and and subs eque equent nt fabrication and asse assembly mbly

Ind nde ept pth h IBIS IBIS As Asso soci cia ates CSP CSP Frame Str truc uctu ture re Ana An aly lysi sis s

• ECONOMIC ADVANTAGES OF ALUMINUM EXTRUSIONS • Using information available in the public domain, IBIS  Associates performed an independent independent detailed detailed analysis of various existing parabolic trough CSP (Concentrated Solar Power) frame designs from steel and aluminum used for utility scale solar power applications. • The following excerpts from the IBIS analysis are extremely useful in understanding why aluminum extrusions represent such exceptional competitive advantages in both cost and performance to steel alternatives. The IBIS slides are are marked “Proprietary “Proprietary and Confidenti Confidential al – Do Not Distribute”; Distribute”;  AEC has permission to utilize these for this presentation.

IBIS: Workplan

1.) Establish baseline designs for f or comparison 1a.) Eurotrough, Eurotrough, Skal-ET 150 & HelioTrough as steel baselines 1b.) “Generized” Aluminum based on public data of Acciona/FPL designs

2.) Collect component, material, process 3.) Build component list and process flow diagrams 4.) Construct cost models for component production and assembly 5.) Use cost model establish cost comparisons and sensitivity analyses 6.) Validate results via external expert reviewers

IBIS: IBI S: Steel Steel Basel Baseline ine - Eur Eurotr otroug ough h

•Consortium composed of industry partners and supported by European commission  –  Collector Length: 12 meters  –   Aperture Width: Width: 5.7 meters

•Skal ET is a scaled up design of the Eurotrough by Flagsol which replaced square tube sections with angles  –  The solar collector assembly assembly in this design is 150m long long vs. the 100m Eurotrough

Eurotrough & Skal ET Subassemblies Torque Box

Sides A & C

Sides B & D

 A D

B C

Cant Cantilevers ilevers (28) (28)

 –  Collector Length: 12 meters  –   Aperture Width: Width: 5.77 meters  –  Total Aperture Area = 69.2 m 2

HelioTrough Collector Design

HelioTrough

 –  Collector Length: 19.1 meters  –   Aperture Width: Width: 6.77 meters  –  Total Aperture Area = 129.3 m 2

Generic Aluminum Frame 12m Baseline

• Collector Length: 12 meters •  Aperture Width: 5.77 meters • Total Aperture Area = 69.2 m 2

 –  Based on Acciona /Nevada Solar One  –  Also  –   Also installed by Florida Power & Light, but heavy duty, hurricane strength version  –  Baseline distilled from patent data and known component sizes, estimated for 8m and 12m frames f rames • 8m scaled-up to 12m length and wider 5.77m aperture area

Summary of Steel and Aluminum Designs ~ 18kg/m2 of aperture

~ 18kg/m2 of aperture

~ 21kg/m2 of aperture

~ 11 kg/m2 of aperture

Comparative Mfg & Ass’y Process Flows Fabrication

Extrusion Chords Struts  Angles Nodes

 All u m i n u m  A Cut & Machine

Kit & Package

Cut Tubes

On-site  Assembly

Shipping (Truck)

Torque Plates Mirrors Receivers Motors Hydraulics

Weld Box Sides

Zn Galv.

Weld  Arms

Zn Galv.

Hammerforge & weld mounts

Steel Kit & Package

Torque Tube (Heliotrough) Pipe Mill

 Assembly

 Additional Components

Torque Box (Eurotrough, Skal-ET) Cut Tubes

Transportation

Zn Galv.

Shipping (Truck)

Mech  Ass’y Box

Mech  Ass’y  Arms

Transport Flatbed

 Additional Components Torque Plates Mirrors Receivers Motors Hydraulics

On-site  Assembly

Cost Modeling Methodology  –  The following cost estimates are built from the bottom up, and consider all variable and fixed elements of each of the operations required to fabricate, assemble and install Solar Thermal Parabolic Collectors.  –  These are the direct manufacturing costs that would be incurred by a company that is completely integrated from raw material acquisition through to final field installation.  –  There are no SG&A costs nor profit added to these estimates.

Material Market Price History

OEM purchase price includes: + $0.10/lb steel long product premium + $0.20/lb $0.20/lb alloy alloy & midwest midwest billet surcha surcharge rge

Material Market Price History

Scenario Comparison •

Collector Cost Comparison in $/frame

Material Fabrication Sub-Assembly Galvanizing Shipping Fiel Fi eld d Assembl Total

 Alu  Al u m inu in u m 12m

Eur Eu r o tro tr o u g h 12m

Skal Sk al ET 12 m

Helio Hel io Tro Tr o u g h 19m

$1,727 $654

$1,430 $258 $517 $1,390 $94 $323 $4,012

$1,439 $289 $622 $1,082 $95 $323 $3,850

$1,446 $2,225 $324 $2,394 $281 $237 $6,907

‐‐ $54 $47 $246 $2,728

average material material market pri ces ($1.10/lb for aluminum billet and NOTE: Material costs based on long term average $0.45/lb for steel based based on long term average prices (for midwest extrusion billet and cold rolled tube tube stock)).  A lat l ater er c h art ar t s h o w s h o w t h e fr f r ame am e co c o s t s i n alu al u m i n u m and an d s t eel v ary ar y o v er t h e pas t 20 year y ears s.

The $’s represented are not Prices charged to customers but are estimated Costs from direct manufacturing only (they do not include overheads and profit from suppliers and contractors).

Collector Cost Summary (per sq meter)

Collector Cost Summary (per sq meter)

Material Market Price History Projected Collector Cost Cost over Mark Market et Histor y $70.00 NOTE: The $’s represented are not Prices charged to customers but are estimated Costs from direct manufacturing only (they do not include overheads and profit from suppliers and contractors).

$60.00 $50.00

  e   r   u    t   r   e   p $40.00   a   r   e    t   e   m$30.00   q   s    /    $

$20.00 $10.00

 A EC Conc  AEC Con c l u s i o n : at n o ti t i m e fro fr o m 1991 th t h r o u g h 2011 wou wo u l d the comparative prices of stee st eel,l, zinc zinc and aluminum alumi num extrusions extrusi ons have h ave result resulted ed in a case case where the cost of the th e modeled extruded aluminum alumin um frame would woul d have been been greater greater than the galvanized steel steel frames whi ch were w ere mod modele eled. d.

Generic Aluminum 12m Eurotrough 12m Skal ET 12m HelioTrough 19m

$0.00

 AE  AEC: Based on publis lished operating ing results lts at Nevada Solar lar One, NREL, the the SEGS fie fields lds and othe thers, the optical efficiency and energy performance of aluminum frames is equal to or better than tested steel designs.

 Ad  A d v an antt ag ages es o f A l u m i n u m

• Lightweight • Strong • Hig igh h Strength Streng th--to to--Weig ight ht Rati tio o • Resilient • Corrosion-Resistant • Heat Condu on duct ctiv ive e • Reflective • Electr lectrically ically Conducive Conduc ive • Non-Magnetic • Nonon -Sparking parkin g and Non Non--Combu om bust stib ible le • Col old d Streng Strength th • Ful ully ly Recy cycl cla abl ble e Important Im portant for f or sol r applications! 

 Ad  A d v an antt ag ages es o f Al A luminum  Al  A l u m i n u m Ext Ex t r u s i o n s c an b e pr p r o d u c ed i n d i f f eren er entt alloys and processed p rocessed to different tempers to achieve desired desired mechanical mechanical properties, p roperties, corrosio n resistance, resistance, machin machina abilit y, formability and other attributes

Photo courtesy of Hydro Aluminum Aluminum

 Ad  A d v an antt ag ages es o f Al A luminum

 Ad  A d v an antt ag ages es o f Al A luminum Lightweight Only about o ne-thi ne-third rd as heavy heavy as iron, iron , steel, steel, copp er or brass; thus, thus , in applications ppli cations where volume remains remains the same regardless regardless o f metal used, us ed, alumin um goes g oes about about three times as far as the oth er metals metals

Photo courtesy of Classic Trailers, Inc.

 Ad  A d v an antt ag ages es o f Al Aluminum Strong  Ap  A p p r o p r i atel at ely y all al l o y ed and an d t r eated eat ed,, alumin um can be stronger than some steels, steels, with ultima ultim ate tensile tensile stre str ength s as high hi gh as 80,0 80,000 00 psi ps i to t o 90,00 90,000 0 psi or more. Material

Modulus (E) (106 psi)

Mi l d St eel

29.0

 Al um i nu m

10.0

B r as s

13.0

Zi n c

13.0

Plastics: PS

0.51

PET

0.29

Ny l o n

0.42

Peek

0.56

The modulus of elasticity (E) is the relationship of how the material deforms compared to the stress that it is under. Photo courtesy of Werner Co.

 Ad  A d v an antt ag ages es o f Al A luminum High ig h Strength Streng th--toto -Weight ig ht Ratio ti o High strength plu s low weight weight permits substantial reduct reductions ions in the weight weight of both bo th parts and final products

Rendering and photo courtesy of Tesla Motors, Inc.

Photo courtesy of Werner Co.

 Ad  A d v an antt ag ages es o f Al A luminum High ig h Strength Streng th--toto -Weight ig ht Ratio ti o High strength plus low weight permits substantial subs tantial reductions reduction s in the weight weight of both parts and final final prod ucts

Rendering and photo courtesy courtesy of Audi USA

 Ad  A d v an antt ag ages es o f Al A luminum Corrosi orr osion on Resista sis tant nt Excellent xcellent c orrosion orros ion resistance in a wide variety variety of o f environme environm ents and contact cont act with a myriad of sub stances; stances; it develops develops its it s own inert alumin alumin um oxide oxid e film, which is self-protective, blocking further oxidation oxidation

Photo courtesy of Light Metal Age magazine

 Ad  A d v an antt ag ages es o f Al A luminum Reflective Highly reflective reflectiv e (mor (more e than 80% 80%)) of b oth visib le light ligh t and and the invisib le radiation radiation beyond both ends of the th e visible visib le spectrum spectrum

Photo courtesy of Alcoa

 Ad  A d v an antt ag ages es o f Al A luminum Cold ol d Streng Strength th 

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 Al  A l u m i n u m ’s m any an y adv ad v ant an t ages ag es are ar e not impaire i mpaired d by exposu re to cold. co ld. In fact, alumin alumin um gains st rength and ductili duct ility ty as temperatur temperatures es are are reduced, makin making g it a preferred preferred metal metal for cryogenic cryog enic (low(lowtemperature) applications. Steel teel and p lastics get brit tle when the temperature temperature drops …  Al  A l u m i n u m g ets et s s t r o n g er and an d tougher!

Photo courtesy of NASA

 Ad  A d v an antt ag ages es o f Al Aluminum Fully ul ly Recycl cy cla able bl e 





 Al  A l u m i n u m i s f u l l y, and an d r epeat ep eated edll y, recyclable, recycl able, able to be recycled recycl ed over and and over o ver without withou t degradation degradation or loss los s of its it s inna inn ate characte characteristi ristics cs For prod ucts wit h a limite limit ed life lif e (such as consumer consu mer durables durables and transportation products), aluminum’s lumin um’s recyclability recyclability c oupled oupl ed with its other outstanding outstanding attributes ttrib utes make it a superior material material choice ch oice  Al  A l u m i n u m h as s i g n i f i c ant an t s c r ap value and is p articu larly environmenta nviro nmentally lly friendly because because recycling requires only 5% of the energy necessary necessary to produce prod uce virgin aluminum

Photo courtesy of Light Metal Age magazine

 Ad  A d v an antt ag ages es o f Al A luminum Fully ul ly Recycl cy cla able bl e 





 Al  A l u m i n u m i s f u l l y, and an d r epeat ep eated edll y, recyclable, recycl able, able to be recycl ed over and and over o ver withou t degradation degradation or loss o f its in nate nate characteristics. For products prod ucts with wi th a limited life (such as co nsumer durable du rables s and transportation products), alumin um’s recyclability recyclability c ouple oupl ed with its ot her her outstanding attrib utes make it a superior material choice.  Al  A l u m i n u m h as s i g n i f i c ant an t s c r ap value and and is i s particularly p articularly enviro nmentally nmentally friendly because because recycling requires only 5% of the energy necessary necessary to produce prod uce virgin aluminum.

Photo courtesy of Light Metal Age magazine

 Ad  A d v an antt ag ages es o f A l u m i n u m • Lightweight • Strong ig h Strength-to-W Strengt h-to-We eight ig ht • High Ratio • Resilient • Corrosion-Resistant hermal Cond Conduct uctivi ivity ty • Thermal • Reflective lectric ally Conducive Conduci ve • Electrica • Non-Magnetic • Non-Sparking • Non-Combustible • Cold Strength ul ly Recyc Recyclable lable • Fully

Photo courtesy of Light Metal Age magazine

 Ad  A d v an antt ag ages es o f A l u m i n u m Ex Extt r u s i o n s  A t t r act ac t i v e •  At ui table e for fo r a Wid Wide e Range of • Suitabl Finishes • Virtually Seamless bri cate • Easy to Fabricate Joi nable by Va Variou ri ous s Meth Methods ods • Joinable ui table for fo r Easy-a Easy-ass sse embly mb ly • Suitable Designs ui table for Compl om ple ex, Int Inte egra gr al • Suitable Shapes ro duced ced to Close Clos e Tolera ol eranc nces es • Produ rod uced with Uniform Unifor m Quality Quality • Produced • Cost-effective ho rt Product Produ ctio ion n Lead Lead Tim Time es • Short

Photo courtesy of Werner Extruded Solutions LLC

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Easy to Fabric br ica ate alumin um • Often, designing with aluminum extrus ions can eliminate eliminate many fabrication and assembly assembly steps  A l u m i n u m ext ex t r u s i o n s c an b e mad m ade e •  Al with almost any cross-sectional shape. Parts Parts can be easil easily y cut, machined, machin ed, finish fin ished, ed, fabricate fabric ated d and assembled.

Photo courtesy of Alexandria Extrusion

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Join Jo ina able bl e by Vario Various us Meth Method ods s  Al  A l u m i n u m ext ex t r u s i o n s c an b e jo j o i n ed to other aluminum aluminum prod ucts or to different dif ferent materials materials by all major methods, inclu ding welding, welding , soldering, brazing, screws, pins, bolts, bol ts, rivets, chips, chip s, adhesives, clinc hing and slide-on, slide-on, snap-together snap-together or interlocking joints

2004 Structural Category Winner 

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Suitable ui table for fo r Complex, Comp lex, Inte nt egra gr al Shapes Shapes Shapes hapes can comb ine functions funct ions that would woul d oth erwise require the producti prod uction on and and joining join ing of several several diffe diff erent parts.

2005 Commercial/Industrial/Consumer Commercial/Industrial/Consumer Winner 

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Suitable ui table for fo r Compl om ple ex, Int Inte egra gr al Shapes Shapes Using sin g the t he Extrusio xtr usion n Process Process for fo r Net Net Shape

 All u m i n u m s h eet s t o c k = 3 op  A o p er erat atii o n s

operations s • Reduce the num ber of operation required

• Reduce the cor ner stress f rom bending • Cosmetically more attractive

Photos courtesy of Alexandria Extrusion Company

Extrusion Extrus ion = 1 operation operation

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Suitable ui table for fo r Complex, Comp lex, Inte nt egra gr al Shapes Shapes  Al  A l u m i n u m Ext Ex t r u s i o n s Repl Replace ace Casting asti ngs s • Significantly lower tooling cost mpro ved strength • Improved

• Improved duc tility mpro ved weldabilit weldabilit y • Improved

• No poro sity • Cosmetically more attractive lead time ti me • Shorter lead

Photo courtesy of Alexandria Extrusion Company

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Suitable ui table for fo r Complex, Comp lex, Inte nt egra gr al Shapes Shapes Shapes hapes can comb ine functions funct ions that would woul d oth erwise require the producti prod uction on and and joining join ing of several several diffe diff erent parts

Photo courtesy of Light Metal Age magazine

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Produ ro duced ced to Close Clos e Tole ol erances Tight igh t tolera to lerances nces are rou tine tin e and the ability of alumin um extruders to meet meet even more critical criti cal dimensions is keepin keeping g pace with wit h advances in technology.

Photo courtesy of Almag

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Produced rod uced with wit h Uniform Quality uality This re r eliability reduces reduces cus tomer costs cost s by minimizing mi nimizing r ejections rate, rate, corrective fabrication fabrication and product ion slowdown – particula particularly rly important important to the manufacturer manufacturer who depends depends up on  ju  j u s t -in -i n -ti -t i m e (JIT) (J IT) del d elii v ery er y

Photo courtesy of Werner Extruded Solutions LLC

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Cost-effective The boundless div ersity of sh apes permitted by the extrus ion pro cess cuts d own or eliminates many many machining as well as as joining join ing operation operations. s. Also, Also , the tools tool s required required for aluminum extrud ing, such as dies dies and related related items are relatively relatively inexpensive.

Process

Typical Toolin ooling g Cost ($)

Vi n y l Ex t r u s i o n

$1,500 an d u p

In j ec t i o n Mo l d i n g

$25,000 an d u p

Di e Cas t i n g s

$25,000 an d u p

Ro l l Fo r m i n g

$30,000 an d u p

St am p i n g s

$5,000 an d u p

 Al  A l u m i n u m Ext Ex t r u s i o n s

$500 to $5,000

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Short hor t produc pro ductio tion n lea lead time tim es L ead Time Tim e in Weeks 20 15 10 5 0

   l   n    i  o  n   s   s   a    l  d   m   n  g    o    t   g     i   r   o   e   s   n   s    i   u    M   u    M    l   l   F  o   a  s   t   i   p   r   r    t    t   r   n   m   x   x   e   o   C    E    t  a   w  d    t   i    R  o    l   E   c   S   y   m   e    P  o   n  u    V   i  n    I  n   j     i   u  m    l   A

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s Examples xamp les of Valu Value e Added Ad ded Operatio Operations ns Finishing Painting ing (wet and and po wder) • Paint anodi ze • Polish, bright dip & anodiz • Mechanical finishes sc reening ning • Silk scree Fabrication • Sawing piercing / drillin g • Punching / piercing • Machining • Bending • Welding • Milling • Tumbling

Photo courtesy of Werner Co.

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s The Pos Possi sibi bilit lities ies are are Boundl Boun dle ess, ss , Limite Lim ited d only on ly by b y the th e Imagin magina ation tio n The extru extrusion sion pictu red is a theoretical theoretical shape create created d to illus trate some of the range range of possibi lities prov ided by aluminum extrusions

How can YO YOU use us e this thi s flexibilit flexibility y to: magination? ? • Spark your i magination reate new produ ct conce conc epts? • Create evelop improved impro ved manufacturing • Develop efficiencies? Photo courtesy of Werner Co.

 Ad  A d v an antt ag ages es o f Al A l u m i n u m Ex Extt r u s i o n s

Photo courtesy of Werner Co.

Overview of the th e Ext xtru rusi sion on Process The Aluminu Alum inum m Extr Extrusi usion on Prof Profile ile

Photo courtesy of SAPA

Overview of the th e Ext xtru rusi sion on Process Extruded xtr uded Prod Product uct Flow

Photo courtesy of Hydro Aluminum

Overview of the th e Ext xtru rusi sion on Process

Overview of the th e Ext xtru rusio sion n Pro Process cess The Ext Extru rusi sion on Process ro cess

Overview of the th e Ext xtru rusi sion on Process

Photo courtesy courtesy of Nancy Molenda/AEC Molenda/AEC

Overview of the th e Ext xtru rusi sion on Proce Proc ess Ho w are Hollo ol low w Shapes Shapes Extruded?

Overview of the th e Ext xtru rusi sion on Process Tooling • Hollow Dies Dies • Solid Dies

• Multiple Hole Dies

Photo courtesy of Werner Extrusion Solutions LLC

Overview of the th e Ext xtru rusi sion on Process Some Limita Lim itatio tions ns Size • Circl e Size The circumscrib circu mscrib ing circle cir cle that the profile could fit through - Larger Larger circle sized sized shapes shapes need need larger larger too ling and equipment (less available and mo re expensive)

• Wt / ft - Too heavy? heavy? Too light? ligh t? Shape Cons Constraint traints s • Shape - High tongue ratios ratios - Somewhat omewhat balance balanced d wall wall thicknesses - Othe ther 

Photo courtesy of Werner Extrusion Solutions LLC

Overview of the th e Ext xtru rusi sion on Process Some Limita Lim itatio tions ns Corresponding Profile weight (lbs/ft)

Circumscr Circum scribed ibed Circ Circle le Size Size in inches in ches Cross Sectio Sectio n Area in sq inches

<1

1 to 7

7 t o 10

10 t o 14

>14

<0.050 0.050 to 0.100 0.100 to 1.0 1.0 t o 2.5 2.5 t o 10 >10

L G W x x x

x G W W W x

x L L W W W

x x x L G G

x x x x L L

x

No t av ai l ab l e

L

L i m i t ed Av ai l ab i l i t y

G

Gen er al l y Av ai l ab l e

W

Widely Wide ly Available

NOTE: There are many presses available available with up to 7" diameter containers There are are fewer presses available with 7" to 10" diameter diameter con tainers There are are even fewer presses available available with 10" 10" to 14" 14" diameter containers There are are very few presses available with greater greater t han 14" diameter diameter co ntainers

Mi n 0.06 0.12 1.18 2.94 11.76

Max 0.06 0.12 1.18 2.94 11.76 -

Overview of the th e Ext xtru rusi sion on Process Diffic iff icul ultt Tongue Tongu e Ratio

Photo courtesy of Hydro Aluminum and Werner Extrusion Solutions LLC

Overview of the th e Ext xtru rusi sion on Process Exampl xample es of Aluminu Alum inum m Extr Extrusi usions ons

Photos courtesy of Hydro Aluminum and Werner Extrusion Solutions LLC

Corr orrosi osion on Resis sista tance nce  Aluminum components components are often utilized utilized due to the inherent corrosion resistance of the material.  Although aluminum is a chemically-active metal, its behavior is stabilized by the formation of a protective oxide film on the surface. Generally, Generally, this film is stable in aqueous solutions with pH 4.5-8.5. Further considerations need to be made if the pH exceeds these limits or if the environment contains chloride.

Corrosion Prevention Prevention Strategies Strategies for fo r  Al  A l u m i n u m Sol So l ar Fram Fr ames es The following variables should be addressed in the project design stage to prevent and/or minimize corrosion: •Fastener material choice •Method of isolating aluminum from concrete when anchoring • Alloy  Alloy choice •General design recommendations

While aluminum aluminum does does not “ rust” , it is subject to corrosion, although although cor rosion is insignificant insign ificant in fresh, unpolluted air. air.

Corr orrosi osion on Resis sista tance nce

Corr orrosi osion on Resis sista tance nce

Corr orrosi osion on Resis sista tance nce

Corr orrosi osion on Resis sista tance nce Understanding nderstanding the t he types types of o f corrosio co rrosion n which wh ich affect aluminu aluminum m Galvanic corrosi corr osion on occurs occu rs whe wh en two metallic metallic materials materials are in cont c ontact act in the th e presence of an an electrolyte for ming a galvanic galvanic cell. Most types of aluminum co rrosion are the result result of so me kind of galvanic galvanic coupling cou pling with wi th a dissimilar dissi milar material.

The least noble material (the anode) preferentially preferentially corrodes while the more noble material (cathode) is protected. Since aluminum is more anodic than most commonly used construction materials, with the exception of zinc, magnesium and cadmium, this can be a serious form of corrosion with aluminum.

Courtesy of Hydro Aluminum

Coupling aluminum with a more noble material can seriously deteriorate the protective effect from the oxide layer. This is especially dangerous in atmospheres atmospheres or water with high concentrations concentrations of chlorides or other aggressive corrosives.

Corr orrosi osion on Resis sista tance nce Understanding nderstanding the t he types types of o f corrosio co rrosion n which wh ich affect aluminu aluminum m Galvanic corrosi corr osion on can be avoided avoided or o r min imized imized by by taking taking th e following actions:  Avo  Av o i d u s i n g m ater at erii als al s w i t h l arg ar g e galvanic galvanic potential dif ferences ferences in a particular environment (stainless steel not included). If that is not practical, different materials have to be properly electrically insulated. insulated. It is very important to use insulation material of proper electrical resistance and to avoid metallic contact in the entire construction. This can be checked with resistance measurement instruments such as a multimeter.

 Al  A l u m i n u m m ay als al s o b e pr p r o t ect ec t ed b y means means of sacrificial anodes. The most cathodic material can be surface treated with a metallic coating (Al/Zn), organic coating (lacquer, paint, plastic, rubber) or a special coating for screws and bolts. Surface treatment has to be carried out correctly and not done only on the anodic material. As a consequence, consequence, a defect in the surface coating may generate a very unfavorable cathode/anode ratio (a big cathode area in relation to a small anode area gives considerable corrosion).

Corr orrosi osion on Resis sista tance nce Understanding nderstanding the t he types types of o f corrosio co rrosion n which wh ich affect aluminu aluminum m Galvanic corrosi corr osion on in combination combi nation with crevice corrosion corro sion may be especia especially lly damaging.  Avo  Av o i d ent en t r apm ap m ent en t o f l i q u i d s i n crevices crevic es between between materials of various galvanic pot entials. entials.

 Al  A l s o avo av o i d t h e tr t r ans an s f er o f i o n s o f galvanic galvanic materials materials on alumin um surfaces. For instance, droplets from a copper tube on an aluminum surface will generate precipitation of copper metal. The result is corrosion of aluminum (deposition corrosion). The next step will be microgalvanic microgalvanic corrosion between aluminum and the copper particles in the aluminum surface. Severe pitting may occur within a few weeks.

Corr orrosi osion on Resis sista tance nce Corrosio orro sion n resistance in differe di fferent nt envi environ ronments ments The atmosphere atmosp here Corrosion is insignificant in fresh, unpolluted air. Aluminum does not corrode where there are high levels of sulphur dioxide but can, under  certain circumstances, become dark or matte in appearance. Water  Pitting can occur in stagnant water. The composition of the water is the important factor as the presence of copper, calcium, chloride and bicarbonate ions increase the risk significantly. This can be prevented by regular cleaning and drying.

Courtesy of Hydro Aluminum

Seawater   Alloys containing containing silicon, silicon, magnesium magnesium and manganese show good resistance to corrosion in seawater. Copper alloys, on the other hand, should be avoided.

Corr orrosi osion on Resis sista tance nce Corrosio orro sion n resistance in differe di fferent nt envi environ ronments ments Soil The resistance to corrosion is, to a great degree, dependent on the moisture in the soil and its pH level.  Aluminum surfaces surfaces which may may come into contact with soil are best treated with a thick layer of bitumen or a powder coating.  Ac  A c i d s The majority of inorganic acids have a very corrosive effect on aluminum, except nitric acid. High temperature, high acid concentrations and high levels of impurities in the aluminum increase the rate of corrosion significantly.

.

 Al  A l k ali al i s Strong alkalis are very corrosive. Sodium hydroxide reacts violently with aluminum. The rate of corrosion can be reduced in environments where the pH is between 9 and 11 by using silicates. Wet cement has a high pH and therefore corrodes aluminum alloys. Organic compounds  Aluminum is is highly resistant resistant to the majority of organic compounds. Corrosion can occur, however, with certain anhydrous liquids. Other materials In practice, the corrosion problem caused by contact with other materials is, for the most part, small. The natural oxide layer usually provides sufficient protection.

For Mor ore e Inf nfor ormation mation This PowerPoint presentation uses information current as of June 21, 2011. 2011. You will note that some of the key slides in the economics area are marked “Preliminary”. Please visit the following to obtain the most up-to-date version of this and other presentations: www.ae www.aec.org/ c.org /exapps/Cust xapps/Custom ome erOutre rOutr each. ch .html ht ml

For Mor ore e Inf nfor ormation mation and Trainin raining g •

Purchase the Alumi num Design Manual 2010 2010 edition editio n from the th e Aluminum Alumi num Associ ation (alumin (alumin um.org)

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Utilize til ize ASCE ASCE Alumin Alu minum um Design Manual training tr aining

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 A 9.75 ho h o u r s emi em i n ar o n d esi es i g n i n g alu al u m i n u m s t r u c t u r es i s o f f ered er ed i n t h ese es e formats:  A n On-l On -lii n e ver v ers s i o n : g o t o w w w.asc w.as c e.or e.o r g /di /d i s t anc an c elear el earn n i n g ; c l i c k o n “ View  –   An a compl ete list of ASCE ASCE cours es” , scroll scrol l down do wn alphabetically alphabetically to “ Designing Aluminum Structures” l i v e ver v ers s i o n at v ari ar i o u s t i m es and an d l o c ati at i o n s : g o t o  –   A li www.a www.asce. sce.org/continuingeducation; org/continuingeducation; click on “ Structural” , scroll down to “ Aluminum Alumi num Struct ural De Design with the 201 2010 0 Aluminum Alumi num Design Manual” Manual” Or, to arrange to have the seminar con ducted duc ted at at your yo ur site, si te, con tact John Jo hn  –  Or, Wyric yr ick k at ASCE at 800800-548 548-2 -272 723 3 or jwy j wyri rick ck@ @asce. asc e.or org g

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Utilize other resources from o ur contrib co ntrib utors, utor s, other qualified qualified extruders and structural struc tural engineers engineers

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Utilize the Alumi num Extruders xtru ders Council website and and other  resources (a (aec.org) for w ebinars o r other o ther key in formation

 All u m i n u m Ex  A Extt r u d er ers s Co Cou uncil  Al  A l u m i n u m Ext Ex t r u d ers er s Cou Co u n c i l Over Ov erv v i ew The Alumin um Extrud ers Council (AEC (AEC), based based in subu rban Chicago, is an associ ation d edicated edicated to helping m anufacturers, engineers, engineers, archi archi tects, and and oth ers to disco ver why alumin alumin um extrusio n is the preferre preferred d metal-forming metal-forming process for optimal product solution s. Aluminum extrusions touch lives in so many ways-from office chairs and cubical partition s to bi cycles and scooters, from the latest latest in alumin um space-frame space-frame technolo gy in t oday’s lighter cars and truck s to fr ames ames and comp onents for green green technology s uch as solar power and and LED ligh ting . The majority of North  Am  A m eri er i c an ext ex t r u d ers er s are ar e mem m emb b ers er s r epr ep r esen es entt i n g h u n d r eds ed s o f p l ant an t s and an d c o u n t l ess es s ext ex t r u s i o n presses produci ng the highest quality pr oduc ts and valuevalue-adde added d services. Specialize Specialized d conf erences, erences, seminars, seminars, worksh ops, and meeting meeting s thr ough out the year year pro vide an outlet where members can can con front and solv e today’s today’s c hallenges hallenges and network with peers peers and sup pliers. As an an advocate representing representing th e alumin alumin um extrusi on i ndus try, AEC also pro vides expertise in o utreach and advocacy to approp riate governmental governmental agencies agencies and indu stry code bodi es.

 Al  A l u m i n u m Ext Ex t r u d ers er s Cou Co u n c i l Mis Mi s s i o n peers and and supp liers, address common i nternal • Provide opportun ities to network wit h peers and external external is sues, share data, data, train train and spo nsor research research enable members members to function func tion more effici ently, ently, cost effectiv ely, ely, • Work together to enable and kno wledgeably wledgeably Enhance the growth grow th of th e industry indu stry b y prom oting otin g the advantage advantages s of • Enhance aluminum extrusion processes processes and produ ct applications

 All u m i n u m A s s o c i at  A atii o n  Al  A l u m i n u m As A s s o c i ati at i o n Over Ov erv v i ew The Alumin um Association , based based in Arlingto n, Virgin Virgin ia, work s globally t o aggressively prom ote aluminum as the most su stainable and and recyclable automo automo tive, packaging packaging and cons truc tion material material in today’s market. The The Association represents represents U.S. U.S. and for eign-based eign-based pr imary pr oduc ers of aluminum , aluminum recyclers and produc ers of fabricated fabricated prod ucts, as well well as industry supp liers. The The Asso ciation pro vides leadership leadership to the indus try thr ough it s progr ams and services services and assists assists in achieving achieving the industry's environmental, environmental, societal, societal, and and economic objectives. Member ember comp anies anies operate more than than 200 plants i n th e United United States, States, with many co nduc ting busi ness worldwide.

 Al  A l u m i n u m As A s s o c i ati at i o n Mis Mi s s i o n The Aluminum Alum inum Ass ociation wi ll pro vide value value to its membership thr ough it s leadership leadership and services services in aggressive aggressively ly promoting the growth of the aluminum aluminum industry globally by:

• Continuously st rengthening rengthening aluminum's aluminum's position versus competitive materials materials Developing, maintaining and promo ting globa glob al standa st andards rds t hat achieve achieve custom er • Developing, requirements requirements for aluminum product applications Representin ntin g the interests of its membership t o the th e U.S U.S.. and and in ternation ternational al governments • Represe research and education to actively address address c ommunity ommu nity and emplo employee yee • Providin g research environm ental, ental, health health and safety iss ues Gathering and presenting data, statist ics, and other info rmation about the alumi aluminum num • Gathering industry in an accurate accurate and timely manner  manner   A n d b y...lev erag er agii n g in i n d u s t r y s t r eng en g t h by b y est es t abl ab l i s h i n g s t r o n g er d o m est es t i c and an d g l o b al • An alliances

Tha hanks nks to All of o f Our Our Cont Contrib ributo utors rs

Tha hanks nks to t o All of o f Our Our Cont Contrib ributo utors rs SAPA SAP A Alumi Alu minum num

Light Ligh t Metal Metal Age

Jeff Henderson 9600 9600 West Bry n Mawr A ve.,Suit ve.,Suit e 250 250 Rosemont, IL 60018 318-303-2 318-303-2661 661 (Off ic e) [email protected]

 An  Ann Marie rie Fello llom 170 S. Spru ce St. Suit e 120 S. San Francis Francis co, CA 94080 94080 650-588-88 650-588-8832 32 (Off ice) ic e) [email protected]

Hydro Aluminum Alumin um Lynn Brown 999 Corpor ate Blvd Linthcium, MD 21090 410-487-8 410-487-8057 057 (Offic (Off ice) e) [email protected]

Kaise Ka iserr Aluminum Aluminu m Doug Richman 24255 24255 Thirteen Mile Rd. Suite 290 Bing ham Farms, Farms, MI MI 48025 48025 248-430-0107 [email protected]

The Aluminum Association Mike Skillingberg 1525 1525 Wilson Wilson Blvd.  Arli  Ar li ng to n, VA 22209 703-358-2 703-358-2988 988 (Off ic e) [email protected]

 Al  A l u m i n u m Ext Ex t r u d ers er s Council Rand Baldwin 1000 N. Rand Rd. Rd. Suit e 214 Wauconda, IL 60084 847-526-20 847-526-2010 10 (Off ice)) ic e)) [email protected]

Werner erner Extrusion Extrusio n Solutions Solutio ns LLC LL C Craig Werner  100 N. Field Dr. Suite 145 Lake Forest Forest , IL IL 60045 60045 847-582-1160 (Offic (Off ic e) 847-910-0607 (Cell) (Cell ) [email protected]