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