Date post: | 13-Nov-2014 |
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Utilizing Aluminum Extrusion
To Reduce System Costs
This webinar will be available afterwards at www.solarpowerworldonline.com & email
Q&A at the end of the presentation Hashtag for this webinar: #SolarWebinar
“Part 1” webinar will be sent in follow-up email
Before We Start
Kathie ZippSolar Power World
Moderator Presenters
Craig WernerWerner Extrusion
Solutions
Jason WeberSAPA Extrusions NA
vite
Utilizing Aluminum Extrusion to Reduce System CostsPresented by:
Craig WernerChairman, AEC AcademyPresident, Werner Extrusion Solutions
Presenting Sponsors:
www.sapagroup.com/NA
Jason WeberDirector – Business DevelopmentSapa Extrusions NA
www.vitexextrusions.com/NA
2
Note: Today’s presentation builds on a July 2013 Webinar on extrusion design available via aec.org/extrusionapplications/energy.cfm and Solar Power World
Today’s Agenda
The Challenge: Driving for Grid Parity … or at least greater cost-effectiveness
Why Aluminum Extrusion
• Initial “out of the box” savings from extrusion’s material and process attributes
• Saving with site-specific solutions• Lifetime … and end of life … benefits
Creating Cost-Effective Solutions with Extrusion
• Alloy selection• Shape design• Structural design
3
This presentation provides both a conceptual and a practical understanding of how best to design for solar applications with aluminum extrusions
The Challenge
Source: Trina Solar; CleanTechnica 02/14
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A recent analysis by Trina Solar shows Racking, Cables and Installation represent nearly 2/3 of PV system costs … with modules at less than 1/4
2010 - 2013
- 66%
- 10%
- 25%
The Challenge
Source: NREL; chart by Daniel Wood; Energy.gov 02/142010 20122011 2013
… the result of dramatic decreases in module costs
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The Challenge
Further progress toward grid parity requires tackling installation and racking costs
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The Challenge
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Commercial & Utility
Lumos Solar, Boulder CO- LSX Canopy: Dwell on Design, best energy product ‘12- Transparent, frameless module
Residential, light Commercial
The Challenge is there for PV …
The Challenge
8
…BIPV …
Nevada Solar One CSP, Boulder, Nevada
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CPV, Durango, Mexico
The Challenge
… and even CPV and CSP
The Challenge
Yet Aluminum is more expensive than Steel* (on a per pound basis)
• Global Carbon Steel Price : $714/MT • Aluminum (LME): $1,838/MT
But …What are the economics when Aluminum’s lower density (1/3 that of steel) and offsets from:• Weight reduction, including that of secondary
elements• Reduced processing & assembly costs from “designed-in” functionality• Maintenance savings• End-of-life costs/credits are considered?
*e.g. June 2014; Source: ycharts.com; Worldsteelprices.com
10
Today’s Agenda
The Challenge: Driving for Grid Parity … or at least greater cost-effectiveness
Why Aluminum Extrusion
• Initial “out of the box” savings from extrusion’s material and process attributes
• Saving with site-specific solutions• Lifetime … and end of life … benefits
Creating Cost-Effective Solutions with Extrusion
• Alloy selection• Shape design• Structural design
11
Advantages of Aluminum
• Lightweight
• High Strength-to-Weight Ratio
• Resilient
• Corrosion-Resistant
• Dissipates Heat
• Reflective
• Electrically Conductive
• Non-Magnetic
• Non-Sparking
• Non-Combustible
• Cold Strength
• Fully Recyclable
Advantages of Extrusion
• Tailored performance
• Suitable for complex, integral shapes
• Produced to close tolerances
• Attractive
• Wide range of finishes
• Virtually seamless
• Easy to fabricate
• Joinable by various methods
• Suitable for easy-assembly designs
• Produced with uniform quality
• Cost Effective
• Short production lead times
12
Why Aluminum Extrusions?
13
Why Aluminum Extrusions?
This combination of attributes yields:• Initial savings due to
• Aluminum’s light weight• Secondary weight savings to other system elements• Integral features to facilitate installation and eliminate “add-ons”
• Optimized site-specific solutions due to• Modest tooling cost and time• Simplified assembly and installation
• Lifetime and end-of-life benefits from• Minimal maintenance• High recycling value
Why Aluminum Extrusions: Advantages of Aluminum
LightweightAluminum is only about one-third as heavy as steel (or copper or brass) Thus, aluminum helps minimize transport costs, roof loading, as well as the demands on tracking system components.
High Strength-to-Weight RatioThe standard aluminum frame for the new 2014 Corvette C7 is over 90 pounds lighter, yet 60% stiffer than the current steel frame
Alu Framing System
Steel Framing System
0 200 400
PV modules
Framing
E.G.: 1MW Ground Mount System
Lbs (000)
14
60% reduction in framing weight22% overall system weight reduction
Why Aluminum Extrusion: Advantages of Aluminum
Electrically ConductiveVolume for volume, aluminum carries electricity about 62% as well as copper. On an equal weight basis, aluminum can be twice as conductive as copper, and aluminum is often the most economical choice.
Aluminum facilitates grounding by eliminating additional components.
Alum
inum
Copp
er
Stee
l
Bras
s
0
20
40
60
80
100
Dissipates HeatConducts – and dissipates - heat better than any other common metal on both a weight and cost basis.
15
Why Aluminum Extrusion: Advantages of Aluminum
Corrosion-resistantAluminum develops its own inert aluminum oxide film, which is self-protective, blocking further oxidation and providing excellent corrosion resistance in a wide variety of environments.
Cold Strength• Aluminum’s many advantages are not impaired by exposure
to cold. In fact, aluminum gains strength and ductility as temperatures are reduced, making it a preferred metal for cryogenic (low-temperature) applications.
• Steel and plastics get brittle when the temperature drops… aluminum gets stronger and tougher!
16
Nevada Solar One2007Extruded Al. frameVirtually no mirror/framefailures
SEGS1984-90Luz steel frameNumerous steel fatigue/mirror failures
Why Aluminum Extrusion: Advantages of Extrusion
Produced to Close Tolerances• The ability to hold tight tolerances over the full extruded
lengths are routine and the ability of aluminum extruders to meet even more critical dimensions is keeping pace with advances in technology.
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Suitable for Complex, Integral Shapes• Shapes can combine functions that would otherwise require
the production and joining of several different parts, reducing part counts and costs.
Welds
Screw bosses
Local thickening
Why Aluminum Extrusion:
Example: Extruded rail for PV Roof MountDesign optimized for pitched installations as well as flat applications
¼" nut channel can accept standard ¼" T-bolts, standard ¼" bolts or ¼" jam nuts
Integral wireway adds strength while providing a location to run wiring
Perforations provide ease of installation and drainage
Available in black powdercoat,or anodized finish
Lumos Solar, Boulder, CO
Screw bosses for end caps
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Why Aluminum Extrusion: Advantages of Extrusion
Suitable for a Wide Range of FinishesAluminum accepts a great variety of finishes, colors &textures (anodize, alodine, wet paint, powder paint, applique, etc.).
However, due to aluminum’s corrosion resistance, the additional cost of finishing is generally not needed, unless for aesthetic reasons such as maximizing curb appeal.
Easy to Fabricate• Often, designing with aluminum extrusions can eliminate
many fabrication and assembly steps
• Aluminum extrusions can be made with almost any cross-sectional shape. Parts can be easily cut, machined, finished, fabricated and assembled.
19
Why Aluminum Extrusion: Advantages of Extrusion
Joinable by Various Methods• Aluminum extrusions can be joined to other aluminum
products or to different materials by all major methods, including welding, soldering, brazing, bolts, rivets, clips, adhesives, clinching and slide-on, snap-together or interlocking joints.
Excellent for easy-to-assemble designs• Aluminum extrusions with integral connection points have
been widely used for elaborate framing, such as the scaffolding for the recent renovation of the Statue of Liberty and the current repair of the Washington Monument
Hinge detail “Christmas tree” for joining with wood or plastic
Screw boss on leg
Groove to accept printed circuit cards
Groove for screw or rivetGroove for rubber moulding
Drill groove
Slot for location of nut or bolt head
Screw bossFluted surface for appearance
Groove to accept printed circuit cards
Dovetail assembly
Snap fit spring assembly
“Heat sink” cooling fin
Patterned surface for appearance
20
Process Typical Part Tooling Cost ($)
Aluminum Extrusion $500 to $5000
Stampings $5000 and up
Injection Molding $25,000 and up
Die Castings $25,000 and up
Roll Forming $30,000 and up
Why Aluminum Extrusion: Advantages of Extrusion
Cost-effective• Tooling costs are modest in comparison with other processes
Time-effective• Extrusion’s short lead times facilitate prototype
development.
21
Aluminum Extrusio
n
Stampings
Roll Form
ing
Die Castings
Injection M
olding048
121620
Typical Tooling Lead Time (weeks)
On one solar project, sequential prototyping facilitated a 40% reduction in material costs!
Why Aluminum Extrusion
Sustainable & Fully Recyclable• Able to be recycled over and over without degradation of
properties; over 75% of the aluminum produced since 1888 is still in productive use!
• Thus, Aluminum has significant scrap value
• Extrusions often contain as much as 80% recycled content; in 2010 North American production had 53% recycled content
22
47%
5%
19%
29%
prime process scrappost-ind. Scrap post-consumer
Why Aluminum Extrusion
With all factors considered, aluminum can cost less!• IBIS Associates assessed the economics of aluminum & steel framing for a variety of PV mounting structures• In all cases, Aluminum was the lower cost alternative, even without considering end-of-life value
23
Note: Steel’s weight (3X Aluminum) can create load problems for older roofs, and require more robust tracking components
Why Aluminum Extrusion
The same conclusion – that aluminum costs less – holds for CSPCost summary: per sq. meter Aluminum 20+% less!
24
Source: IBIS Associates
Why Aluminum Extrusion
But what if commodity prices change?
25
Source: IBIS Associates
Today’s Agenda
The Challenge: Driving for Grid Parity … or at least greater cost-effectiveness
Why Aluminum Extrusion
• Initial “out of the box” savings from extrusion’s material and process attributes
• Saving with site-specific solutions• Lifetime … and end of life … benefits
Creating Cost-Effective Solutions with Extrusion
• Alloy selection• Shape design• Structural design
26
Creating Cost-Effective Solutions
Feedstock: heated aluminum alloy “billet”
Desired final “profile” or shape
Steel die and supporting tooling
The Extrusion Process
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The Extrusion Process
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Creating Cost-Effective Solutions
Creating Cost-Effective Solutions
Aluminum extrusions offer outstanding design flexibility …
• To tailor component performance with alloy and temper choice
• To inexpensively incorporate functional details that simplify assemble, reduce part counts, and enhance utility
…but, there are some limitations
• Circle Size (the circumscribing circle that the profile could fit through)
• Weight/Ft (Too heavy? Too light?)
• Shape Constraints
– High tongue ratios
– Somewhat balanced wall thicknesses
– Other
• Press availability
29
Cost-Effective Solutions: Design Considerations
Availability of various profile circle size / area / weight combinations
Circumscribed Circle Size in inchesCorresponding Profile weight
(lbs/ft)
Cross Section Area in sq inches
<1 1 to 7 7 to 10 10 to 14 >14Min Max
<.050 L x x x x - 0.06
.050 to .100 G G L x x 0.06 0.12
.100 to 1.0 W W L x x 0.12 1.18
1.0 to 2.5 x W W L x 1.18 2.94
2.5 to 10 x W W G L 2.94 11.76
>10 x x W G L 11.76 -
x Not available
L Limited Availability
G Generally Available
W Widely Available
NOTE:There are many presses available with up to 7" diameter containersThere are fewer presses available with 7" to 10" diameter containersThere are even fewer presses available with 10" to 14" diameter containersThere are very few presses available with greater than 14" diameter containers
30
Cost-Effective Solutions: Alloy Selection
Alloy strength will be a consideration …Increasing
strength
31
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
00 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
% Si
% Mg
6082
60636060
6005A
6061
60636060
6082
60636060
6061
6005A
6061
6063
6061
6082
6063
6061
6005A
6082
6063
6061
6060
6005A
6082
6063
6061 Excellent for less structural applications
(e.g. framing, rooftop PV)
Preferred for structural solar
applications(e.g. Ground
mounts)
Cost-Effective Solutions: Alloy Selection
32
Str
engt
h**
(ksi
)
Extrudability index0 50 100 150
Yield Tensile
3003
6060/63*
6082* 7020
7075
Al 99.5
6005A*
0
90
80
70
60
50
10
40
30
20
Mild steel
Mild steel
… as will be cost
* T6, except 6005A @ T61**typical properties
Cost-Effective Solutions: Alloy Selection
“Newer” alloys often provide superior performance
6005A T5 vs 6061 T6 (6061 is an “older” alloy, often specified out of habit / momentum)
33
Cost-Effective Solutions: Shapes
Shape Classifications (per Aluminum Association)
Solids
Semi-hollow
Hollows
Class I Class II
Class I(Balanced
round int. > 1”)
Class II(< 5”, > 0.11”)
Class III
34
Cost-Effective Solutions: Shapes
Good Design Practices• Balance walls
• Avoid hollows
• Generous tapers
Uniformity
This!Not this!
Smooth Transitions
Symmetry
• Practice symmetry/minimize asymmetrical detail
• Use grooves, webs, and ribs
• Minimize perimeter/cross-section ratio
Enhance visual surfaces
This!Not this!
This!Not this!
This!Not this!
This!Not this!
This!Not this!
35
Cost-Effective Solutions: Shapes
Extrusion Design HintWhere possible, maintain consistent wall thickness
This! Not this!
36
Cost-Effective Solutions: Shapes
Extrusion Design HintWhere possible, reduce deep narrow “tongues” by re-designing the profile
This! Not this!
37
Cost-Effective Solutions: Shapes
Extrusion Design HintScrew slots are often simple to incorporate in the profile
Screw slots can often eliminate the need for a more expensive hollow die (which also extrudes more slowly, further increasing costs)
Self tapping screw Thread cutting screw
Not this!
This!
38
Cost-Effective Solutions: Shapes
Extrusion Design HintWhere possible, re-design the profile to reduce cost
(for example, a single void hollow die with smoothed transitions vs. a multiple void hollow die)
Or, in this case, 10% less costs, lighter, and less likely to have die break.
This! Not this! This! Not this!
39
Cost-Effective Solutions: Structure
So how do we know that this shape is structural sufficient?A comprehensive discussion of the design and analysis of extrusions for structural applications is beyond the scope of this webinar. However:
• The basic process is similar to that for steel
• Designing steel structures generally involves assembling standard shapes for which structural performance is known and readily available in tables and software
• Designing extruded aluminum structures involves creating optimized shapes for the desired function and economics. Thus, structural performance will have to be calculated.
• Design calculations, incorporating material and shape characteristics like yield strength & moment of inertia are based on the same fundamentals that define steel design
• The Aluminum Association’s “Aluminum Design Manual – 2010 Edition” (www.aluminum.org) provides the key data – and is structured so that one familiar with steel will be able to easily understand and utilize the data.
41
Suggested Design Steps to create an efficient extruded structure
1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
Cost-Effective Solutions: Structure
42
Courtesy:
Suggested Design Steps to create an efficient extruded structure
1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
Cost, Performance, Aesthetics,
Weight, # of parts, etc…
Cost-Effective Solutions: Structure
43
Courtesy:
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
44
Courtesy:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure
1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
1.31.21.11.00.90.80.70.60.50.40.30.20.1
0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
% Si
% Mg
6082
60636060
6005A6061
60636060
6082
606360606061
6005A6061
60636061
6082
60636061
6005A
6082
60636061
6060
6005A
6082
60636061
6XXX alloy strength
45
Courtesy:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
46
Courtesy:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure
1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
47
Exclusive Property of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
48
Courtesy:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
49
Exclusive property of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible ally and temper selections with
extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
Exclusive property of WES LLC
Cost-Effective Solutions: Structure
50
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible ally and temper selections with
extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
51
Exclusive property of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y
costs, using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
$52
Courtesy of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
53
Exclusive property of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible ally and temper selections with
extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
54
Exclusive property of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
55
Exclusive property of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible alloy and temper selections
with extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
56
Courtesy of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure
1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible ally and temper selections with
extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
Cost-Effective Solutions: Structure
57
Courtesy of:
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible ally and temper selections with
extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive
summaries of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
58
Exclusive Property of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible ally and temper selections with
extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
59
Courtesy of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible ally and temper selections with
extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
60
Courtesy of:
Cost-Effective Solutions: Structure
Suggested Design Steps to create an efficient extruded structure
1. Understand the Design Objectives2. Involve Trusted Extruders Up Front3. Discuss possible ally and temper selections with
extruder4. Understand the location req’ts5. Fully understand the functional req’ts6. Detail out the known constraints7. Develop alternative geometries8. Utilize design software to create “idealized”
members9. Vary the designs, geometry, etc…, estimating
the weights, costs…10. Use engineering analysis to estimate ass’y costs,
using known info11. List out various alternatives, incl. weights, part
counts, $’s,…
12. Choose alternatives to fine-tune13. Use ADM 2010, FEA, Autodesk Inventor and other
design tools to develop ACTUAL part designs14. Iteratively design the system and parts to achieve
optimal cost and performance solutions15. Understanding likely failure modes, consider
alternative alloys/tempers16. Provide decision-makers with executive summaries
of alternatives17. Detail out the chosen design(s)18. Provide rapid prototyped parts (?)19. Obtain final quotations / make final decisions;
work with extruders on final tolerancing
61
Courtesy of:
Cost-Effective Solutions: Structure
Design Considerations: Structure
The Aluminum Association’s “Aluminum Design Manual – 2010 Edition” (www.aluminum.org) provides the key data – and is structured so that one familiar with steel will be able to easily understand and utilize the data.
Aluminum Design Manual 2010 (ADM)
• General Provisions
• Design Requirements
• Design for Stability
• Design of Members for Tension
• Design of Members for Compression
• Design of Members for Flexure
• Design of Members for Shear
• Design of Members for Combined Forces and Torsion
• Design of Connections
• Design for Serviceability
• Fabrication and Erection
Appendix
Testing
Design for Fatigue
Design for Fire Conditions
Evaluation of Existing Structures
Design of Braces for Columns and Beams
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Design Considerations: Structure
The Aluminum Association’s Aluminum Design Manual (ADM) provides information on utilizing the safety factors, formulae, tabular information (strength, etc…) to analyze and design a structure.
This process is familiar to mechanical, structural and other engineers, and the latest version of the ADM presents key concepts in a format that users of the AISC steel manual will find familiar.
The analysis and calculations are often iterative, allowing the designer to alter specific variables (tube diameters & wall thicknesses, etc.) to see the effect on the overall design.
??
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Additional Resources
For more Information and Training
Purchase the Aluminum Design Manual 2010 edition from the Aluminum Association (aluminum.org)
Reference other resources available from the Aluminum AssociationAluminum Standards and Data: nominal and specified chemical compositions of alloys; typical mechanical and physical properties; mechanical property limits; definitions, and dimensional tolerances for semi-fabricated products
Utilize ASCE Aluminum Design Manual training
– On-line: go to www.asce.org/distancelearning; click on “View a complete list of ASCE courses”, scroll down y to “Aluminum Structural Design with the 2010 Aluminum Design Manual”
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Additional Resources
For more Information and Training
• Utilize the Aluminum Extruders Council website (aec.org) for webinars or other key information
• Find an Extruder search• Extrusion Applications• Extrusion Design Resources• Sustainability Info• And more!
About AEC: The Aluminum Extruders Council (AEC) is an international trade association dedicated to advancing the effective use of aluminum extrusion in North America. AEC is committed to bringing comprehensive information about extrusion's characteristics, applications, environmental benefits, design and technology to users, product designers, engineers and the academic community. Further, AEC is focused on enhancing the ability of its members to meet the emerging demands of the market through sharing knowledge and best practices.
AEC Aluminum Extrusion Manual (www.AECmanual.org)
AEC Buyers’ Guide (www.AECguide.org)
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Conclusion
Aluminum extrusions provide a cost-effective resource for your next project or design
• They are lightweight, strong, corrosion resistant, fully recyclable . . . a sustainable material
• They accommodate complex shapes, can incorporate multiple functions and are easy to fabricate, providing a custom design response quickly and at minimal cost.
• With appropriate design, aluminum extrusions are the cost effective option for racking and mounting. They are clearly less expensive over the project life … and may be less costly initially.
• While there are important nuances to the extrusion process, available fabrication/finishing options, alloy selection, and extrusion design details, there are a wealth of resources to help you make smarter – more cost effective – decisions
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Thanks to Our Presenting Sponsors
www.sapagroup.com/NA
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www.vitexextrusions.com/NA
Questions?Kathie ZippSolar Power [email protected]: @SolarKathieZ
Jason WeberDirector, Business Development - Energy ProductsSapa Extrusions North [email protected]
Andy CurlandPresidentVitex [email protected]
This webinar will be available at www.solarpowerworldonline.com & email
Tweet with hashtag #SolarWebinar
Connect with Solar Power World
Discuss this topic on EngineeringExchange.com
“Part 1” webinar will be sent in follow-up email
Thank You
… and to all the members of the AEC
To find an extruder: go to aec.org <http://aec.org/search/index.cfm> and choose “Find an Extruder”
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ABC Aluminium SolutionsAerolite Extrusion CompanyAkzo Nobel Coatings Inc.Albarrie Canada LimitedAlcoa Forgings and ExtrusionsAlcoa Primary MetalsAlexandria IndustriesAlexin LLCAlmag Aluminum Inc.Al-Taiseer Aluminium FactoryAltec LLCAluminio de Centro AmericaAluminium Bahrain B.S.C,Aluminium Products Co. Ltd.Aluminum Shapes LLCAMCOL CorporationAPEL Extrusions LimitedApex Aluminum Extrusions Ltd.Arabian Extrusions FactoryAstro Shapes Inc.Azon USA Inc.BCI Surface TechnologiesBelco Industries Inc.Bonnell AluminumBriteline Extrusions, Inc.Butech BlissCapral AluminiumCardinal Aluminum Co.CASTOOL Tooling SystemsCometal Engineering S.p.A.
Compes InternationalCrown Extrusions Inc.Crystal Extrusion Systems Ltd.Crystal Finishing Systems Inc.Custom Aluminum Products Inc.Dajcor Aluminum Ltd.Danieli CorporationDienamexDrache USA Inc.Dubai Aluminium Co. Ltd.EmmebiEnsinger IndustriesETS-Exco Tooling SolutionsEXCOExtruded Aluminum CorporationExtruders DivisionExtrudex Aluminum Ltd.Foy Inc.Frontier Aluminum Corp.Futura Industries Corp.General Extrusions Inc.GIA ClecimGranco Clark Inc.Gulf Extrusions Company LLCHoughton Metal Finishing CompanyHulamin Extrusions Hydro Aluminum North America Inc.ILSCO Extrusions Inc.iNOEX LLCInternational Extrusions
Jordan Aluminum Extrusions, LLCKeymark Aluminum CorporationLight Metals CorporationMagnode CorporationMarx GmbH & Co. KGMatalco Inc.M-D Building ProductsMetal Exchange CorporationMetra Aluminum Inc.MI Metals Inc.Mid South Extrusion Die Co.Mid-States Aluminum Corp.Nanshan America Co.National Aluminium Ltd.Noranda Aluminum Inc.Ohio Valley Aluminum Co. LLCOMAV S.p.A.PanAsia Aluminium LimitedPeerless of America Inc.PengCheng AluminumPenn Aluminum International Inc.Pennex Aluminum CompanyPostle ExtrusionPPG Industries Inc.Presezzi Extrusion North AmericaPries Enterprises Inc.Reliant Aluminum Products LLCRichardson MetalsRio Tinto AlcanSapa Extrusions
Service Center MetalsSierra AluminumSilver City Aluminum Corp.SMS Meer Service Inc.Spectra Aluminum Products Ltd.Spectrum Metal Finishing Inc.Superior Extrusion Inc.Taber Extrusions LLCTecalex USATechnoformTecnoglass S.A.Tellkamp Systems Inc.Thumb Tool & EngineeringTri City Extrusion Inc.Tubelite Inc.Turla S.r.L.Ube Machinery Inc.Valspar CorporationVidrieria 28 de Julio S.a.C.Vitex ExtrusionWagstaff Inc.Walgren CompanyWEFA Cedar Inc.Werner Co.Werner Extrusion Solutions, LLCWestern Extrusions Corp.Whitehall IndustriesYKK AP America Inc.Youngstown Tool & Die Co. Inc.
Proper Use of the Presented Information
The Aluminum 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. Such information is generally intended for users with a technical background and may be inappropriate for use by lay persons.
This presentation does NOT attempt to thoroughly discuss all load types, materials, profiles, design requirements, etc.
The purpose is to provide an overview of topics/issues to consider when utilizing aluminum extrusions for designs
Full understanding and adherence to the Aluminum Design Manual (Aluminum Association 2010) and all documents referenced by it is required for proper design
In all cases, users should not rely on this information without consulting original source material and/or undertaking a thorough scientific analysis with respect to their particular circumstances. Information presented here does not replace the independent judgment of the user or of the user’s company and/or employer.
AA AND AEC EXPRESSLY DISCLAIM ANY AND ALL GUARANTEES OR WARRANTIES WITH RESPECT TO THE INFORMATION PROVIDED HERE. AA AND AEC FURTHER DISCLAIM ANY LIABILITY IN CONNECTION WITH THE USE OR MISUSE OF ANY INFORMATION PROVIDED OR IN CONNECTION WITH THE OMISSION OF ANY INFORMATION.
Photos, Illustrations, Graphics used in this PowerPoint courtesy of: Akzo Nobel Coatings Inc./Bill Hanusek, Gossamer Innovations, Hydro Aluminum North America Inc., Light Metal Age Magazine, MAADI Group, SAPA Extrusions, Skylne Solar, Werner Co., Werner Extrusion Solutions, LLC
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