ALUMINUM EXTRUSION

IDENTIFICATION,
CLASSIFICATION,
AND
TRADE LAW SEMINAR

For U.S.
CUSTOMS AND BORDER
PROTECTION, ICE/HSI, AND OTHER
ALUMINUM EXTRUSION-FOCUSED USG
OFFICIALS AND CUSTOMHOUSE BROKERS
AUGUST 22 – AUGUST 23, 2017

U.S. Customs and Border Protection Offices

301 E. OCEAN BLVD, SUITE 1400
LONG BEACH, CA 90802

Presented and Sponsored by the

ALUMINUM EXTRUDERS COUNCIL

Represented by

RIO TINTO ALUMINIUM

FRONTIER ALUMINUM CORP.
SIERRA ALUMINUM
SAPA
 Aluminum Extrusion Identification, Classification & Trade Law Seminar
U.S. Customs & Border Protection, HSI, Other U.S. Government agencies, and Customhouse Brokers
U.S. Customs and Border Protection Offices – 301 E. Ocean Blvd, Suite 1400
Long Beach, CA 90802
Presented by: Aluminum Extruders Council, Rio Tinto Aluminium,
Frontier Aluminum Corp., Sierra Aluminum, Sapa, Wiley Rein

Time Sect. Topic Discussion Presentations Tuesday, August 22, 2017

9:30 – 10:00 AM Overview of the aluminum extrusion industry – Jeff Henderson, Aluminum Extruders Council

Break (10 mins.)

10:00 – 10:55 AM Primary, Remelt, Alloys, Billet – Jerome Fourmann, Rio Tinto Aluminium

Break (10 mins.)

11:05 – Noon Extrusion Press and Dies – Mike Rapport, Frontier Aluminum Corp.

Noon – 1:30 PM Lunch

1:30 – 2:25 PM Finishing; Paint, Powder, Anodizing – Shayne Seever, Sierra Aluminum

2:25 – 3:20 PM Fabrication – Jason Weber, Sapa

Break (10 mins.)

3:30 – 4:00 PM Circumvention / Transhipment – Jeff Henderson, Aluminum Extruders Council

4:00 – 4:50 PM Legal Presentation; Orders, Enforcement – Wiley Rein Attorneys

Wednesday, August 23, 2017

8:30 – Noon Tour of Extrusion Facility Hosted by Mike Rapport, President

Frontier Aluminum Corp. Frontier Aluminum Corp.
2480 Railroad Street
Corona, CA 92880

Current as of August 7,
2017
 Aluminum Extrusion Identification, Classification & Trade Law Seminar
Post-Seminar Participant's Survey
Location: Long Beach, CA Date: August 22-23, 2017

Representing: Customs & B.P.___ ICE/HSI___ Other USG___ Customhouse Broker___ Other___

Rate the program elements on a scale of 1 (poor) to 5 (excellent):

Overall: ___
Seminar Format: ___ Format Suggestions: _______________________________________

Overview of the Aluminum Extrusion Industry

1. Introductory Overview, Market Perspective – Henderson ___

Primary Aluminum, Remelt, Alloys, Billet Topics

2. A. Standards, Specifications, Metallurgy, – Fourmann ___

Extrusion Press/Dies
3. Overview of Key Equipment Components – Rapport ___

Finishing Processes
4. A. Anodizing – Seever ___
B. Powder/Liquid Paint – Seever ___

Fabrication/Products
5. Profiles/Products – Weber ___

Seminar met my expectations ___

Subject areas of greatest interest to me are ___________________________________

I would like to see greater emphasis on _________________________________________

I would like the following uncovered topics covered in future seminars ______________

I would like the following topics deemphasized or deleted in future seminars ________

Personal Information (optional, but appreciated):

Name: ____________________________________________________________________
Organization: _______________________________________________________________
Address: ___________________________________________________________________
Phone: _________________________ Email: ________________________________
 U.S. Aluminum Extrusion Industry Contact List
Customs, Import and Trade Issues

Name Company Represents Expertise Phone/Fax/email

Jeff Henderson Aluminum Extruders Aluminum Extrusion 847.416.7222
Council (AEC) Industry 318.348.0425 Cell
[email protected]
Robert DeFrancesco, Wiley Rein LLP Bars, structurals, Trade law (bars, 202.719.7473
Esq. grating, flat rolled structural, flat rolled, and 202.719.7049 Fax
grating) [email protected]
Alan Price, Esq. Wiley Rein LLP Bars, structurals, Trade law (bars, 202-719-3375
grating, flat rolled structural, flat rolled, and 202-719-7049
grating) [email protected]
Richard DiDonna Wiley Rein LLP Bars, structurals, Trade law (bars, 202-719-7196
grating, flat rolled structural, flat rolled, and 202-719-7049
grating); licensed [email protected]
customs broker
Jerome Fourmann Rio Tinto Aluminium Primary producers 440.460.3320
Of aluminum billett 440.520.4975 Cell
[email protected]

Mike Rapport. Frontier Aluminum Extrusion Plants 951.735.1770

Corp. [email protected]
Shayne Seever Sierra Aluminum Extrusion Plants 951.781.7800
951.837.0671 Cell
[email protected]
Jason Weber Sapa Extrusion Plants 605.321.4387
[email protected]
 BIOGRAPHIES

(In order of the agenda including industry team members not attending this event)

Jeff Henderson is President of the Aluminum Extruders Council (AEC). In addition to managing the overall activities
at AEC, Mr. Henderson is responsible for directing and managing the Fair Trade Committee, which is the U.S.
aluminum extrusion industry’s team that successfully petitioned the U.S. government for free and fair trade action
against China in 2011. He also manages the AEC’s Industry Promotion effort that has resulted in thousands of
inquiries each year to aec.org. Mr. Henderson is also the owner and president of The Sanford Organization (TSO),
which is an association management company that runs non-profit organizations. In addition to the AEC, TSO
manages the Aluminum Anodizers Council, the National Plasterers Council, and several other trade associations.

Jerome Fourmann is Technical Director, Global Customer Support and Product Development for the aluminum metal
group of Rio Tinto. Since joining Rio Tinto in 2000, Jerome has utilized his technical expertise to support customers
and the market development of value added product in extrusion and foundry products. He holds a MS degree in
Metallurgy and serves on committees at The Aluminum Association, ASTM and AEC; he is based in Cleveland, Ohio.
In addition of being a frequent presenter at industry conferences, Jerome has authored several papers and is a
contributing editor for the magazine Light Metal Age.

Mike Rapport is the President of Frontier Aluminum Corporation. Started as a family business in 1990, Frontier has
grown to become a leading independent West Coast aluminum extruder and finishing company. As the sole owner
since 2013, Frontier remains on the cutting edge of the aluminum extruding industry. Mr. Rapport has traveled
extensively around the “extrusion” world including multiple visits for China, Italy and Spain applying what he has
learned from those travels to Frontier. Mr. Rapport was the early warning signal and call to action for the formation of
the anti-dumping action against Chinese imports. He is still active today in his efforts to monitor and assist in
regulation the burgeoning extrusion juggernaut in China. With 27 years of experience in extrusions, Mr. Rapport is a
qualified aluminum extrusion expert on the West Coast.

Shayne Seever is VP of Administration for Sierra Aluminum, a full service manufacturer of standard and custom
aluminum extrusions located in Riverside, California. He earned a B.S. in Physics with a minor in Engineering Studies
from Carnegie Mellon University and an MBA from the Drucker School of Management at the Claremont Graduate
University. Shayne started working in the aluminum extrusion industry when he was 21 year old and has been in it for
21 years. His background has allowed him to evolve into and out of a number of positions within Sierra, depending on
what was needed by the company at the time. Over the years he has been involved with building construction and
process line installations and upgrades (casting, extrusion, anodizing, and paint), equipment specification, P&L
responsibility for the paint and anodizing departments along with oversight of approximately 100 employees, and was a
fiduciary for the Sierra Employee Stock Ownership Trust (the legal entity which owns Sierra). His vast experience has
allowed Shayne the freedom to be involved in many parts of the business.

Jason Weber is the Director of Business Development for Energy and Industrial Products at Sapa Extrusion North
America. With over 20 years of experience in the aluminum extrusion industry Weber and his team are responsible for
increasing extruded aluminum content, promoting Sapa’s brand, and developing local and global product strategies
within the Energy and Industrial Product segments. Weber is a member of the Aluminum Extruders Council with a seat
on the AEC’s Board of Directors and holds a Bachelor of Science degree in Business Administration and Marketing
from Minot State University in North Dakota.

Richard F. DiDonna is the director of the U.S. domestic steel industry customs seminar program. In addition, Mr.
DiDonna is an International Trade Analyst at the Washington, D.C., law firm of Wiley Rein LLP. Mr. DiDonna assists
clients before federal Executive agencies and independent federal agencies on a variety of issues including trade
remedies, customs compliance, entry and clearance of goods into the U.S., and other related matters. Licensed as a
U.S. Customs Broker since 2010, he has particular experience with issues including tariff classification, free trade
agreements, rules of origin, country of origin marking rules, and post-entry procedures. Mr. DiDonna has also
represented clients before the Committee for Statistical Annotation of Tariff Schedules (the “484(f) Committee”) in
proposing and securing revisions to the Harmonized Tariff Schedule of the United States (“HTSUS”).

Mr. DiDonna’s representative industry experiences spans a broad spectrum of products including ferrous goods of all
types (carbon and alloy long products, carbon and alloy flat-rolled products, tubular goods, semifinished steel inputs,
and fabricated structural goods), nonferrous metals including copper and aluminum products, paper products,
photovoltaic goods, and various manufactured OEM products.

Mr. DiDonna earned his B.A. in politics and East Asian Studies – focusing on Japan – from Washington and Lee
University.

Alan H. Price is a partner in the Washington, D.C. law firm of Wiley Rein LLP and serves as the chairman of the
firm’s international trade practice. Alan has more than 25 years of experience representing clients in high-profile,
complex international trade regulatory matters, including trade litigation involving public and government relations
issues. In addition to being chair of the firm’s international trade practice, he heads the firm’s antidumping and
countervailing duty practice. He also counsels clients on bilateral and multilateral agreements, trade legislation,
customs regulation, Foreign Corrupt Practices Act (“FCPA”) compliance issues, escape clause investigations, and
Section 301 cases.

Alan has particularized expertise in the fields of metals – including both ferrous and non-ferrous metals and has
represented these industries in high-level proceedings before CBP, the U.S. Department of Commerce, the U.S.
International Trade Commission, the U.S. Court of International Trade, the U.S. Court of Appeals for the Federal
Circuit, and various international bodies. Alan has served as the president (2012-2014), vice president and president
elect (2010-2012) of the Committee to Support U.S. Trade Laws (“CSUSTL”).

Alan obtained his Bachelor of Arts degree with high honors from the State University of New York at Stony Brook,
and obtained his J.D. with honors from the George Washington University Law School.

Robert DeFrancesco is a partner in Wiley Rein’s International Trade Practice, handles all aspects of trade remedy
proceedings. He has particular expertise in both U.S. antidumping and countervailing duty proceedings appearing
before the Department of Commerce, the International Trade Commission, the U.S. Trade Representative, the Court of
International Trade, and the Court of Appeals for the Federal Circuit. Mr. DeFrancesco has also actively assisted in
World Trade Organization matters, providing advice regarding WTO obligations and dispute settlement proceedings
for various clients and governments.

2
 Aluminum Extrusions Identification, Classification, and Trade Law Seminar

Intellectual Property Rights

Copyright 2017 Aluminum Extruders Council. All rights reserved. Written

materials may not be reproduced electronically or mechanically and may not be
disseminated without the written permission of the authors and compilers. The
seminar may not be recorded or reproduced electronically in any manner without
the written permission of the presenters.

Disclaimer

The information included in the written materials and the presentations is

represented to be accurate to the best of the knowledge of the authors and
presenters. It is intended to provide general information to Customs & Border
Protection personnel and the trade community. The information represents the
views of the authors and does not necessarily represent the views or official
positions of the United States Department of Homeland Security, United States
Customs & Border Protection, United States Department of Commerce, the
United States International Trade Commission or any other government agency.
The materials presented are not intended to constitute legal advice, do not
supersede U.S. laws, regulations, or rulings of any government agency, and
should not be used as the basis for any legal claim or defense. Reliance on the
information presented in this seminar alone may not be considered reasonable
care. The authors and presenters shall not be liable for any incidental or
consequential harm resulting from reliance on the information presented in the
seminar or written materials. Please report any errors, omissions or suggestions
to the authors or to Richard F. DiDonna, U.S. Domestic Steel Industry Seminar
Program Director.
Aluminum Extrusion Seminar
U.S. Customs & Border Patrol
Long Beach, CA
August 22, 2017
Aluminum Extruders Council - Membership

The Aluminum
Extruders Council
Represents:

 124 Members
 64 U.S. Extrusion
Members
 7 new members in
2017
 97.7% Renewal Rate
 Vendors, Suppliers,
Aluminum Producers
 84% of Reported U.S.
Extrusion Capacity AEC has been the only association dedicated to the
Aluminum Extrusion industry. AEC members have plants in
35 states in the U.S.
What is an aluminum extrusion?

The extrusion process is relatively simple. Use a large

hydraulic press to push a heated aluminum billet
through a steel die.
What is an aluminum extrusion?

About 40% of all aluminum extrusions are either

painted, anodized, or coated in some way. Applications
can range from storm doors to luggage racks on vehicles.
What is an aluminum extrusion?

Virtually all extrusions are fabricated in some way after

extrusion. This is performed by either the extruder, the
customer, or a third party. Extruders continue to grow
their businesses in this area as more OEM’s want ‘parts’
versus raw material.
What is an aluminum extrusion?

In some cases, customers ask extruders to kit or

assemble their fabricated extrusions.
Extrusion Industry Overview
• There are over 100 extrusion companies in the U.S.
• Most are ‘one-shop’ operations that service customers in their region
• They tend to specialize in the types of extrusions demanded from their regional
customers
• The industry has always had at least one large extruder with a few multi-site
extruders
• Over the last 30 years, extruders have evolved into a more integrated supplier with
their customers
• More fabrication
• In house coatings
• Assembly & fabrication
• JIT programs
• It wasn’t until the Chinese ramp up in 2009-2010 that imports became a major
threat to our industry.
Extrusion Industry Overview

Exports Other
2% 2%
Machinery &
Equipment Distribution
11% Building &
4%
Electrical Construction
6% 36%

Consumer
Durables
5%
Transportation
34%

Total Pounds: 5,502,121

Source: AEC Annual End Use Survey 2016

Extrusion Industry Overview

Primary Doors &

All Other Building Windows
& Construction 25%
33%

Secondary Doors &

Windows
15%
Store Fronts &
Entrance Doors
11% Curtain Walls
12% Awnings &
Canopies
Bridge, Street & 2%
Highway Mobile
Construction Homes/Manufactu
1% red Housing
1%

Building & Construction Uses

Source: AEC Annual End Use Survey 2016
Extrusion Industry Overview
Travel Trailers & All Other Aircraft &
Recreational Transportation Aerospace
Vehicles 4% 5%
14%

Trailers &
Semitrailers
39%
Passenger Car &
Light Truck
31%
Truck & Bus
7%

Transportation Uses
Source: AEC Annual End Use Survey 2016
Extrusion Industry Overview

Refrigerators & Other Major

Freezers Appliances
5% 10%
All Other Consumer
Durables
26%

Furniture
26%

Sporting & Pleasure Boats &

Athletic Goods Outboard Motors
and Toys 23%
10%

Consumer Durables Uses

Source: AEC Annual End Use Survey 2016
Extrusion Industry Overview
Power
Transmission &
Distribution
17%
All Other
Electrical
42%

Solar, Wind,
Alternative
Energy
33%

Electronics &
Communications
8%

Electrical Uses
Source: AEC Annual End Use Survey 2016
Extrusion Industry Overview

Ladders & Scaffolds

11%

All Other Machinery

& Equipment
89%

Machinery & Equipment Uses

Source: AEC Annual End Use Survey 2016
Thank You
Aluminum Alloys
Extrusion application
Jerome Fourmann – Long Beach, CA - August 22, 2017
Agenda
1 History of metal over the years…
Historical background
Aluminum production process

2 Aluminum alloys
Wrought Alloys designation
Alloy families
Alloy selection
5050 vs. 6063 or 6463

3 Extrusion billet making

© Rio Tinto 2017

History of metal used over the years…

Copper used for 9,000 years

Bronze (Copper + Tin) used for 4,000 years

Iron used for 3,000 years

Steel (Iron + Carbon) used for 300 years

Aluminum used for 131 years

3 © Rio Tinto 2017

Historical background

English chemist Sir Humphry Davy found the existence of the metal in 1808

First produced in 1825 (in an impure form) by Danish chemist Hans Christian Oersted.

First Chemical Production in 1855

2 tons of Aluminum were produced in 1869

Capstone on the Washington Monument

- December 1884 - 100 ounce -
4 © Rio Tinto 2017
Historical background – Ground breaking discovery

Electrochemical Production by Charles Hall (Oberlin, Ohio USA) and Paul Heroult (France) in 1886

Bayer Process for Alumina in 1892

Alumina

5 © Rio Tinto 2017

Aluminum production process

The Five Steps in the Aluminum Cycle

1. Mining

2. Refining

3. Smelting

4. Casting

5. Recycling

6 © Rio Tinto 2017

Aluminum production process
1. Mining
3rd most abundant element in the earth’s crust
The most abundant metal in nature

All others
Calcium 9%
Iron 4%
5%
Aluminum
Oxygen
8%
46%

Silicon
28%

7 © Rio Tinto 2017

Aluminum production process
1. Mining
Bauxite is an ore rich in Aluminum Oxide

Mined in Tropical regions of the World.

The production on aluminum consumes

90% of global bauxite mined.

Aerial view of bauxite mining operations,

Gove, Australia

8 © Rio Tinto 2017

Aluminum production process
2. Refining
Bauxite is turned into Aluminum Oxide or “Alumina” (Al2O3)
The Bayer process

9 © Rio Tinto 2017

Aluminum production process
3. Smelting
“Hall-Heroult process” in which an electrolytic reduction turn Aluminum Oxide (Alumina) into
Aluminum (Metal)

Alumina +
Anode

Alumina Feeding

Anode (+)
Electrolytic Bath
Molten Aluminium
Cathodic Block (-)

2Al2O3 + 3C = 4Al + 3CO2

10 © Rio Tinto 2017
Aluminum production process
4. Casting
Alloy batching and solidification of the molten aluminum

Smelter to Casthouse

11 © Rio Tinto 2017

Mining – Refining – Smelting – Casting - &…

12 © Rio Tinto 2017

Aluminum production process
5. Recycling
“The most valuable material in the waste stream”
• Over 66 billion cans were recycled last year

Recycling uses 5% of the energy of producing Aluminum

from ore

Aluminium Stewardship initiative – a unique aluminum value chain initiative

that define and deliver the first standard for responsible aluminum
13 © Rio Tinto 2017
Aluminum Alloys
Wrought Alloys designation
Alloy families
Alloy selection
5050 vs. 6063 or 6463
Wrought Alloys Designations

WROUGHT ALUMINUM ALLOYS

1954 1957 1970
• Adopted in US • Became the • Internationally
National accepted
Standard

1948 1962

TEMPERS • Took effect in • Adopted and

the US included in
ANSI H35.1

15 © Rio Tinto 2017

Wrought Alloys designation
A designation system of four-digit numerical designations
• *1000 series: Al – dilute alloys Al > 99%
• *2000 series: Al + Cu
• *3000 series: Al + Mn
• *4000 series: Al + Si
• 5000 series: Al + Mg
• *6000 series: Al + Mg + Si
• *7000 series: Al + Zn + Mg/Cu
• *8000 series: Al + Other elements

* Most extrusions are made from these alloy series

Heat treatable alloys, other are non-heat treatable
16 © Rio Tinto 2017
Wrought Alloys designation
4-Digit Designation system since 1954

XXXX
First digit classifies alloy by principal alloying element or series

Second digit if different from 0 is a modification of a specific alloy

Third and Fourth digits form an arbitrary number to identify a specific alloy in the series

17 © Rio Tinto 2017

Wrought Alloys designation

Xxxx xXxx xxXX

1xxx: indicates If Zero: 1xxx:
the minimum
aluminum
1xxx: unalloyed aluminum with minimum
natural impurity limits aluminum
content is
percentage
99.00% or 2xxx-8xxx: original alloy of a
greater family

Other than Zero: 2xxx-8xxx:

2xxx-8xxx: identify
indicates the alloy 1xxx: special control of one or more
individual impurities or alloying different
group determined aluminum
by the most elements
families within
prevalent alloying 2xxx-8xxx: modifications of the a group
element original alloys

For further information refer to Recommendation Section of the Teal Sheets http://www.aluminum.org/resources/industry-standards
18 © Rio Tinto 2017
1xxx – dilute alloys >99% Aluminum
• Where strength is not a primary consideration

• Where high press productivity is essential

• Where formability and corrosion resistance needs to be high

Applications

Heat exchanger tubing

Electrical rod and sheathing

Appliance trim

Non Heat Treatable 19 © Rio Tinto 2017

2xxx – Al + Copper
• Where strength is a primary consideration

• Responds well to natural and artificial aging

Applications

Structural members aerospace & military (2014 / 2024)

Free machining stock (2011)

Heat Treatable 20 © Rio Tinto 2017

3xxx – Al + Manganese
• Where a higher strength than 1xxx series alloys is required

• Formability, corrosion resistance, thermal stability to be high

Auto Condenser

Applications

Heat exchanger tubing

Photocopier drums

Furniture tubing

Chemical equipment

Non Heat Treatable 21 © Rio Tinto 2017

4xxx – Al + Silicon
Not widely used in extruded form, except:

• 4032

Forging stock for pistons where wear resistance and thermal stability are required

• 4021

ABS brake components, machineable, strength close to AA6061 / AA6082

• Welding Wire, Brazing sheet 4043, 4047

Low melting point, high molten metal fluidity

Heat Treatable 22 © Rio Tinto 2017

5xxx – Al + Magnesium
• Where good corrosion resistance is needed

• Where good weldability and good post-welded strength are required

• Alloys with useful strength (~5% Mg) are difficult to extrude

Applications
Ship superstructures

Cryogenic applications

Offshore construction

Automotive

Non Heat Treatable 23 © Rio Tinto 2017

6xxx – Al + Magnesium + Silicon (Soft)

• 6060 / 6063 / 6360 / 6560

− Most popular extrusion alloys
− Fast extruding, lower strength, anodize well
− General applications i.e. door and window,
heat sinks, architectural, transportation

• 6463 / 6463A
− Specialized “6063” type to give bright finish after
chemical brightening.
i.e. tub and shower, picture frame

Heat Treatable 24 © Rio Tinto 2017

6xxx – Al + Magnesium + Silicon (Medium Strength)

• 6061 / 6082 / 6005 / 6005A

− Medium strength, transportation, ladders, scaffolding, general engineering, gas
cylinders, forging stock, welded construction…

Heat Treatable 25 © Rio Tinto 2017

Composition limits of 6xxx series alloys
1.4

1.2
Wt% Magnesium

6061 6082
1.0

0.8

0.6
6005A
0.4

0.2

0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4

Wt% Silicon
Common Medium Strength 6xxx alloys
26 © Rio Tinto 2017
Composition limits of 6xxx series alloys
1.4

1.2
Wt% Magnesium

6061 6082
1.0

0.8 6063

0.6
6060
6005A
0.4
6360
0.2

0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4

Wt% Silicon
Common Soft 6xxx alloys
27 © Rio Tinto 2017
7xxx – Al + Zinc-Magnesium
• Where strength >6xxx is required, along with extrudability, ease of quenching and weldability.
Stress corrosion has to be managed

• Can be processed on standard presses

Applications
Bumpers systems

Automotive

Transportation

Military bridging

Heat Treatable 28 © Rio Tinto 2017

7xxx – Al + Zinc-Magnesium-Copper
• Where high strength and toughness are required

• Available Complex process route, low extrudability - not compatible with standard operations

Applications

Major structural members - Aerospace

Military application

Medical cylinders

Heat Treatable 29 © Rio Tinto 2017

8xxx – Other aluminum alloys
• Other alloying elements: Li, Fe, Zr…

Applications

Al-Li: high stiffness, low density  Aerospace structural components

Al-Fe: electrical wire, where higher strength than AA1350 is required, i.e. building wire

Al-Zr: electrical wire, where good thermal stability is required. GATSR & ZATSR overhead cables

30 © Rio Tinto 2017

Alloy selection – Mechanical Properties
Non Heat Treatable Heat Treatable
600

Strength (MPa) 500

400

YS
300
YS mild steel UTS

200

100

0
1060- 1100- 3003- 5005- 3105- 5052- 5454- 5083- 5056- 5456- 6063- 6061- 2011- 4032- 2024- 2014- 7050- 7075-
O O O O O O O O O O T6 T6 T3 T6 T3 T6 T651 T6

31 © Rio Tinto 2017

Alloy selection – Extrudability (speed)

Extrudability falls with increasing flow stress and lower melting point

32 © Rio Tinto 2017

Alloy selection – Alloy vs. Process

Some extruders specialize

1xxx in these products
3xxx
5xxx

Possible on most
Formal solution Solution treat commercial
Specialised treat in Press presses
Process 2xxx 6xxx
Difficult to cast 7xxx 7xxx
(Al-Zn-Mg-Cu) (Al-Zn-Mg)

33 © Rio Tinto 2017

Alloy selection – Extrusion as a Heat Treatment
650
600 Melting starts (solidus)
Quench
550
Mg and Si in solution (solvus)
500
Temperature (oC)

450
400
350
300
250

Extrusion
200
150 Induction
furnace
100 Preheat 250oC/min
50
0 5 10 15 20 25 30
Time (mins)

34 © Rio Tinto 2017

Alloy selection – 6XXX Compositions vs. Properties

35 © Rio Tinto 2017

Chemical composition 5050 vs. 6063 or 6463
1.4
5050
1.2
Si 0.40 max
Mg 1.1 – 1.8
Wt% Magnesium

1.0 5005
Si 0.30 max
0.8 Mg 0.50 - 1.1
6063 / 6463
Si 0.20 – 0.6
0.6 Mg 0.45 – 0.9

0.4

0.2

0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4
AA6063 and 6463 have the same
Wt% Silicon Mg and Si composition

36 © Rio Tinto 2017

 Mechanical Properties 5050 vs. 6063 or 6463
Industry standards

Tensile data for the 5050 alloy extrusion samples as received

The AA limits for properties are only published for sheet and plate products, not extrusions

37 © Rio Tinto 2017

Mechanical Properties 5050 vs. 6063 or 6463
Natural ageing
16

14

Webster Hardness
12
6082 6061
10

8
6063 - 6463
6

2
1 year
0
1 10 100 1000 10000
Time Hours

ALL 6XXX alloys naturally age at room temperature after extrusion, 5050 does not
Hardness proportional to log time 38 © Rio Tinto 2017
Mechanical Properties 5050 vs. 6063 or 6463

Except “6063 Ref”, all other 5050 samples do not naturally age over time

39 © Rio Tinto 2017

Mechanical Properties 5050 vs. 6063 or 6463

Barcol™ is a simple,
rapid and non-
destructive method to
measure extrusion
hardness

LD hardness : ~220 – 255

HB (Brinell): ~32 - 43

40 © Rio Tinto 2017

Extrusion billet making
42 © Rio Tinto 2017
 Billet casthouse layout Metal treatment

Casting table

Alloy batching

Homogenization - Heat
treatment

43 © Rio Tinto 2017

Billet casting table

*From Wagstaff Website

44 © Rio Tinto 2017
Thank you for your attention!

Aluminum alloy
Jerome Fourmann – Long Beach, CA - August 22, 2017
 Major Extrusion Press Components:

Dealing with Defects, Failures, Repairs and

Replacements

Presented By

Loewy_Lombard_Wean_Youngstown_HydroPress_BLH

Designers and Manufacturers of Heavy Machinery

and Components for the Metals Industry Worldwide
We Build Things. Better.

1
 Major Extrusion Press Components:
Main Cylinder
 Integral cylinder / rear platen (1 piece)
 Separate inserted cylinder
 Separate rear platen
Main Ram
Crosshead
Piercer (if equipped)
Piercer Cylinder
Piercer Ram
Piercer Crosshead
Tie Rods
Container Housing
Front Platen

2
 Common Materials in Use

Cast Iron (Chilled)

Cast Ductile Iron
Cast Steel
Fabricated Plate, Bar and Structural Steel
Fabricated/Forged Combination
Forged Steel

3
Main Cylinder
Integral cylinder / rear platen (1 piece)
Cast steel
Fabricated Steel / Forging combination
Multi-piece Forging / Welded
Solid Forging
Separate cylinder
Cast Steel
Multi-piece Forging / Welded
Solid Forging
Separate rear platen
Cast Steel
Fabricated Steel
Fabricated Steel / Forging combination
Solid Forging

4
Main Ram
Cast Iron
 Chilled casting process
Forged / Welded Multi-piece
 Flame hardened
Quench and Temper HT
 Welded Surface Overlay
Solid Forged
 Flame hardened
Quench and Temper HT
 Welded Surface Overlay

5
 Crosshead

Cast Steel
Fabricated Steel
Fabricated Steel / Forging Combination
Solid Forging

6
Tie Rods
Rolled Steel
Forged Steel
Forged/Rolled Flat Bar

Tie Rod Nuts:

Rolled Steel
Forged Steel
Solid
Split
Tensioning
(Supernut)

7
Container Housing

Cast Steel
Fabricated Steel
Forged / Fabricated Steel
Solid Forged

8
Front Platen
Cast Steel
Fabricated Steel
Forged / Fabricated Steel
Solid Forged

9
Common Defects by
Material Type
Cast Irons and Cast Steel:
 Stress / Fatigue cracking
 Brinelling / Coining
 Latent casting defects
*Shrinkage
*Sand pockets
*Inclusions/Voids

10
Common Defects by
Material Type

Fabricated Plate and Structural Steel:

 Fatigue cracking
 Brinelling / Coining
 Stress Cracking
 Material Defects
 Weld Failures

11
Common Defects by
Material Type
Forged Construction:
 Fatigue cracking
 Brinelling / Coining
 Stress Cracking
 Weld Failures
 Material Defects

12
 Common Defects / Failure Locations
Integral Rear Platen / Main Cylinder
Internal rear radius of cylinder bottle
Main body of cylinder
Inside corners
Bolt holes for prefill
Vent port
Drain Port
Underneath tie rod nuts (cracks/coining)
Inside near main bushing shoulder
All structural welds
Intersection of the cylinder and rear platen
Any welds added for mounting accessories
Near all drilled holes or penetrations

13
 Common Defects / Failure Locations
Inserted Main Cylinder

Internal rear radius of cylinder bottle

Main body of cylinder
Cylinder shoulder
Bolt holes for prefill
Vent port
Drain Port
Inside near main bushing shoulder
All structural welds
Any welds added for mounting accessories
Near all drilled holes or penetrations

14
 Common Defects / Failure Locations
Rear Platen

Cylinder retention shoulder

All structural welds
Any welds added for mounting accessories
Near all drilled holes or penetrations

15
 Common Defects / Failure Locations
Main Ram

Scoring / Scratching along length of Ram

 “Hourglass” wear pattern
 Near all drilled holes or penetrations

16
 Common Defects / Failure Locations
Crosshead
 Behind pressure plate / Stem area
 Base of pullback cylinder connection
 All structural welds
Any welds added for mounting accessories
Near all drilled holes or penetrations

17
 Common Defects / Failure Locations
Tie Rods
 Root of threads
 Thread relief area
 Inside corners or steps
 Holes or lathe centers on ends
Any welds added for mounting accessories

18
 Common Defects / Failure Locations
Container Housing

Container keyways
 Base of connection to container shift cylinders
 All sharp or inside corners
All structural welds
Any welds added for mounting accessories
Near all drilled holes or penetrations

19
 Common Defects / Failure Locations
Front Platen
 Behind pressure plate
 Underneath tie rod nuts (cracks/coining)
 Near “mouse ears” on discharge side
 All sharp or inside corners
All structural welds
Any welds added for mounting accessories
Near all drilled holes or penetrations

20
 Common Defects / Failure Causes
 Press Misalignment
Components are loaded off center
Binding
 Overloading press
 Unequal pullback or container shift cylinders
 Inadequate preload on tie rods
 Design flaws
Stress Concentrations
Poor weld locations
Drain / Vent design and location
 Manufacturing defects
Weld flaws (penetration, inclusion, HAZ)
Tool marks, rough finishes
Unblended radii
 Press accident
 Drilling, welding on press in critical areas
 Weakened / cracked adjacent component

21
Course of Action once damage is found
Determine extent of damage:
 Do not panic, may be old defect
 May never propagate
 May crack and stop
 Crack may be located in non critical area
 Clean, Excavate / Explore crack
 Scribe ends of crack and date
 Relieve ends gently
 Arrange for NDT services
 Check loaded /unloaded
 Monitor hourly, daily, weekly
 Record progression
 Confirm max press loading
 Consider reducing press tonnage
 Check hydraulic system safeties
 Locate drawings of component
 Get costs / lead time for replacement

22
Course of Action once damage is found
Repair options:
Welding
 Field welding must be done carefully
 Small local welding vs. major repair
 Poor weld repair breeds more cracks
 Welding success is material dependent
 Preparation is very important
 Bridging may be appropriate
 Pre and post heating required
 Stress relieving
 Distortion can occur
 Disassembly will probably be required
 Field machining may be required
 Weld repairs considered temporary
 Can be expensive
 3-7 days downtime depending on scope

23
Course of Action once damage is found

Repair options:

Metal Stitching
 Specialized service
 Works with different materials
 Distortion is minimized
 Disassembly may not be required
 Field machining may not be required
 Stitch repairs considered less temporary
 Can be expensive
 Potentially less downtime than welding

24
Course of Action once damage is found
Repair options:
Mechanical Reinforcement/Repair
 Engineered repair
 Bridging, strapping
 Studs perpendicular to crack
 Banding around cylinder
 External clamping
 Sometimes used with welding
 Works with different materials
 Distortion is minimized
 Disassembly may not be required
 Field machining may be required
 Most repairs considered temporary
 Can be less expensive
 Potentially less downtime than welding

25
Specifying / Procuring new Components

Design Considerations:
 Engineered Replacement vs. duplicate
*Finite Element and Fatigue analysis
*Service factor
 Understand reason for failure and modify design
 Manufacturing methods
*Certified weld procedures and personnel
*NDT inspections at specified intervals
*Thermally stress relieve all fabrications
*No welding after stress relief
*Attach accessory mounts during manufacturing
*No chain or tool marks

26
 Common Material Comparison
Material Cost Life Ease of Machinability Flexibility in Domestic Field NDT
Expectancy Welding design Availability repairable Inspection
Difficulty

Fabricated $ Mid- Easy Easy Excellent Excellent Yes Easy

Low Carbon High
Steel
Forged $$ Very Easy Easy Very Good Yes Easy
Low Carbon High Good
Steel

Forged Alloy $$$ Very Difficult Moderately Limited Limited by Limited Easy
Steel High Difficult Dependent size
upon size

Cast Steel $ Mid- Difficult Moderately Very Very Difficult Very

High Difficult Good Limited Difficult

27
Specifying / Procuring new Components

Design Considerations (cont’d):

 Material Selections
*Forged vs. Fabricated vs, Casting
*Alloys
*Material quality very important (NDT inspected)
*Cost vs. life expectancy
 Time to upgrade?
*Higher tonnage, longer billet,
*4 corner guiding, flat ways, etc
 Consider used or reconditioned
 Lead time for new can be 6 months or more

28
 Major Press Components:
Dealing with Defects, Failures and Replacements

Thank You!

Loewy_Lombard_Wean_Youngstown_HydroPress_BLH

Designers and Manufacturers of Heavy Machinery

and Components for the Metals Industry Worldwide
We Build Things. Better
Salem, Ohio USA
www.butechbliss.com 330-337-0000 29
ALUMINUM EXTRUSION
IDENTIFICATION,
CLASSIFICATION,
AND
TRADE LAW SEMINAR

Aluminum Extrusions:
Tooling and Dies
FEEDERS

Feeders come in many shapes, sizes and forms. A feeder can be built
into the die known as a pocket die, or as a separate unit known as a
feeder plate. It has an orifice that controls the flow of aluminum to the
die. There are many advantages in using feeders.

WELD BILLETS TOGETHER

Once the first billet is pushed through the die stack and the extruded
aluminum is past the pressure ring, the chance of the aluminum
plugging up somewhere in the die stack is virtually eliminated because
each billet thereafter will weld together in the feeder plate with the
previous billet.
CONTROL CONTOUR

Certain dies that have thin-walled shapes and/or special tolerances

need a feeder plate to control the contour. The feeder plate alone
may not always be the answer. Sometimes, in conjunction with the
feeder, a contoured pocket in the die plate, which allows additional
control of metal flow, is needed.

SPREAD ALUMINUM

When the circle size of a shape is larger than 85% of the inside
diameter of the container, a feeder plate should be used to spread
the aluminum to the needed areas. The feeder plate should be
designed with a relief angle up to, but not exceed, 30 degrees.
POCKET DIES

The most popular form of a feeder is the pocket die. Also known
as a weld pocket or cavity feed. The pocket depth can vary from
as little as .250” deep to as much as .750” deep. Any deeper than
.750” normally would be a feeder plate. The lighter the shape
(thinner walls), less depth; the heavier the shape (thicker walls),
deeper depth. When walls are light, sometimes it helps to put a
second pocket much closer to the shape, to help control the
contour. The pocket die is user friendly. It is very easy to open up
the pocket on a mill if flow corrections need to be made to the
pocket.
 ALUMINUM EXTRUSION
IDENTIFICATION,
CLASSIFICATION,
AND
TRADE LAW SEMINAR

Painting, Anodizing, and Coating Aluminum Extrusions

Efficiency Through Process Control
• A Process is a Process
• Man, Machine, Material, Method, Metrics
– Skills, Cross Training, Cont. Ed., Associate Accountability
– Equipment, Tooling, Robust PM/TPM, Housekeeping
– Material Certification & Tractability, Supplier
Accountability
– Critical variables, control plans, standard work
– What gets measured gets managed!!
• Continuous Improvement with LSS & QRM
• Understand your constraints and capacities
 TYPICAL ANODIZING LINE

• Process Tanks
– Cleaning
– Etch (Acid Etch)
– Desmut
– Three Anodizing Tanks
– Hot / Cold Seal
– One Two-Step Tank
• Class I & II
• Two-Step Anodizing (AAMA 608 Certified)
– Champagne thru Black colors
• Velo (Clear) Anodizing (AAMA 607 Certified)
• 35’ Maximum Piece Length
TYPICAL PAINT LINE

• Vertical Wet Paint Line

• Five Stage Cleaning and Chrome
Phosphate Pretreatment System
• Four Booth Ransburg Electrostatic
Painting System with Matrix Recipe
Management and Thermal Oxidizer to
Control VOC Emissions
• 24’ 2” Maximum Length
 Regular Paint (AAMA 2603 Certified)

 High Performance Paint (AAMA 2604/2605 Certified)

 Valspar, PPG, AkzoNobel, AAMA Approved Paint

Applicator
TYPICAL THERMAL BARRIER LINE(S)

• Automated Thermal Bar System

– Polyamide 6/6 Nylon Strip
Reinforced with Glass Fibers in
three dimensions.
• Standard & Special Strips
– Two Tone System
– 26’ Maximum Length
• Pour and Debridge System (AAMA
TIR A8)
– Automated Line
– Skip Debridge Capability
– 32’ Maximum Length
– AZO-Brade Capability Azo Brade
Finishing Workshop

Paint – People and Process Issues

Increasing colors  Change Over Efficiency

Powder/Wet Paint  Same Shared Equipment

HP/Regular Paint  Group Similar Products

…These issues have to be balanced in your Pull System

Vertical Paint Line
Chrome Phosphate Pretreat Dip Tanks
Horizontal power and free conveyor
Liquid Mix Room
Liquid Rotary Atomizers
Powder Booth
 Quality Tools

Dry Film Gauge Adhesion Test

Color Match
Tooke Gauge
Finishing Workshop

Anodizing – Labor Coordination

• Daily Production Plan (To Optimize Tank
Utilization)
– 2Step, Clear, 15min, 30min, 60min coatings
– Seal Types
• Float working crews between Racking and
Unracking depending on the parts
• Use of 2-Way Radios is helpful to coordinate
quick labor changes based on production
demands
Anodizing – Racking Best Practices

• Rack to maximize process

tank utilization
– Mix
– Rail Density
– Style (Pin, Clamp, Twist, Stack)
– Consistency (order to order)
– Part Spacing & Orientation
– Rack Maintenance & Consistent
Electrical Conductivity
Anodizing – Crane & Process Control
Crane Operations Tank and Process Control
• Waste Time (secs/rail) • Caustic Etch
• Active Time (%) • Acid Etch
• Tank Drag Out/In • Desmut Sulfuric
• Anodize Build (amp/sqft) • Anodize Sulfuric Concentration
– 12 – 24 amps/sqft • Anodize Aluminum Concentration

Anodize Video
Click to Play
 Finishing Workshop

Anodizing – Manufacturing Best Practices

 Anodize/Color Capacity & Tank Utilization

 Rack & Rail Loading Densities

 Power and Utility bill management

 Power contracts and management strategies

Finishing Workshop

Anodizing – Environmental & Chemical Issues

 Chemistry & Temperature Control

 Cross Contamination Issues

 Chemical Control Strategies

 Environmental Considerations
THANK YOU
Making Extruded Aluminum Solutions
More Cost Effective
Making Extruded Aluminum Solutions
More Cost Effective
Presented by:

Mark Telander
Inside Sales Representative
Alexandria Industries

Sponsors:

2
About AEC

• The industry association for North

American extruders
• ~ 60 extruder members, accounting
for ~ 75% of extrusion produced in
North America
• Focused on:
– User education
– Member excellence
– Fair trade

• Fifty years of pushing boundaries

• AEC member, with extrusion
operations in Minnesota & Indiana
• A leading supplier of precision
custom extrusions & fabricated
components
3
Agenda
This presentation provides an overview
of aluminum extrusion—how to utilize
alloys, design features, and secondary
processes—to create cost-effective
extruded aluminum solutions.
• Introduction
• Extrusion Process & Economics
• Creating Cost Effective Solutions
– Alloys
– Profile Design
– Tolerances
– Secondary Processes
• Tips for Sourcing Extrusions
• Additional Resources

4
Introduction
With aluminum extrusions, designers are able to join the outstanding
characteristics of aluminum with the unique attributes of the extrusion process to
create compelling product solutions.

Aluminum Extrusion
• Lightweight • Tailored performance – put metal where
it is needed
• Strong
• Suitable for complex, integral shapes,
• High strength-to-weight ratio produced to close tolerances
• Resilient • Attractive, wide range of finishes
• Corrosion resistant • Virtually seamless
• Heat conductive • Easy to fabricate
• Reflective • Joinable by various methods

• Electrically conductive • Suitable for easy-assembly designs

• Produced with uniform quality
• Non-magnetic
• Cost effective
• Non-sparking
• Short production lead-times
• Non-combustible
• Cold strength
• Fully recyclable
5
Introduction
Aluminum extrusion offers you the ability to create the
shapes to meet design challenges from large …

Electric motor
housing

5.16”
Roof bow
A pillar

Structure: Ford F-150

6
Introduction

… to small

1.5”

Radiation “shutter”

Onyx on-camera LED light

professional videography
Housing, Apple watch,
sport edition
7
Extrusion Process & Economics

8
Extrusion Process & Economics
Extrusion Cost Structure

Other
Dies
Feedstock: Heated Facility
aluminum alloy “billet” Labor
Metal*
*may vary with alloy

Steel die and supporting tooling Desired final “profile” or shape

9
Source: Rio Tinto Alcan
Creating Cost Effective Solutions

• Alloys
• Profile Design
• Tolerances
• Secondary Processes

10
Alloys

Select the appropriate alloy

• Review alternative alloys to determine best alloy for

the application / end use
• Understand the differences when prototyping or
testing with material that is easier to obtain, e.g.
6061 bar stock
• The alloy may have a big effect the extrudability of a
profile (i.e. processing cost), and may impact surface
finish and tolerances

11
Alloys / Tempers
Aluminum extrusions can be produced in different alloys and processed to
different tempers to achieve desired mechanical properties.

Typical
Alloy Major Alloying Elements and Alloy Characteristics Extrusion Description
Tempers
1000 Minimum 99% Aluminum
Series High corrosion resistance. Excellent finish-ability. Easily joined by all methods. Low F Extruded and air cooled
strength, poor machinability. Excellent workability. High electrical conductivity.
O Fully annealed
2000 Copper
Series High strength. Relatively low corrosion resistance. Excellent machinability. Heat H112 Strain-hardened; used for
treatable. nonheat-treatable alloys
3000 Manganese T1 Cooled from an elevated
Series Low to medium strength. Good corrosion resistance. Poor machinability. temperature/naturally aged
Good workability.
T4 Solution heat-treated and
4000 Silicon
naturally aged
Series Not available as extruded products Broadest
applicability T5 Cooled from an elevated
5000 Magnesium
temperature/artificially aged
Series Low to moderate strength. Excellent marine corrosion resistance.
Very good weldability. T6 Solution heat-treated and
6000 Magnesium & Silicon artificially aged
Series Most popular extrusion alloy class. Good strength. Good corrosion resistance.
Good machinability. Good weldability. Good formability. Heat treatable.

7000 Zinc
Series Very high strength. Poor corrosion resistance. Good machinability. Heat treatable. Firearms, Aerospace
12
Alloys – Extrudability
Extrudability – conversion cost – will vary with chemistry.
90
Tensile
Yield
80
7075
Strength** (ksi)

70

60
7020 6082* Mild steel
50
6005A*

40 6060/63*

30 Mild steel

20 3003

10 Al 99.5

0
0 50 100 150
Extrudability index
Conversion Cost
* T6, except 6005A @ T61 **typical properties 13

Source: Rio Tinto Alcan

 Alloys – Strength

Any one alloy can have a variety of Increasing

formulae e.g.: 6XXX alloy series strength

1.3
Typical Applications
1.2

1.1
Auto Intrusion Beams
6082 Bumper Beams
1.0
Auto Chassis/Structural
0.9
0.8
6005A Auto Chassis/Structural
0.7
Solar racking systems
0.6 6061
% Si 0.5

0.4
6060 6063 Trim components
0.3
Heat sinks
0.2
Electronics housings
Window/Façade systems
0.1
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
% Mg 14
Alloys – Characteristics
Alloy Characteristics
6005A Mechanical properties similar to 6061. Used in structural applications.

6060 Has better extrudability than 6063. The minimum mechanical properties (with the
exception of minimum welded properties), response to finishing processes, and corrosion
resistance are similar to 6063.
6061 Most versatile of heat-treatable group. Will take considerable forming in T4. Good
corrosion resistance. Used in transportation and structural applications.
6063 The most popular extrusion alloy. Takes a good surface finish, is corrosion-resistant, and
can be heat-treated for strength.
6101 High strength bus conductors; good extrudability, weldability, braze-ability, good resistance
to stress corrosion cracking with average machinability.
6105 Good medium to high strength with average machinability and good corrosion resistance.

6262 Best machining of all extrusion alloys. Good corrosion resistance.

6351 Mechanical properties similar to 6061. Used in structural applications. Will take
considerable forming in T4. Good corrosion resistance. Used in transportation and general
structures.
6463 Designed to accept a bright finish through anodizing or polishing. Decorative trim
applications; machinable and heat-treatable.
6082 Highest strength of 6000 series. Excellent corrosion resistance and machinable.
15
Alloys – Extrudability
Yield Surface Bending Machining Joining Extrudability/
Strength Quality (based on Processing/
(min) chips, Cost
finish)
6060/63 25 ksi Excellent finish Good in T6, C B 100 - Superior
& corrosion VG in T1/T4 extrudability,
resistance easy quench
6005A 38 ksi Superior Good in T6, C: C 95 - Superior
corrosion VG in T1/T4 continuous extrudability &
resistance chip, good quench vs.
finish 6061/6082
6061 38 ksi Good Manageable C B 80 - Good
corrosion in T6511, extrudability,
resistance VG in T1/T4 quench
demanding
6082 38 ksi Good Manageable C B 80 – Good
corrosion in T6511 extrudability,
resistance very quench
demanding
7005 44 ksi Zn precludes Acceptable B : curled D 50 - ½ speed;
good anodize in T53 chip, good- quench,
Stress exc. finish special ageing
corrosion
16
Source: Rio Tinto Alcan
Real World Application – Alloy Selection

Geometry can offset lower alloy strength

17
Source: Lotus Engineering
Profile Design – Manufacturability

• Geometry
• Features
• Functionality

(Dark bands are markers to illustrate material flow.)

Think about the material flow through a

multi-hole hollow die like this!

18
 Profile Design – Geometry

General Preferable Design Practices

Uniformity Symmetry

Not This! Not This! This!

this! Not
this!
this!
Smooth Transitions
Enhance Visual Surfaces

Not This!
this!
Not This! Not This!
this! this!

19
Profile Design – Geometry

Extrusion Die Tongue Ratios

20
Profile Design – Geometry

Extrusion Die Tongues

21
Profile Design – Features

Screw slots are more often simple to incorporate in

the profile and can eliminate a more expensive hollow
die, which extrudes more slowly and increases cost.

Self tapping screw Thread cutting screw

This!

Not this!
22
 Profile Design – Features

This housing for a lighting fixture incorporates slots

for the electronic components, short fins for heat
dissipation, and screw bosses to secure the end cap
on each end to enclose the lighting unit.

23
Profile Design – Features

Sometimes a “complex hollow die” will yield a superior

solution!
Screw
bosses

2 5

1 7
3 6
4

SOLID HOLLOW

24
Profile Design – Features

Design specific
features into your Hinge detail
“Christmas tree” for joining with
wood or plastic

extrusion to:
• Enhance joining to other Patterned surface for
appearance
Screw boss on leg

extrusions or other Groove to accept printed

circuit cards
materials “Heat sink” Groove for screw or

• Facilitate assembly cooling fin rivet

Groove for rubber

• Provide added Snap fit spring
assembly
moulding

functionality, e.g. heat Drill groove

dissipation Dovetail assembly

• Enhance aesthetics, etc. Groove to accept printed

Slot for location of nut or bolt
head
circuit cards

Screw boss
Fluted surface for
appearance

25
Real-World Application – Design Features

26
© 2017 Alexandria Industries
Real-World Application – Design Features

27
© 2017 Alexandria Industries
Design – Tolerances

Understand Tolerances
• Critical-to-function vs. non-critical
• CPK requirements
• Capability requirements – PPAP
• Geometric Dimensioning & Tolerancing (GD&T)
• Method of inspection
• Effects of chemical finishing
• Effects of thermal expansion

28
Design – Tolerances

• Design dimensions for functionality

– Designate critical features and tolerances
• Apply appropriate tolerances to non-critical or non-
functional features
– Avoid titleblock
– Consider GD&T
• Understand method of inspection used
– Correlation between customer and vendor
– Accuracy of method of inspection
– Inspect in restrained or non-restrained state

29
Design – Tolerances
Tolerance Tables
(The Aluminum Association’s Aluminum Standards & Data)

30
Source: The Aluminum Association
Design – Tolerances

Which are the critical dimensions? These?

Base of Gap Dimensions

Wall Thickness

31
Design – Tolerances

Hollow/Gap Definition
Or these? Hollow/Gap Dimensions – Column 4-9?

Gap Dimension Hollow Dimension

32
Design – Tolerances

Parameters that will affect variation / tolerances:

Design Dependent Extruder Dependent

Alloy
Exit temperature
Extrusion speed
Die shape and type
Cooling time
Amount of post-stretch
Multiple die copies
Multiple holes in die
Press size
Method of inspection

33
Fabrication
Extrusions can be machined, formed and assembled with
a wide variety of familiar technologies. Yet some
processes – particularly bending and welding – benefit
from prior extrusion fabrication experience.

34
Fabrication

• Sawing
• Punching / piercing / drilling
• Bending
• Stretch-forming
• Welding
• Milling
• Tumbling

35
Real-World Application – Fabrication

• Sawing • Welding
• Punching/piercing/drilling • Milling
• Bending • Tumbling

36
Fabrication – Machining

• CNC and Robotics

• Lineal Advance Machines

37
Fabrication – Bending

• Stretch Bending
• CNC Bending
• Roll Bending

38
Real-World Application – Bending
Bending Technologies
• Stretch bent, over a form r=99”

• Both T4 and T5 conditions

• Complex bends are feasible

39
Source: Almag
Secondary Processes – Finishing

• Anodizing
• Powder Coating
• Painting
• Plating
• Mechanical

40
Conclusion

Get the most out of your aluminum extruded components.

The combination of alloy, design features, tolerances, and

any needed secondary processes, allows you to:
• Optimize component performance
• Reduce part counts, and enhance utility
• Develop creative designs that can simplify and or
eliminate secondary processes and assembly steps
• Easily cut, machine, finish, bend, weld, fabricate and
assemble components

41
Tips for Sourcing Extrusions

• Get your extruder

involved early in the
design stage
• Ensure you have realistic
cost expectations
• Leverage extruder
experience for small
changes that can yield
significant savings
• Look for an extruder that
offers other manufacturing
services and vertical
market experience

42
 Additional Resources
For more Information and Training
visit the Aluminum Extruders Council
website www.aec.org.

• 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 AEC Buyers’ Guide AEC Aluminum
members to meet the emerging demands of the market (www.AECguide.org) Extrusion Manual
through sharing knowledge and best practices. (www.AECmanual.org)
43
Additional Resources

Joining
The rapid increase in automotive aluminum content – and in multi-material
solutions – has led to a dynamic evolution in material joining technology. In
response, a comprehensive Aluminum Joining Manual, has recently been
developed.

The manual addresses:

• Adhesive Bonding
• Beam Welding
• Brazing
• Mechanical Joining
• Resistance Welding
• Fusion
• Combined Joining
• Joining Dissimilar Materials

To access, go to: www.aec.org/JoiningManual 44

Additional Resources

The Aluminum Association

Aluminum Design Manual
– 2010 Edition
(www.aluminum.org) Aluminum 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

45
 Thanks to Our Presenting Sponsors…

… and to all the members of AEC

ABC Aluminium Solutions Compes International Lake Park Tool & Machine, LLC Service Center Metals
Aerolite Extrusion Company Crown Extrusions Inc. Light Metals Corporation Sierra Aluminum
AkzoNobel Coatings Inc. Crystal Finishing Systems Inc. Magnode Corporation Shoals Extrusion, LLC
Albarrie Canada Limited Custom Aluminum Products Inc. Marx GmbH & Co. KG Silver City Aluminum Corp.
Alcoa, Inc. Dajcor Aluminum Ltd. Matalco Inc. SMS Technical Services LLC
Alexandria Industries Danieli Corporation M-D Building Products Southeastern Extrusion & Tool, Inc.
Alexin LLC Dienamex Metal Exchange Corporation Spectra Aluminum Products Ltd.
Alfiniti, Inc. Drache USA Inc. Metra Aluminum Inc. Spectrum Metal Finishing Inc.
Alliantgroup Dubai Aluminium Co. Ltd. MI Metals Inc. Superior Extrusion Inc.
Almag Aluminum Inc. Elixir Extrusions, LLC Mid South Extrusion Die Co. Taber Extrusions LLC
Almex USA, Inc. Emmebi Mid-States Aluminum Corp. TCI Powder Coatings
Aluminio de Centro America ETS-Exco Tooling Solutions Nanshan America Co. Technoform Bautec North America
Aluminium Bahrain B.S.C, EXCO National Aluminium Ltd. Tecnoglass S.A.
Aluminium Products Co. Ltd. Extrudex Aluminum Ltd. Ohio Valley Aluminum Co. LLC Tellkamp Systems Inc.
AMCOL Corporation FOM USA, Inc. OMAV S.p.A. Thumb Tool & Engineering
APEL Extrusions Limited Foy Inc. Penn Aluminum International Inc. Tower Extrusions, LLC
Apex Aluminum Extrusions Ltd. Frontier Aluminum Corp. Pennex Aluminum Company Tri City Extrusion Inc.
Arabian Extrusions Factory Gateway Extrusions Ltd. Postle Extrusion Tubelite Inc.
Arconic, Inc. General Extrusions Inc. PPG Industries Inc. Turla S.r.L.
Astro Shapes Inc. Granco Clark Inc. Presezzi Extrusion North America Ube Machinery Inc.
Azon USA Inc. Gulf Extrusions Company LLC PRICEWalgren Valspar Corporation
BCI Surface Technologies Houghton Metal Finishing Company Pries Enterprises Inc. Vedanta Limited
Belco Industries Inc. Hulamin Extrusions Profile Custom Extrusion Co. Vitex Extrusion
Bonnell Aluminum Hydro Aluminum North America Inc. Reliant Aluminum Products LLC Wagstaff Inc.
Bowers Manufacturing ILSCO Extrusions Inc. Republic Chemical Co., Inc. WEFA Cedar Inc.
Briteline Extrusions, Inc. iNOEX LLC Richardson Metals Werner Co.
Butech Bliss International Extrusions, Inc. Rio Tinto – Aluminium Product Group Western Extrusions Corp.
Cardinal Aluminum Co. Jordan Aluminum Extrusions, LLC R.L. Best Company Whitehall Industries
CASTOOL Tooling Systems Kaiser Aluminum Rusal America Corp. YKK AP America Inc.
Century Aluminum Kataman Metals, LLC Sapa Extrusions Youngstown Tool & Die Co. Inc.
Cometal Engineering S.p.A. Keymark Aluminum Corporation SAT S.p.A.

To find an extruder: go to www.aec.org/FindExtruder 46

Questions?

Joining us for your questions:

Mark Telander, Inside Sales Associate

[email protected]

Rob Nelson, VP Sales & Marketing

[email protected]

Jason Weber, Director of Business

Development, Emerging Markets
[email protected]

47
 Proper Use of the Presented Information
The Aluminum Association (AA), Aluminum Extruders Council In all cases, users should not rely on this information without
(AEC), the authors and contributors of this overview provide consulting original source material and/or undertaking a
information and resources about aluminum products and thorough scientific analysis with respect to their particular
aluminum-related technology as a service to interested circumstances. Information presented here does not replace
parties. Such information is generally intended for users with the independent judgment of the user or of the user’s
a technical background and may be inappropriate for use by company and/or employer.
lay persons.
AA AND AEC EXPRESSLY DISCLAIM ANY AND ALL
This presentation does NOT attempt to thoroughly discuss all GUARANTEES OR WARRANTIES WITH RESPECT TO
load types, materials, profiles, design requirements, etc. THE INFORMATION PROVIDED HERE. AA AND AEC
The purpose is to provide an overview of topics/issues to FURTHER DISCLAIM ANY LIABILITY IN CONNECTION
consider when utilizing aluminum extrusions for designs WITH THE USE OR MISUSE OF ANY INFORMATION
PROVIDED OR IN CONNECTION WITH THE OMISSION
Full understanding and adherence to the Aluminum Design OF ANY INFORMATION.
Manual (Aluminum Association 2010) and all documents
referenced by it is required for proper design

Photos, illustrations, and graphics used in this PowerPoint courtesy of: Accuray, Alexandria Industries, Almag, Akzo Nobel Coatings Inc./Bill Hanusek, Gossamer
Innovations, GM, Hydro Aluminum North America Inc., Light Metal Age Magazine, MAADI Group, SAPA Extrusions, Skylne Solar, Taber Extrusions, Werner Co., Werner
Extrusion Solutions, LLC

48
Aluminum Extrusion Seminar
U.S. Customs & Border Patrol
Long Beach, CA
August 22, 2017
Key Trade Issues

 Circumvention

 Transshipment
 Key Trade Issues

 Circumvention
5050 Alloy – Several extruders reported issues with this scheme. It impacted
shower door applications, railings, fencing, drawn tube products, and various B &
C applications

Mislabeling – Several reports that fabricated extrusions are being labelled as

‘machine parts’

The mislabeling reports generally come when a part or sub-assembly is not being
declared a fabricated extrusion. Instead it is labeled as a door threshold, or fan
housing, etc. These parts may have been directly identified by Commerce.

Is the part in question really just a fabricated extrusion, or is it a final, finished product?
Key Trade Issues
 Transshipment
Vietnam – There is growing alarm at the increase in Vietnamese exports to the
U.S. It is unlikely that all of this metal has actually been extruded in Vietnam.
Elkhart, IN has been especially impacted in recent months.

Chinese Brokers are sending ‘spam email’ out to possible buyers offering ‘creative
trade solutions’ that will enable U.S. buyers to evade duties.

Malaysia remains at the top of the list when it comes to transshipments. There
have already been two cases and convictions of transshipments through Malaysia.

Generally, extrusion presses in Vietnam and Malaysia are not particularly

sophisticated. There are also size limitations concerning a shape, i.e., the circle
size of the shape is too wide for any presses in Vietnam.

Is the finish on that extrusion even produced in Malaysia? Certain applications

may or may not be available in these countries, i.e., wet paint vs. powder.

Is it likely that the extrusion being declared could even be extruded in a third country?
AEC wants to help!

The Aluminum Extruders Council wants to help in suspected cases of

transshipment or circumvention, etc.

My Direct Line is 847-416-7222. Call me, and if I can’t answer your question, I can
find someone that can.

More Seminars! As we move forward, we may want to drill down into certain
applications to give staff an even greater understanding of extrusion applications.

Thank you all for your time and support!

 Aluminum Extrusion Industry Identification, Classification & Trade Law Seminar
U.S. Customs & Border Protection, HSI, Other U.S. Government agencies, and Customhouse Brokers
301 E. Ocean Blvd.
Suite 1400
Long Beach, CA 90802

Presented by:
Aluminum Extruders Council (AEC),
Rio Tinto Aluminium
Frontier Aluminum Corp.
Sierra Aluminum
Sapa/Hydro

Aluminum Extrusion Tour of Frontier Aluminum

2480 Railroad Street
Corona, CA 92880
Tuesday, August 23, 2017
Departing USCBP Offices (Long Beach) - 8:00 am; Returning – noon

Name:

Organization:

Phone Number:

Email Address:

Coat Size (small, medium, large, extra-large (err on sizing up)):

Please reply to Richard DiDonna ([email protected]) by August 14, 2017. Information

will be kept confidential and shared only with responsible individuals at Frontier Aluminum.