aluminum extrusion

Introduction
This PowerPoint presentation uses information current as of J une 21, 2011.
You will note that some of the key slides in the economics area are marked
“Preliminary”.
Please visit the following to obtain the most up-to-date version of this and
other presentations:
www.aec.org/exapps/CustomerOutreach.html
Introduction
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.
Information provided by them is generally intended for users with a
technical background and may be inappropriate for use by lay persons.
While the AA, AEC, authors and contributors make every effort to
disseminate the most reliable and current information available, they do
not warrant that the use of such information as appropriate for any
particular purpose.
In all cases, users should not rely on this information without consulting
original source material and/or undertaking a thorough scientific analysis.
•Introduction
•Economic Advantages of Aluminum Extrusions
•Advantages of Aluminum
•Advantages of Aluminum Extrusions
•Overview of the Extrusion Process
•Corrosion Resistance
•Finishing / Fabricating Aluminum Extrusions
•Additional Information, Education and Training
Table of Contents
Courtesy of Light Metal Age magazine
Introduction
Introduction
•The aluminum extrusion process is
incredibly versatile and capable of
converting ideas to reality quickly,
accurately and inexpensively
•Designers can utilize a near-net
shape process to close tolerances,
coupled with a list of superior
physical characteristics to optimize
their designs
This presentation provides both a
conceptual and a practical
understanding of how best to design
with aluminum extrusions
Extrusion: often the most cost effective and quickest
path between concept and product
Introduction
Example of Aluminum Extrusions used in the
Nevada Solar One Concentrated Solar Power Plant
Aluminum extrusions are strong and efficient for
creating long lasting structures, critical to our future
Photos courtesy of Hydro Aluminum
Introduction
Introduction
•Aluminum extrusions offer a long
list of advantages – both those
inherent in aluminum as well as
those gained from the extrusion
process
•Combining aluminum and the
extrusion process yields results
which are second-to-none regarding
form, fit, function, appearance and
cost, producing amazing, attractive
parts and advantages
•Aluminum extrusions are green,
providing strong, lightweight
designs which are fully recyclable
Extrusion: often the most cost effective and quickest
path between concept and product
Photo courtesy of Hydro Aluminum
Introduction
Ideas taking shape
•An idea takes shape in the
designer’s mind and then takes
shape as a final product
•Through the flexibility of the
aluminum extrusion process,
profiles can be creatively
fine-tuned to specifically fit the
design requirements or to be
specifically branded with your
details
•All thanks to the amazing
versatility of aluminum extrusion
Introduction
The Shape is the Idea
•Almost any shape can be produced
through aluminum extrusion
•The highly workable material can
create a shape that can then be
enhanced and perfected through
additional machining, finishing and
fabrication
2008
Transportation
Category Winner
Electric
motorcycle frame
Introduction
The Shape becomes more than an end in itself
•The Shape can be designed
and extruded to be more than
the base for a useful product
•It can be formed to:
• Reduce piece count / provide
complex integral features
• Facilitate manufacturing and
assembly
• Reduce costs and lead times for
materials and production
• Increase product reliability and
durability
Photo courtesy of Light Metal Age magazine
• Simplify maintenance and repairs for
the final user of the product
• “Build in” an attractive appearance that
can make the product easier to sell
Consider the Advantages:
Photo courtesy of NASA
•From simple household appliances to exotic space and electronics
applications, products made from aluminum extrusions are superior in:
– Design Flexibility
– Performance
– Efficiency
– Reliability
– Cost
Introduction
Aluminum extrusions remain the best choice for
many applications
The aluminum extrusion process is flexible
and has both extremely low tooling costs
and short lead times, enabling efficient
production of near net shape, complex
integral parts – allowing exceptional
reductions to part counts and subsequent
fabrication and assembly
•Advancing techniques in
manufacturing and assembly can
extend aluminum’s use to even
more applications, including those
in which other materials have long
been employed
•The combination of the basic
properties of aluminum and its
alloys, plus the infinite variety of
shapes possible in the extrusion
process give aluminum extrusion
its many advantages over other
materials and methods of forming
Introduction
Indepth IBIS Associates CSP Frame Structure Analysis
• ECONOMIC ADVANTAGES OF ALUMINUM EXTRUSIONS
• Using information available in the public domain, IBIS
Associates performed an independent detailed analysis of
various existing parabolic trough CSP (Concentrated Solar
Power) frame designs from steel and aluminum used for
utility scale solar power applications.
• The following excerpts from the IBIS analysis are extremely
useful in understanding why aluminum extrusions represent
such exceptional competitive advantages in both cost and
performance to steel alternatives.
The IBIS slides are marked “Proprietary and Confidential – Do Not Distribute”;
AEC has permission to utilize these for this presentation.
IBIS: Workplan
1.) Establish baseline designs for comparison
1a.) Eurotrough, Skal-ET 150 & HelioTrough as steel baselines
1b.) “Generized” Aluminum based on public data of Acciona/FPL designs
2.) Collect component, material, process
3.) Build component list and process flow diagrams
4.) Construct cost models for component production and assembly
5.) Use cost model establish cost comparisons and sensitivity analyses
6.) Validate results via external expert reviewers
Proprietary & Confidential – Please Do Not Distribute
IBIS: Steel Baseline - Eurotrough
•Consortium composed of industry partners and supported by European
commission
– Collector Length: 12 meters
– Aperture Width: 5.7 meters
•Skal ET is a scaled up design of the Eurotrough by Flagsol which
replaced square tube sections with angles
– The solar collector assembly in this design is 150m long vs. the 100m
Eurotrough
Proprietary & Confidential – Please Do Not Distribute
Eurotrough & Skal ET Subassemblies
Sides A & C
Sides B & D
A
B
C
D
Cantilevers (28)
Torque Box
Proprietary & Confidential – Please Do Not Distribute
– Collector Length: 12 meters
– Aperture Width: 5.77 meters
– Total Aperture Area = 69.2 m
2
HelioTrough Collector Design
Proprietary & Confidential – Please Do Not Distribute
HelioTrough
Proprietary & Confidential – Please Do Not Distribute
– Collector Length: 19.1 meters
– Aperture Width: 6.77 meters
– Total Aperture Area = 129.3 m
2
Generic Aluminum Frame 12m Baseline
– Based on Acciona /Nevada Solar One
– Also installed by Florida Power & Light, but heavy duty,
hurricane strength version
– Baseline distilled from patent data and known component
sizes, estimated for 8m and 12m frames
• 8m scaled-up to 12m length and wider 5.77m aperture area
Proprietary & Confidential – Please Do Not Distribute
• Collector Length: 12 meters
• Aperture Width: 5.77 meters
• Total Aperture Area = 69.2 m
2
Summary of Steel and Aluminum Designs
~ 18kg/m
2
of aperture
~ 18kg/m
2
of aperture
~ 21kg/m
2
of aperture
~ 11 kg/m
2
of aperture
Proprietary & Confidential – Please Do Not Distribute
Assembly Transportation Fabrication
Kit &
Package
Shipping
(Truck)
Cut &
Machine
Extrusion
Chords
Struts
Angles
Nodes
Comparative Mfg & Ass’y Process Flows
Additional
Components
Torque Plates
Mirrors
Receivers
Motors
Hydraulics
On-site
Assembly
Cut
Tubes
Mech
Ass’y
Box
Mech
Ass’y
Arms
Transport
Flatbed
On-site
Assembly
Shipping
(Truck)
Cut
Tubes
Weld
Box
Sides
Weld
Arms
Zn
Galv.
Kit &
Package
Zn
Galv.
Additional
Components
Torque Plates
Mirrors
Receivers
Motors
Hydraulics
Aluminum
Steel
Pipe
Mill
Hammer-
forge &
weld
mounts
Zn
Galv.
Torque Tube (Heliotrough)
Torque Box (Eurotrough, Skal-ET)
Proprietary & Confidential – Please Do Not Distribute
– The following cost estimates are built from the bottom
up, and consider all variable and fixed elements of
each of the operations required to fabricate, assemble
and install Solar Thermal Parabolic Collectors.
– These are the direct manufacturing costs that would
be incurred by a company that is completely
integrated from raw material acquisition through to
final field installation.
– There are no SG&A costs nor profit added to these
estimates.
Cost Modeling Methodology
Proprietary & Confidential – Please Do Not Distribute
Material Market Price History
Proprietary & Confidential – Please Do Not Distribute
OEM purchase price includes:
+ $0.10/lb steel long product premium
+ $0.20/lb alloy & midwest billet surcharge
Material Market Price History
Proprietary & Confidential – Please Do Not Distribute
• Collector Cost Comparison in $/frame
Scenario Comparison
Aluminum Eurotrough Skal ET HelioTrough
12m 12m 12 m 19m
Material
$1,727 $1,430 $1,439 $1,446
Fabrication
$654 $258 $289 $2,225
Sub-Assembly
‐‐ $517 $622 $324
Galvanizing
$54 $1,390 $1,082 $2,394
Shipping
$47 $94 $95 $281
Field Assembly
$246 $323 $323 $237
Total
$2,728 $4,012 $3,850 $6,907
Proprietary & Confidential – Please Do Not Distribute
NOTE: Material costs based on long term average material market prices ($1.10/lb for aluminum billet and
$0.45/lb for steel based on long term average prices (for midwest extrusion billet and cold rolled tube stock)).
A later chart shows how the frame costs in aluminum and steel vary over the past 20 years.
The $’s represented are not Prices charged to customers but are estimated Costs from direct manufacturing
only (they do not include overheads and profit from suppliers and contractors).
Collector Cost Summary (per sq meter)
Proprietary & Confidential – Please Do Not Distribute
Collector Cost Summary (per sq meter)
Proprietary & Confidential – Please Do Not Distribute
$0.00
$10.00
$20.00
$30.00
$40.00
$50.00
$60.00
$70.00
$
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Projected Collector Cost over Market History
Generic Aluminum 12m
Eurotrough 12m
Skal ET 12m
HelioTrough 19m
Material Market Price History
Proprietary & Confidential – Please Do Not Distribute
AEC Conclusion: at no time from 1991 through 2011 would
the comparative prices of steel, zinc and aluminum
extrusions have resulted in a case where the cost of the
modeled extruded aluminum frame would have been greater
than the galvanized steel frames which were modeled.
AEC: Based on published operating results at Nevada Solar One, NREL, the SEGS fields and others, the
optical efficiency and energy performance of aluminum frames is equal to or better than tested steel designs.
NOTE: The $’s represented are not Prices charged to customers but are estimated Costs from direct manufacturing only
(they do not include overheads and profit from suppliers and contractors).
•Lightweight
•Strong
•High Strength-to-Weight Ratio
•Resilient
•Corrosion-Resistant
•Heat Conductive
•Reflective
•Electrically Conducive
•Non-Magnetic
•Non-Sparking and Non-Combustible
•Cold Strength
•Fully Recyclable
Important for solar applications!
Advantages of Aluminum
Advantages of Aluminum
Aluminum Extrusions can be produced in different alloys and processed to
different tempers to achieve desired mechanical properties, corrosion
resistance, machinability, formability and other attributes
Photo courtesy of Hydro Aluminum
Advantages of Aluminum
Advantages of Aluminum
Lightweight
Only about one-third as heavy as
iron, steel, copper or brass; thus, in
applications where volume remains
the same regardless of metal used,
aluminum goes about three times as
far as the other metals
Photo courtesy of Classic Trailers, Inc.
Advantages of Aluminum
Strong
Appropriately alloyed and treated,
aluminum can be stronger than some
steels, with ultimate tensile strengths
as high as 80,000 psi to 90,000 psi or
more.
Photo courtesy of Werner Co.
Material
Modulus (E)
(10
6
psi)
Mild Steel 29.0
Aluminum 10.0
Brass 13.0
Zinc 13.0
Plastics:
PS 0.51
PET 0.29
Nylon 0.42
Peek 0.56
The modulus of elasticity
(E) is the relationship of
how the material deforms
compared to the stress that
it is under.
Advantages of Aluminum
High strength plus low weight
permits substantial reductions in
the weight of both parts and final
products
Rendering and photo courtesy
of Tesla Motors, Inc.
High Strength-to-Weight Ratio
Photo courtesy of Werner Co.
Advantages of Aluminum
Rendering and photo courtesy of Audi USA
High Strength-to-Weight Ratio
High strength plus low weight permits
substantial reductions in the weight of
both parts and final products
Advantages of Aluminum
Excellent corrosion resistance in a
wide variety of environments and
contact with a myriad of substances;
it develops its own inert aluminum
oxide film, which is self-protective,
blocking further oxidation
Photo courtesy of Light Metal Age magazine
Corrosion Resistant
Advantages of Aluminum
Reflective
Photo courtesy of Alcoa
Highly reflective (more than 80%) of both
visible light and the invisible radiation
beyond both ends of the visible spectrum
Advantages of Aluminum
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!
Photo courtesy of NASA
Advantages of Aluminum
Fully Recyclable
Aluminum is fully, and repeatedly,
recyclable, able to be recycled
over and over without degradation
or loss of its innate characteristics
For products with a limited life
(such as consumer durables and
transportation products),
aluminum’s recyclability coupled
with its other outstanding
attributes make it a superior
material choice
Aluminum has significant scrap
value and is particularly
environmentally friendly because
recycling requires only 5% of the
energy necessary to produce
virgin aluminum
Photo courtesy of Light Metal Age magazine
Advantages of Aluminum
Aluminum is fully, and repeatedly,
recyclable, able to be recycled
over and over without degradation
or loss of its innate
characteristics.
For products with a limited life
(such as consumer durables and
transportation products),
aluminum’s recyclability coupled
with its other outstanding
attributes make it a superior
material choice.
Aluminum has significant scrap
value and is particularly
environmentally friendly because
recycling requires only 5% of the
energy necessary to produce
virgin aluminum.
Fully Recyclable
Photo courtesy of Light Metal Age magazine
• Lightweight
• Strong
• High Strength-to-Weight
Ratio
• Resilient
• Corrosion-Resistant
• Thermal Conductivity
• Reflective
• Electrically Conducive
• Non-Magnetic
• Non-Sparking
• Non-Combustible
• Cold Strength
• Fully Recyclable
Advantages of Aluminum
Photo courtesy of Light Metal Age magazine
• Attractive
• Suitable for a Wide Range of
Finishes
• Virtually Seamless
• Easy to Fabricate
• Joinable by Various Methods
• Suitable for Easy-assembly
Designs
• Suitable for Complex, Integral
Shapes
• Produced to Close Tolerances
• Produced with Uniform Quality
• Cost-effective
• Short Production Lead Times
Advantages of Aluminum Extrusions
Photo courtesy of Werner Extruded Solutions LLC
Advantages of Aluminum Extrusions
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.
Photo courtesy of Alexandria 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, screws, pins,
bolts, rivets, chips, adhesives,
clinching and slide-on, snap-together
or interlocking joints
2004 Structural Category Winner
Advantages of Aluminum Extrusions
Suitable for Complex, Integral Shapes
Shapes can combine functions that
would otherwise require the
production and joining of several
different parts.
2005 Commercial/Industrial/Consumer Winner
Advantages of Aluminum Extrusions
Advantages of Aluminum Extrusions
• Reduce the number of operations
required
• Reduce the corner stress from
bending
• Cosmetically more attractive
Aluminum sheet stock = 3 operations
Extrusion = 1 operation
Photos courtesy of Alexandria Extrusion Company
Using the Extrusion Process
for Net Shape
Suitable for Complex, Integral Shapes
Advantages of Aluminum Extrusions
Photo courtesy of Alexandria Extrusion Company
•Significantly lower tooling cost
•Improved strength
•Improved ductility
•Improved weldability
•No porosity
•Cosmetically more attractive
•Shorter lead time
Aluminum Extrusions
Replace Castings
Suitable for Complex, Integral Shapes
Advantages of Aluminum Extrusions
Suitable for Complex, Integral Shapes
Shapes can combine functions that
would otherwise require the
production and joining of several
different parts
Photo courtesy of Light Metal Age magazine
Produced to Close Tolerances
Advantages of Aluminum Extrusions
Tight tolerances are routine and the
ability of aluminum extruders to meet
even more critical dimensions is
keeping pace with advances in
technology.
Photo courtesy of Almag
Produced with Uniform Quality
Advantages of Aluminum Extrusions
This reliability reduces customer
costs by minimizing rejections rate,
corrective fabrication and production
slowdown – particularly important to
the manufacturer who depends upon
just-in-time (JIT) delivery
Photo courtesy of Werner
Extruded Solutions LLC
Cost-effective
Advantages of Aluminum Extrusions
The boundless diversity of shapes
permitted by the extrusion process
cuts down or eliminates many
machining as well as joining
operations. Also, the tools required
for aluminum extruding, such as dies
and related items are relatively
inexpensive.
Process
Typical Tooling
Cost ($)
Vinyl Extrusion $1,500 and up
Injection Molding $25,000 and up
Die Castings $25,000 and up
Roll Forming $30,000 and up
Stampings $5,000 and up
Aluminum Extrusions $500 to $5,000
Short production lead times
Advantages of Aluminum Extrusions
0
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Lead Time in Weeks
Examples of Value Added Operations
Advantages of Aluminum Extrusions
Finishing
•Painting (wet and powder)
•Polish, bright dip & anodize
•Mechanical finishes
•Silk screening
Fabrication
•Sawing
•Punching / piercing / drilling
•Machining
•Bending
•Welding
•Milling
•Tumbling
Photo courtesy of Werner Co.
The Possibilities are Boundless,
Limited only by the Imagination
Advantages of Aluminum Extrusions
The extrusion pictured is a theoretical
shape created to illustrate some of
the range of possibilities provided by
aluminum extrusions
Photo courtesy of Werner Co.
How can YOU use this
flexibility to:
•Spark your imagination?
•Create new product concepts?
•Develop improved manufacturing
efficiencies?
Advantages of Aluminum Extrusions
Photo courtesy of Werner Co.
Overview of the Extrusion Process
The Aluminum Extrusion Profile
Photo courtesy of SAPA
Extruded Product Flow
Overview of the Extrusion Process
Photo courtesy of Hydro Aluminum
Overview of the Extrusion Process
The Extrusion Process
Overview of the Extrusion Process
Overview of the Extrusion Process
Photo courtesy of Nancy Molenda/AEC
Overview of the Extrusion Process
How are
Hollow Shapes
Extruded?
Tooling
Overview of the Extrusion Process
Photo courtesy of Werner Extrusion Solutions LLC
•Hollow Dies
•Solid Dies
•Multiple Hole Dies
Some Limitations
Overview of the Extrusion Process
Photo courtesy of Werner Extrusion Solutions LLC
• Circle Size
The circumscribing circle
that the profile could fit through
- Larger circle sized shapes need
larger tooling and equipment
(less available and more expensive)
• Wt / ft
- Too heavy? Too light?
• Shape Constraints
- High tongue ratios
- Somewhat balanced wall
thicknesses
- Other
Overview of the Extrusion Process
Some Limitations
Circumscribed Circle Size in inches
Corresponding
Profile weight
(lbs/ft)
Cross Section Area in sq
inches
<1 1 to 7 7 to 10 10 to 14 >14
Min Max
<0.050 L x x x x - 0.06
0.050 to 0.100 G G L x x 0.06 0.12
0.100 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 containers
There are fewer presses available with 7" to 10" diameter containers
There are even fewer presses available with 10" to 14" diameter containers
There are very few presses available with greater than 14" diameter containers
Difficult Tongue Ratio
Overview of the Extrusion Process
Photo courtesy of Hydro Aluminum and Werner Extrusion Solutions LLC
Examples of Aluminum Extrusions
Overview of the Extrusion Process
Photos courtesy of Hydro Aluminum and Werner Extrusion Solutions LLC
Aluminum components are often utilized due
to the inherent corrosion resistance of the
material.
Although aluminum is a chemically-active
metal, its behavior is stabilized by the
formation of a protective oxide film on the
surface.
Generally, this film is stable in aqueous
solutions with pH 4.5-8.5. Further
considerations need to be made if the pH
exceeds these limits or if the environment
contains chloride.
Corrosion Prevention Strategies for
Aluminum Solar Frames
The following variables should be addressed
in the project design stage to prevent and/or
minimize corrosion:
•Fastener material choice
•Method of isolating aluminum from
concrete when anchoring
•Alloy choice
•General design recommendations
While aluminum does not “ rust” , it is
subject to corrosion, although corrosion is
insignificant in fresh, unpolluted air.
Corrosion Resistance
Corrosion Resistance
Corrosion Resistance
Corrosion Resistance
Corrosion Resistance
Galvanic corrosion
occurs when two metallic materials
are in contact in the presence of an
electrolyte forming a galvanic cell.
Most types of aluminum corrosion
are the result of some kind of
galvanic coupling with a dissimilar
material.
The least noble material (the anode)
preferentially corrodes while the more
noble material (cathode) is protected.
Since aluminum is more anodic than
most commonly used construction
materials, with the exception of zinc,
magnesium and cadmium, this can be
a serious form of corrosion with
aluminum.
Understanding the types of corrosion which affect aluminum
Coupling aluminum with a more noble
material can seriously deteriorate the
protective effect from the oxide layer. This
is especially dangerous in atmospheres
or water with high concentrations of
chlorides or other aggressive corrosives.
Courtesy of Hydro Aluminum
Corrosion Resistance
Galvanic corrosion
can be avoided or minimized by
taking the following actions:
Avoid using materials with large
galvanic potential differences in a
particular environment (stainless
steel not included). If that is not
practical, different materials have to be
properly electrically insulated. It is very
important to use insulation material of
proper electrical resistance and to
avoid metallic contact in the entire
construction. This can be checked with
resistance measurement instruments
such as a multimeter.
Understanding the types of corrosion which affect aluminum
Aluminum may also be protected by
means of sacrificial anodes.
The most cathodic material can be
surface treated with a metallic
coating (Al/Zn), organic coating (lacquer,
paint, plastic, rubber) or a special coating
for screws and bolts. Surface treatment
has to be carried out correctly and not
done only on the anodic material. As a
consequence, a defect in the surface
coating may generate a very unfavorable
cathode/anode ratio (a big cathode area
in relation to a small anode area gives
considerable corrosion).
Corrosion Resistance
Galvanic corrosion
in combination with crevice
corrosion may be especially
damaging.
Avoid entrapment of liquids in
crevices between materials of
various galvanic potentials.
Understanding the types of corrosion which affect aluminum
Also avoid the transfer of ions of
galvanic materials on aluminum
surfaces.
For instance, droplets from a copper tube
on an aluminum surface will generate
precipitation of copper metal. The result is
corrosion of aluminum (deposition
corrosion). The next step will be
microgalvanic corrosion between
aluminum and the copper particles in the
aluminum surface. Severe pitting may
occur within a few weeks.
Corrosion Resistance
Courtesy of Hydro Aluminum
Corrosion resistance in different environments
The atmosphere
Corrosion is insignificant in fresh,
unpolluted air. Aluminum does not
corrode where there are high levels of
sulphur dioxide but can, under
certain circumstances, become dark or
matte in appearance.
Water
Pitting can occur in stagnant water.
The composition of the water is the
important factor as the presence of
copper, calcium, chloride and
bicarbonate ions increase the risk
significantly. This can be prevented by
regular cleaning and drying.
Seawater
Alloys containing silicon, magnesium and
manganese show good resistance to
corrosion in seawater. Copper alloys, on
the other hand, should be avoided.
Corrosion Resistance
Corrosion resistance in different environments
Soil
The resistance to corrosion is, to a
great degree, dependent on the
moisture in the soil and its pH level.
Aluminum surfaces which may come
into contact with soil are best treated
with a thick layer of bitumen or a
powder coating.
Acids
The majority of inorganic acids have a
very corrosive effect on aluminum,
except nitric acid. High temperature,
high acid concentrations and high
levels of impurities in the aluminum
increase the rate of corrosion
significantly.
.
Alkalis
Strong alkalis are very corrosive. Sodium
hydroxide reacts violently with aluminum.
The rate of corrosion can be reduced in
environments where the pH is between 9
and 11 by using silicates. Wet cement has
a high pH and therefore corrodes
aluminum alloys.
Organic compounds
Aluminum is highly resistant to the
majority of organic compounds. Corrosion
can occur, however, with certain
anhydrous liquids.
Other materials
In practice, the corrosion problem caused
by contact with other materials is, for the
most part, small. The natural oxide layer
usually provides sufficient protection.
For More Information
This PowerPoint presentation uses information current as of J une 21, 2011.
You will note that some of the key slides in the economics area are marked
“Preliminary”.
Please visit the following to obtain the most up-to-date version of this and
other presentations:
www.aec.org/exapps/CustomerOutreach.html
• Purchase the Aluminum Design Manual 2010 edition
from the Aluminum Association (aluminum.org)
• Utilize ASCE Aluminum Design Manual training
• A 9.75 hour seminar on designing aluminum structures is offered in these
formats:
– An On-line version: go to www.asce.org/distancelearning; click on “ View
a complete list of ASCE courses” , scroll down alphabetically to
“ Designing Aluminum Structures”
– A live version at various times and locations: go to
www.asce.org/continuingeducation; click on “ Structural” , scroll down to
“ Aluminum Structural Design with the 2010 Aluminum Design Manual”
– Or, to arrange to have the seminar conducted at your site, contact John
Wyrick at ASCE at 800-548-2723 or [email protected]
• Utilize other resources from our contributors, other qualified extruders and
structural engineers
• Utilize the Aluminum Extruders Council website and other
resources (aec.org) for webinars or other key information
For More Information and Training
Aluminum Extruders Council
Aluminum Extruders Council Overview
The Aluminum Extruders Council (AEC), based in suburban Chicago, is an association dedicated
to helping manufacturers, engineers, architects, and others to discover why aluminum extrusion is
the preferred metal-forming process for optimal product solutions. Aluminum extrusions touch
lives in so many ways-from office chairs and cubical partitions to bicycles and scooters, from the
latest in aluminum space-frame technology in today’s lighter cars and trucks to frames and
components for green technology such as solar power and LED lighting. The majority of North
American extruders are members representing hundreds of plants and countless extrusion
presses producing the highest quality products and value-added services. Specialized
conferences, seminars, workshops, and meetings throughout the year provide an outlet where
members can confront and solve today’s challenges and network with peers and suppliers. As an
advocate representing the aluminum extrusion industry, AEC also provides expertise in outreach
and advocacy to appropriate governmental agencies and industry code bodies.
Aluminum Extruders Council Mission
•Provide opportunities to network with peers and suppliers, address common internal
and external issues, share data, train and sponsor research
•Work together to enable members to function more efficiently, cost effectively,
and knowledgeably
•Enhance the growth of the industry by promoting the advantages of
aluminum extrusion processes and product applications
Aluminum Association
Aluminum Association Overview
The Aluminum Association, based in Arlington, Virginia, works globally to aggressively promote
aluminum as the most sustainable and recyclable automotive, packaging and construction
material in today’s market. The Association represents U.S. and foreign-based primary producers
of aluminum, aluminum recyclers and producers of fabricated products, as well as industry
suppliers. The Association provides leadership to the industry through its programs and services
and assists in achieving the industry's environmental, societal, and economic objectives. Member
companies operate more than 200 plants in the United States, with many conducting business
worldwide.
Aluminum Association Mission
The Aluminum Association will provide value to its membership through its leadership and
services in aggressively promoting the growth of the aluminum industry globally by:
•Continuously strengthening aluminum's position versus competitive materials
•Developing, maintaining and promoting global standards that achieve customer
requirements for aluminum product applications
•Representing the interests of its membership to the U.S. and international governments
•Providing research and education to actively address community and employee
environmental, health and safety issues
•Gathering and presenting data, statistics, and other information about the aluminum
industry in an accurate and timely manner
•And by...leveraging industry strength by establishing stronger domestic and global
alliances
Thanks to All of Our Contributors
Thanks to All of Our Contributors
SAPA Aluminum
Jeff Henderson
9600 West Bryn Mawr Ave.,Suite 250
Rosemont, IL 60018
318-303-2661 (Office)
[email protected]
Hydro Aluminum
Lynn Brown
999 Corporate Blvd
Linthcium, MD 21090
410-487-8057 (Office)
[email protected]
Kaiser Aluminum
Doug Richman
24255 Thirteen Mile Rd. Suite 290
Bingham Farms, MI 48025
248-430-0107
[email protected]
The Aluminum Association
Mike Skillingberg
1525 Wilson Blvd.
Arlington, VA 22209
703-358-2988 (Office)
[email protected]
Light Metal Age
Ann Marie Fellom
170 S. Spruce St. Suite 120
S. San Francisco, CA 94080
650-588-8832 (Office)
[email protected]
Aluminum Extruders
Council
Rand Baldwin
1000 N. Rand Rd. Suite 214
Wauconda, IL 60084
847-526-2010 (Office))
[email protected]
Werner Extrusion Solutions LLC
Craig Werner
100 N. Field Dr. Suite 145
Lake Forest, IL 60045
847-582-1160 (Office) 847-910-0607 (Cell)
[email protected]