Reynaers Aluminium WE BRING ALUMINIUM TO LIFE

Els Fonteyne
1 31 mei 2011

Reynaers gives added value to aluminium

Sustainable Low melting temperature Light metal Strength by alloys Electrical conductivity No corrosion / coating possibilities

Long lifespan in building Large designfreedom by extrusion Construction possibilities / transport Strength by design Insulation of profiles Low maintenance

31 mei 2011

Contents
Introduction Production of aluminium Recycling of aluminium Properties of aluminium Aluminium alloys Processing techniques for aluminium Extruded aluminium profiles Reynaers systems Reynaers

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Introduction
Discovery of aluminium
Old material / new material?
Basic material alum Discovery of the metal aluminium: 1825-1888 Production starts to increase: World production in 1900: 6700 tonnes World production in 2006: more than 35 million tonnes (source: EAA)

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Production of aluminium
Starting material: Bauxite: Ore with a high aluminium oxide content

Production of aluminium: 2 steps

Chemical process: Winning of aluminium oxide Electrolytic process: Production of aluminium

31 mei 2011

Production of aluminium
Chemical process: Winning of aluminium oxide

Electrolytic process: Production of aluminium

4 ton bauxite 6

2 ton alumina

0.5 ton electrolyte

20-15000 kW/h

= 50% production cost

1 ton aluminium 31 mei 2011

Recycling of aluminium
Recycling of aluminium saves 95% of energy needed for primary production
Alumina Al i Billets E t i Extrusion Isolation
100 90 80 70 60 50 40 30 20 10 0

Closed recycling loop

PA Extrusion

Energy y required (% %)

primary re ecycled
Recyclage

5%
Surface treatement

use

Fabrication

Various applications

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Properties of aluminium
General
Atomic number: 13 Light: Density = 2702 kg/m kg/m ( (= 1/3 of steel) Strength
Unalloyed aluminium: No high strength Addition of relatively small percentages of other metals: Alloys with strength significantly higher th that than th t of f normal l structural t t l steel t l

Rigidity: Modulus of elasticity = 7200 kg/mm (= 1/3 of steel) Elasticity (3x steel) Cond cts electricity Conducts electricit and heat Low melting temperature: 660C
Very easily worked, hence large number of forming techniques Easily recycled

Corrosion resistance: Stable in air due to thin and closed oxide skin Non-magnetic p 1.19 mm p per m with 50 temperature p difference Low coefficient of thermal expansion:

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Aluminium alloys
Alloys to improve:
Mechanical properties Castability

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Aluminium alloys
Addition of other elements

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Aluminium alloys
Types of alloy

1000 Al 2000 Al + Cu 3000 Al + Mn 4000 Al + Si 5000 Al + Mg g + Si 6000 Al + Mg 7000 Al + Mg + Zn

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Aluminium alloys
Reynaers alloy
Silicon:
Increases tensile strength Improves castability and corrosion resistance DIN 6060 Si Fe Cu Mn Mg Cr Zn Ti Other single Other total 0 30 0.60 0.30 0 60 % 0.10 0.30 % 0.1 % 0.1% 0.35 0.60 % 0.05 % 0.15 % 0.1 % 0.05 % 0.15 % Reynaers 0 30 0.55 0.30 0 55 % 0.10 0.30 % 0.02 % 0.1 % 0.35 0.60 % 0.05 % 0.15 % 0.1 % 0.05 % 0.15 %

Copper:
Increases tensile strength and hardness All i Alloy is h hardenable d bl Corrosion resistance decreases slightly Electrical conductivity increases

Manganese:
Improves corrosion resistance Thermal and electrical conductivity decrease slightly

Magnesium
Increases tensile strength and hardness Thermal and electrical conductivity decrease slightly

Avoidance of filiform corrosion: Pickling 2 gr/m gr/m before painting remains most important

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Processing techniques for aluminium

Rolling Spinning Bending Bending and setting Deep drawing Roll forming Cold extrusion Forging Superplastic forming Hydroforming Casting Friction Stir Welding Machining Extrusion

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Processing techniques for aluminium

Rolling

Spinning

Bending

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Processing techniques for aluminium

Bending and setting

Deep drawing

Roll forming

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Processing techniques for aluminium

Cold extrusion

Forging

Superplastic forming

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Processing techniques for aluminium

Hydroforming

Casting

Friction stir welding

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Extruded aluminium profiles

1) Preheating of billet to +/- 450C (melting at 600C) 2) Extrusion of billet through die under high pressure (40 to 70 kg/mm) 3) Rapid cooling of profile at 1C/sec 4) Straightening of profile at room temperature 5) Sawing to the desired length 6) Hardening/ageing: 6 to 15 hours at 150-200

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Extruded aluminium profiles

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Extruded aluminium profiles

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Extruded aluminium profiles

Insulation process

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Extruded aluminium profiles

Surface treatement
2 processes: - Powder P d coatingoederlakken i d l kk - Anodisation 1.

2.

3.

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Reynaers systems

Advantages Long lifespan (30-40 year) Large glass surfaces with slim profiles Low maintenance Insulation levels: large choice depending on location and orientation
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Reynaers systems
Problem: Global warming due to greenhouse gases G Greenhouse h gases are emitted itt d b by b burning i f fuels l 40% of CO2 production in Europe is emitted from buildings: heating and use of equipment Solution with Reynaers systems = development of sustainable systems which contribute to sustainable buildings

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Reynaers systems
Reduce energy losses through building

Reducing heat loss by insulation

Reducing heat loss by air tightness of building ventilation required

Heat gain by use of passive solar energy

General G l trend t d for f low l energy building b ildi High insulation windows required: Uw < 1.5 W/mK
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Reynaers systems
Reynaers high insulation systems CS 86 HI: av. Uf 1.5 W/mK

CS 104: av. Uf 1.0 W/mK

Passiv Haus

CP 155 HI-Minergie: av. Uf 2 W/mK

CW 50 HI: av. Uf 0.9W/mK

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Reynaers systems
Reynaers green energy systems CW 60 solar: BIPV

BS solar

BS 100: sun shading

Large glass surfaces for passive heating of buildings

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Reynaers systems
Reynaconnect: solution for building connections

Airtight Simple Installation Acoustic insulation Thermal insulation Damp regulation Watertight

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31 mei 2011