About andre

This author has not yet filled in any details.
So far andre has created 252 blog entries.
4 08, 2011

The 101 on Recycling Aluminum Materials

2015-06-18T15:33:41+00:00August 4th, 2011|

Here are 10 important and interesting facts about recycling aluminum materials…

-A used aluminum can is recycled and back on the grocery shelf as a new can, in as little as 60 days. That’s closed loop recycling at its finest!

-Used aluminum beverage cans are the most recycled item in the U.S., but other types of aluminum, such as siding, gutters, car components, storm window frames, and lawn furniture can also be recycled.

-Recycling one aluminum can saves enough energy to run a TV for three hours — or the equivalent of a half a gallon of gasoline.

-More aluminum goes into beverage cans than any other product.

-Because so many of them are recycled, aluminum cans account for less than 1% of the total U.S. waste stream, according to EPA estimates.

-An aluminum can that is thrown away will still be a can 500 years from now!

-There is no limit to the amount of times aluminum materials can be recycled.

-We use over 80,000,000,000 aluminum soda cans every year.

-At one time, aluminum was more valuable than gold!

-A 60-watt light bulb can be run for over a day on the amount of energy saved by recycling 1 pound of steel. In one year in the United States, the recycling of steel saves enough energy to heat and light 18,000,000 homes!

To learn more about the process aluminum recycling, and how to begin recycling yourself, please visit Earth911.

12 07, 2011

Aluminum Can Recycling Rate Reaches Highest Level in More than a Decade

2015-06-18T15:33:41+00:00July 12th, 2011|

The U.S. recycling rate for aluminum beverage cans has reached its highest level in a decade, with 58.1% of all cans recycled last year – a rate that is more than double that of any other beverage container, according to the Can Manufacturers Institute (CMI) and Institute of Scrap Recycling Industries (ISRI).

Nearly 56 billion aluminum cans were recycled in 2010, leading to a used beverage container (UBC) recycling rate of 58.1% – the highest in 11 years.  Because it takes 95% less energy to produce a can from recycled material, the high recycling rate also resulted in significant energy savings.  The amount of energy saved just from recycling cans in 2010 is equal to the energy equivalent of 17 million barrels of crude oil, or nearly two days of all U.S. oil imports.

Aluminum beverage cans are unique in that they can be infinitely recycled back into new cans, keeping waste out of landfills and providing a significant amount of the material to make new cans.  Indeed aluminum cans not only have the highest recycling rate of all beverage packages, they also have the greatest amount of recycled content – by far – at 68%.

Read the full article about the aluminum can at The Aluminum Association.

6 07, 2011

Aluminum Association Releases Video Honoring the Flag’s Unsung Partner: The Aluminum Flagpole

2017-01-26T23:37:32+00:00July 6th, 2011|

The Aluminum Association is paying tribute with a video of the flag and its unsung partner, the flagpole.  The video includes images of the American flag flying over various U.S. historical locations as well as the extrusion process used to create flagpoles.

Among the most notable applications of aluminum flagpoles are the 50 flags representing each state that fly around the base of the Washington Monument in Washington, D.C.  At one time, flags were flown on specific days of national celebration using temporary wooden flagpoles.  For the George Washington Birthday celebration of 1958, it was determined that the flags would be flown permanently at the Monument, and aluminum flagpoles were installed.

These flagpoles represent the modern age of aluminum production, a material used in applications ranging from wiring to automobiles to building facades and beverage cans. Aluminum is lightweight, durable, and does not corrode; these properties make it the perfect material for permanent applications, such as flagpoles, that must uphold Old Glory under even the harshest weather conditions.

To see the video, visit the Aluminum Association’s Facebook by CLICKING HERE.

Or visit YouTube: http://www.youtube.com/watch?v=1RvfLj2CY6Y

8 06, 2011

Taber Extrusions LLC Awarded Austal LCS and JHSV Contracts

2017-01-26T23:37:32+00:00June 8th, 2011|

Russellville, Ark. (June 2, 2011) – Taber Extrusions LLC and Austal USA have entered into contracts for Taber to supply extruded products for the Austal USA Littoral Combat Ship Jackson (LCS 6), as well as Austal USA’s Joint High Speed Vessel Fortitude (JHSV 3).  Extrusions used on these all-aluminum vessels make up some of the ship’s decking, superstructure and bulkheads. Some structural extrusions for both ships will also be manufactured by Taber and supplied to Austal through a contract with O’Neal Steel Corp.  Taber operates manufacturing facilities in Russellville, AR and Gulfport, MS.  The extrusions to be provided for the LCS and JHSV programs will be produced at both facilities.

According to Taber: “The use of our 8,600-Ton extrusion press with its unique rectangular container and billet configuration enables us to successfully produce wide multi-void extrusions that are friction stir welded into panels. The combination of the superior metal flow patterns associated with our rectangular configuration along with the press size gives us an advantage over competitors trying to make similar extrusions with round containers on smaller presses.  The unique flow pattern in this design allows us to hold much tighter tolerances for flatness, straightness and twist as well as assure that critical thickness dimensions on the internal webs are achieved. We also produce tee extrusions in various alloys that are friction stir welded into panels.”

Taber’s ability to hold tight tolerances has allowed for a significant increase in productivity in the friction stir-welding rates and reduced downstream scrap and weld repairs. Taber maintains an exemplary record for quality and on-time delivery.

Taber’s President, Mr. Bill Wetmore, commented: “Our quality and delivery record has given Austal the confidence to expand our business relationship.  We look forward to working with Austal on both of these major programs for many years.” 

The U.S. Navy’s shipbuilding plan envisions building 55 Littoral Combat Ships accounting for about 18% of the Navy’s planned 313-ship force. Austal is teamed with General Dynamics Advanced Information Systems, serving as ship systems integrator, responsible for the design, integration and testing of the ship’s mission systems.  Jackson (LCS 6) is the first ship awarded under Austal’s recently announced US Navy contract for construction of up to an additional 10 Littoral Combat Ships to be appropriated over the following five years with a total value exceeding $3.5B.

The JHSV program provides high-speed transport vessels for the Army and the Navy. These vessels will be used for fast intra-theater transportation of troops, military vehicles and equipment. The JHSV program merges the previous Army Theater Support Vessel (TSV) and the Navy High Speed Connector (HSC), taking advantage of the inherent commonality between the two programs.  Authorization to proceed with construction of JHSV 3 was granted in January 2010 and authorization to procure long lead time material for JHSV 4 & 5 was granted in June 2010. The current program with all awards is for total 10 ships for use by Army, Navy, and Marine Corps. The first ship is intended to be delivered in year 2011.

Taber Extrusions’ unique capabilities in wide, long and complex extrusion profiles and our experience in manufacturing such shapes in both the 5000 and 6000 series alloys has made Taber the extruder of choice for the next generation of aluminum ships.  Furthermore, Taber is the only U.S. based manufacturer of 5000 series aluminum extrusions designed primarily for the ship building market to maintain an uninterrupted supply for over 35 years.

7 06, 2011

Aluminum: A Closer Look at The Element

2015-06-18T15:33:41+00:00June 7th, 2011|

Aluminum is the most abundant metallic element in the Earth’s crust (about 8%) and is the third most common element after oxygen and silicon. Unlike copper or gold, aluminum cannot be found in nature in the pure state because of its high affinity with oxygen, being so always combined with another element like in alum (KAl(SO4)2∙12H2O) and in aluminum oxide (Al2O3). So, up to 1820, the aluminum was unknown as a metal.

In the 19th century the production process was so expensive and available quantities so small that aluminum was a precious metal ($1200/kg in 1852). Indeed, Napoleon III emperor of France had a baby rattle and some other small objects made of it, and a story tells that during a banquet the most honoured guests were given aluminum utensils, while the other guests were given gold utensils.

Presently, aluminum is the second largest used metal in the world, mainly due to its light weight, high strength and recyclability.

Aluminum is heavily used in the transportation industry because of its durability, strength and lightweight. Aluminum weight is one third of steel or cast iron. Taking into account increased thickness of the aluminum parts compared to steel, 1 kg of aluminum replaces 2 kg of steel, leading to lighter cars, trucks, etc… with reduced fuel consumption and CO2 generation.

Without aluminum the commercial aircraft industry would not have existed. The new A380 employs 66% of aluminum in the airframe, while a Boeing 747 contains 75 tons of aluminum.

The use of aluminum for the building of ships is increasing year by year. Today, single and multiple hull boats are made entirely of aluminum alloy. This kind of marine applications involve the largest usage of aluminum per produced object (400 ton) compared to a large, all aluminum car (1 ton).

The usage of aluminum is increasing in the military field too, where it is used as a substitute for the steel.

In building and construction aluminum find a wide variety of applications, and its use is steadily increasing. It can be used to manufacture structural elements, as in bridges (for example, the Corbin Bridge in Pennsylvania has been retrofitted with an extruded aluminum deck, which is lighter than the previous deck made of steel and timber, allowing the bridge to sustain 22 tons load compared to the previous 7 tons). Curtainwall made of extruded aluminum and glass are very attractive for the design of new buildings or retrofit of old ones. Windows made of extruded aluminum are attractive, energy-efficient (with thermal broken technology), and reliable. Domes for gymnasiums, schools, theme parks, storage facilities, multi-purpose arenas, industrial roof systems, and churches are made with aluminum because of its strength and low weight. Aluminum is one of the best material also in the roof construction, because of its strength against corrosion and, hence, weathering and influence of pollutants in the atmosphere. Low maintenance aluminum facades are used to cover old houses facades made with thin or wide wooden clapboard.

Aluminum find also wide use in the packaging industry, being produced in both rigid and foil forms. Rigid aluminum containers are used for beverage and food packaging. Aluminum cans account for all of the beverage can market, but only a small percentage of the food can market. Cans are 79 percent of aluminum packaging by weight. Foil packaging is used as a wrapping foil, as semi-rigid packages such as pie plates and frozen food trays, and as flexible packaging such as cigarette foil and candy wrappers.

For more information, please visit AluminumSmeltingProcess.com!

18 05, 2011

The Process of Aluminum Extrusion

2015-06-18T15:33:41+00:00May 18th, 2011|

“Extrusion” is often defined as the process of shaping a material, such as aluminum, by forcing it to flow through a shaped opening in a die. The extruded material emerges as an elongated piece with the same profile as the die opening. 

In thinking about the extrusion process, consider a Play Doh Fun Factory and how it might work. Think of the Fun Factory as the extrusion press, the handle as the ram, the shape bar as the die, and the Play Doh as the aluminum billet.

The first step is to choose the desired shape and color. Think of the shape as the die which will be used and the color as the temper and alloy needed. Next, the Play Doh is inserted into the holding chamber and pressure is applied to the handle, which forces Play Doh through the shape. In an extrusion press, pressure is applied to the billet by the ram where the dummy block is attached to the end of the ram stem.

When Play Doh begins to emerge, it has effectively been “extruded”. The same principles apply to extrusions from aluminum billets but considerably more detailed and sophisticated technology are involved.

Press size determines how large of an extrusion can be produced. Extrusion size is measured by its longest cross-sectional dimension (i.e. its fit within a circumscribing circle). A circumscribed circle is the smallest circle that will completely enclose the cross section of an extruded shape.

The most important factor to remember in the extrusion process is temperature. Temperature is most critical because it gives aluminum desired characteristics such as hardness and finish.

4 05, 2011

Tips for Extrusion Design

2015-06-18T15:33:41+00:00May 4th, 2011|

When you start designing a new extruded aluminum piece, there are several important factors you should keep in mind.  Here is a quick list of design tips to get you started:

1. Know the circle size of your vendor.  If you don’t know the extruder’s limitations you’ll likely design a part they can’t produce and end up redesigning the part or shopping it around to find a fit.  Additionally, the greater the circle size the more tolerance becomes an issue.  Start working with an extruder early on.  Some offer engineering support and some don’t.

2. Evaluate your tolerance requirements to that which your extruder can support. You can look to aluminum.org for design guidance in addition to your extruder.  Aluminum.org’s information is somewhat technical however.  So, for quick answers call/email your extruder or you can use Qualified Vendor’s quote service to find suppliers.

3.  If your parts require secondary machining, make sure you design in indexing features.   This can be as simple as an extruded groove in which the machinist can use to take a hole dimension off of.

4.  Wall thickness – design them as uniformly as possible.  This will prevent voids in the extrusion.

5.  Designate critical and cosmetic surfaces. This will prevent unintended marring of critical surfaces.

6.  Heat sinks – as a rule of thumb, fins should not exceed 10:1 length to thickness.

7.  Screw bosses – keep a 60 degree opening otherwise the die will require a torpedo which will significantly affect the cost and life of the die.  Use your machinery’s handbook for McMaster Carr for screw hole guidance.  I recommend self cutting/starting thread forming screws.  They’re inexpensive and yield a great strength, so much so that you need to be careful when inserting them so you don’t shear off the heads – use a driver with a clutch.

8.  Make transition areas smooth with gentle radii.

9.  Select the proper alloy for your application and make sure your extruder can use this alloy.  Many only work with one or two series of aluminum – 2XXX or 6XXX are most common.

10.  Lastly, consider your finish.  Design with appearance and performance in mind.  Don’t forget that the parts have to have secondary operations, packaged and shipped.  Many finishes like anodizing will change your tolerances.  Keep this in mind.  Likewise, if you’re going to powder or wet paint your finished parts make sure you designate which features (holes, grooves, etc.) need to be masked off to prevent paint contamination.  This may affect your final assembly.

31 03, 2011

Aluminum Extrusions are used for defense systems

2015-06-18T15:33:41+00:00March 31st, 2011|

So just how do aluminum extrusions factor into the military world you may ask? Well since extruded aluminum can be found in many aspects of defense systems, I will start by exploring how armor, armored cars, decking and missile containers all use extruded aluminum. One can see that when quality aluminum extrusions are used for all aspects of defense, the defense systems in place will be more thorough.

Military and armored vehicles have to stay upright even when there is a massive use of force against them. Aluminum extrusions also are used for launch pads! It is pretty exciting to find out that aluminum extrusions are used for such an exciting aspect of military defense. Next time you are reading up on technological feats within the military there is a chance that there is some form of extruded aluminum being used!

21 03, 2011

Aviation Week & Space Technology

2017-01-26T23:37:32+00:00March 21st, 2011|

Inside Track A Talk With SuppliersReveals ‘Pain Points’
Aviation Week & Space Technology

March 21, 2011, p. 16
By: Michael Mecham

Printed headline: From Ohio to Arkansas

Ohio is the No. 1 U.S. supplier toEADS/Airbus($4.3 billion in annual sales) and No. 2 toBoeing($4.8billion), after California.General Electric’s engine works in Evendale and Peebles account for much of that, but there are thousands of other suppliers spread across the state, some dating to World War II,when the government pushed aircraft production inland to make it less vulnerable to attacks. We recentlyvisited with Ohio’s suppliersat a roundtable in Cleveland hosted by Aviation Week and the OhioAerospace Institute. Not surprisingly, workforce topped the list of today’s pain points.

Alcoa Forgings and Extrusions President Eric V. Roegner reports having to compete with banks andconsulting companies for top college graduates. He’s honed his pitch to include topics that will appeal toyoung professionals, such as green and sustainability. Stephen P. Johnson, director of process technologyat Timkin Co., has had two senior technical positions open for two years. He also worries about how hewill replace his company’s aging baby boomers. And Fred Lisy, the president of tiny Orbital Research,laments that he spends time and money training young engineers, only to lose them after a few years tobigger companies.

Lisy and other small suppliers also complain about their difficulty in finding sufficient financing tosustain them through the program delays that are endemic in aerospace. Financing worried larger contractors, too. With cuts in U.S. and European defense spending, how can they take a chance on long-lead R&D investments for next-generation products that may not be funded?

Then there’s China, whose aerospace market the group views with a mixture of excitement andapprehension. “If you’re an engineer and you’re interested in working in China, we’d be interested inspeaking with you,” says Christopher Farage of Parker Hannifin,a major contractor on China’s newComac C919 jet.

But Ohio’s suppliers worry that the Chinese government’s push to create a domestic aerospace and defense (A&D) base could one day squash them. Roegner points to Chinese investments in new forges that could compete with Alcoa. If Boeing and Airbus find viable suppliers in China, “the game is on,” he says. Is the challenge China poses to U.S. technological leadership being taken seriously enough? “You kind of wish that the U.S. government would wake up,” says Roegner.

But China is not the only challenge for the Ohioans. Across Lake Erie, Canada has instituted a tax credit of up to 48% for companies creating R&D jobs there. Then there are competitors springing up in lower-cost, non-union southern U.S. states. Farage says higher tax and labor costs push his company’s costs40% above some of his competitors. “Ohio is not cost competitive,” he complains.

If you talk to one of those southern competitors, Taber Extrusions, the competitiveness answer comes not just in lower costs but specialized skills. Privately held and with 250 employees, Taber makes large, long and wide aluminum alloy extrusions in numerous rod, angle, hollow and beam shapes. It uses multiple forming technologies, including friction stir welding, and focuses on high-value, intricate small-lotcontracts. Taber’s 8,600-ton press in Russellville, Ark. (shown), can, for instance, extrude a 100-ft.-longwing stringer that is so large that special routing is needed to rail ship it.

Its answer to low-cost China is high-value American expertise. “We specialize in hard-to-make things,”says sales manager Steve Althardt.

A Silver Supplier Excellence award winner from Boeing, Taber also serves Gulfstream, Cessna andLockheed Martin’s aircraft programs. It has felt the downturn in general aviation but balances its aviation portfolio with defense and naval contracts—the MRAP mine-resistant vehicle, M-113 Bradley andLittoral combat ship among them. And Taber has a niche as a major supplier of compound aluminum bow risers for archers.

Naturally, the company is watching the evolution of composite structures in aircraft. “It doesn’t make us happy that aluminum will decrease in the aircraft segment,” he says. “But there’s a lot of aluminum that will be used in airplanes for years to come.”

With Joseph C. Anselmo and Graham Warwick in Cleveland.

Featured on www.scribd.com

16 03, 2011

Aluminum extrusions are found in structural components

2015-06-18T15:33:41+00:00March 16th, 2011|

The home is one of the most important places in our hearts. It comes as no surprise that aluminum extrusions are used for structural components. Structural components that use aluminum extrusions include decking, tent poles, and well…most things that help hold your home up, whether it is a tent or a house by the beach. From beams to circle sized architectural sections aluminum extrusions are key.

Think of anything that needs to hold something up…it just might incorporate aluminum extrusions. Those signs on the street corner, or on the highway will probably be made out of extruded aluminum. It is everywhere in our lives, even in what we consider to be normal day-to-day structures.  So take a deep breath and learn about the fascinating world of aluminum extrusions and how they are incorporated into almost everything in our lives from structures to airplanes.

Go to Top