9 10, 2013

Laser Welding Powers Aluminum Manufacturing

2015-06-18T15:33:07+00:00October 9th, 2013|

Last week, we noted that aluminum usage for auto manufacturing is now higher in the United States than in Europe. Today, materials-industry website Industrial Laser Solutions provided a little more background on the how and why of this statistic. It’s not just that manufacturers like Ford and Chevrolet are using more aluminum pieces as a cumulative total in their cars — in fact, it’s cutting-edge manufacturing techniques that are allowing aluminum to be more versatile than ever before.

From Industrial Laser Solutions: http://www.industrial-lasers.com/articles/2013/10/laser-welding-leads-to-corvettes-strength-refinement-and-quality.html

 

General Motors’ $131 million investment in technology at the Bowling Green Assembly Plant, which includes the first production use of a GM-patented process, allowing aluminum to be spot welded to aluminum and laser welding of aluminum panels, is resulting in the strongest and most precisely built Corvette in its six-decade history.

 

To show off the Corvette and its plant, public tours at the plant will resume on Monday, October 14. The plant tour and customer programs were halted last fall while the plant underwent the upgrade. The sports car has been built there exclusively since June 1981.

 

New technologies enable more accurate and efficiently produced subassemblies such as the frame and the components attached to it. “For example, the new aluminum-welding process enabled us to make the frame lighter and stiffer, improving the performance and driving confidence,” said Dave Tatman, plant manager.

 

These new techniques allow aluminum to be more intricately used in all types of situations and circumstances. The result is a manufacturing world that truly allows engineers and designers to get creative with their design.

2 10, 2013

American Automakers Now Source More Aluminum Than European Ones

2017-01-26T23:37:29+00:00October 2nd, 2013|

Over the past five years, European car manufacturers carried the flag as users of aluminum. However, this year marks a tipping point as American companies have now overtaken their European counterparts when it comes to aluminum usage. This is most likely due to a combination of factors — market demands for innovation, overall vehicle frame size, and government standards for MPG. From Bloomberg:

Ford Motor Co. is among manufacturers rolling out new cars that substitute aluminum for heavier steel. Use of the lightweight metal in vehicles is rising about 5 percent a year, according to Barclays Plc. Making car bodies consumes about 350,000 metric tons of aluminum sheet a year, of which Atlanta-based Novelis produces 250,000 tons, according to Erwin Mayr, president of Novelis Europe.

U.S. vehicles are incorporating more aluminum because of Corporate Average Fuel Economy standards that limit fuel usage and consumer demand for cars that are more economic and cause less pollution, Mayr said in an interview. European manufacturers including Volkswagen AG’s Audi unit and Daimler AG were leaders in the past five years, he said.

“Now the trend is being completely taken over by the big carmakers in North America,” Mayr said in Geneva on Sept. 18. “Americans tend to drive big cars, so they need to make them lighter. You need a lot of aluminum.”

Ford’s F-150 truck, containing more than 1,000 pounds of the metal, may raise the average content in vehicles to 650 pounds, according to Bloomberg Industries estimates. Aluminum usage per car will average 160 kilograms (352 pounds) by 2020, against 140 kilograms last year, according to slides in a presentation last week by Werner Stelzer, a former executive at Canadian producer Alcan who is an auto and aluminum consultant.

In addition to the F-150, Chevrolet’s new Corvette Stingray will feature an aluminum frame. It’s not just for hybrid’s and MPG-conscious commuter cars; now we’re seeing aluminum used as the body for American standards across the spectrum.

25 09, 2013

The Ultimate Aluminum Can Castle

2015-06-18T15:33:07+00:00September 25th, 2013|

It may be one of the more obscure Guinness World Records out there, but it’s been broken. Just a few days ago — September 21st to be exact — a group in Japan shattered the record for “an object fashioned with aluminum cans.” Hey, if you’re going to break an obscure world record, you might as well go the distance and obliterate it, right?

From The Asahi Shimbun:

Guinness World Records on Sept. 21 certified that the newly constructed “castle” is now the world record holder for an object fashioned with the largest number of aluminum cans, 104,840.

The Toyohashi Junior Chamber had been engaged in the project since June to show the importance of recyclable materials at Toyohashi Park, located on the site of historic Yoshida Castle.

The artwork draws its design from the reconstructed corner tower of Yoshida Castle. The landmark structure was destroyed in a fire during the Meiji Era (1868-1912) and reconstructed shortly after the end of World War II.

The artwork, which was built in a plaza in front of the tower and measures 6.6 meters in width, 5.5 meters in length and 5 meters in height, is entirely constructed with aluminum cans. The cans were affixed with an adhesive agent.

In the certification ceremony held in the plaza, members of the junior chamber cried “banzai” when an official Guinness record adjudicator certified the structure as the new record holder.

The previous record was held by an object built in Saudi Arabia in May, which used 66,400 cans.

If you’re curious, 104,840 aluminum cans translates to about 3083.5 pounds of aluminum. And with the going rate of about 40 cents per pound of recycled aluminum, that structure would earn you about $1,233. However, getting in the Guinness Book Of World Records is probably priceless.

20 09, 2013

Official Study: Aluminum Really Is The Best Thing Ever For Cars

2017-01-26T23:37:29+00:00September 20th, 2013|

It’s now official: aluminum is the best choice for car manufacturers to increase fuel efficiency and reduce their carbon footprint. How official? Try the United States Department of Energy. The DoE’s Oak Ridge National Laboratory just released findings from a study regarding energy reduction in car manufacturing. Some of the highlights, courtesy of the Fort Mill Times:

Reducing vehicle weight with aluminum can result in the lowest total vehicle lifecycle environmental impact – cradle-to-grave – as compared to both traditional and advanced steels.

An aluminum-intensive vehicle can achieve up to a 32 percent reduction in total lifecycle energy consumption, and up to a 29 percent reduction in CO2 emissions, compared to a typical vehicle on the road today which uses traditional and high-strength steel in the body construction.

While a lightweight steel vehicle has a lower production phase environmental impact, those initial gains are erased by higher energy use and carbon emissions during the steel vehicle’s use phase.

More than 90 percent of automobile energy consumption and carbon emissions occurs during the vehicle’s use phase, with the mining, production and manufacturing phases accounting for just 10 percent or less.

For an aluminum intensive vehicle, the breakeven point in its use phase for making up the energy consumed during the initial production phase is 9,300 miles – of which most automobiles on U.S. roads would reach in their first year of operation.

For more information, visit the Aluminum Association’s Drive Aluminum site.

11 09, 2013

Jaguar Announces New Line Of Aluminum-Body Cars

2015-06-18T15:33:07+00:00September 11th, 2013|

Jaguar is tossing their hat (presumably a British bowler hat) into the aluminum ring. At the recent Frankfurt auto show, the luxury auto manufacturer announced its plans to compete with mid-size BMW and Merecedes-Benz sedans. A big part of the conceptual design will be the industry’s first aluminum unibody for the segment. From autonews.com:

Jaguar claims the sedan will be the first aluminum unibody vehicle in the C and D segments.

The sedan and other variants off the platform will use a new-generation Jaguar Land Rover-developed four-cylinder engine. Jaguar plans gasoline and diesel versions of the high-output, fuel-efficient engines.

The small-displacement engines will be made in a new $776 million factory in Wolverhampton, England.

One of Jaguar’s major stumbling blocks in the United States has been its lack of smaller, fuel-efficient powerplants. A Ford-based, 2.0-liter 240-hp, turbocharged four-cylinder engine was made available in the XF sedan only last fall.

The new modular and scalable architecture, Jaguar said, is made of high-strength, lightweight aluminum that is extremely stiff and will enable high-volume production.

It also will allow for “competitive interior packaging,” a growing concern for luxury brands as they scale down vehicle size and weight to meet consumer preferences and fuel efficiency standards.

This comes on the heels of the company’s investment in a new British manufacturing plant as it ramps up production. However, it still doesn’t explain why its (fictional) early 1960s models failed to start at crucial times.

5 09, 2013

Aluminum Enclosures Create Awesome Acoustics

2017-01-26T23:37:29+00:00September 5th, 2013|

Aluminum isn’t usually known for its audio properties, but Bluetooth/headset company Jawbone has found a new way to utilize aluminum in this way. Jawbone’s Jambox line of products has been pumping out 85 decibels of quality audio in a compact portable speaker since 2010. However, Jawbone has decided that they want to go even smaller than the original Jambox; that’s why they’ve just announced the new Mini Jambox. From Engadget:

When Jawbone came out with the Jambox back in 2010, the sales pitch was simple: here was a really loud Bluetooth speaker that was small enough to stuff inside a backpack when you wanted to have a dance party at the beach. (Okay, we’re paraphrasing a little bit.) Three years later, though, “small enough to stuff in a backpack” isn’t quite small enough. What about small enough to fit inside a suit pocket? Or a purse? That’s the promise of the Mini Jambox, a $180 speaker announced today that’s — you guessed it — even tinier than the original.

 

Oh, and don’t forget the aluminum manufacturing:

 

As you’d expect, the Mini Jambox pumps out surprisingly loud sound, given its petite frame. What’s interesting is that the unibody aluminum casing (designed by Chief Creative Officer Yves Behar) acts as both an enclosure and an acoustic cavity for the two internal drivers. That helps explain why the speaker is as small as it is (6.06 x 2.88 x 0.96 inches). Despite its size, it also promises the same battery life as the regular Jambox: about 10 hours of playback.

 

For those of you that aren’t into technical sound design, an acoustic cavity naturally works with audio frequencies to resonate the sound. In other words, the Mini Jambox’s single pice of extruded aluminum makes tiny sound become louder and better. If big noises out of small boxes interest you, the Mini Jambox is available for preorder now

27 08, 2013

Hemet RV Announces New High-Polish Aluminum Siding For Trailers, RVs

2015-06-18T15:33:07+00:00August 27th, 2013|

 

1950s retro aesthetic has come back into style for RVs and trailers. The shiny look brings both a classic and modern feel, and it’s something that Hemet Valley RV specializes in. With a focus on both aluminum and fiberglass siding for RVs and travel trailers, the family-owned company offers a wide range of colors and patterns. In particular, Hemet Valley RV announced this week a new line High-Polish Aluminum Siding. From PR Web:

 

As a leading provider of trailer siding and RV storage throughout the United States and Canada, Hemet Valley introduces a brand new product to its extensive list of inventory. The new 48-foot coil high-polish .025 aluminum siding is an ideal choice for both new a returning customers who are interested in building custom and vintage-style trailers.

 

The aluminum siding comes with a pre-mask, making it much easier for builders to simply peel it off after installation. As an additional bonus, the pre-mask also acts as a barrier between the siding and the builder’s hands, eliminating the possibility that fingerprint smudges might hinder the look of the completed trailer. While other types of siding may risk a lack of luster, becoming dingy over time, Hemet Valley RV’s new high-polish aluminum siding has a clear sealant coat that keeps it looking shiny for a much longer period of time.

 

Looking to hit the open road with a trailer in tow? Do it with some aluminum panache. Hemet Valley RV’s hardware is built to withstand the elements and last through the test of time. For more information, visit their official website.

21 08, 2013

Aluminum Slims Down Next-Gen iPads

2017-01-26T23:37:29+00:00August 21st, 2013|

Here’s a bit of juicy news for you Apple fans out there. While the new iterations of the iPad and iPad Mini haven’t been officially revealed, sneak-peak photos show a thinner back body. Why would Apple slim down its tablet line? The only reason you’d want to reduce a form factor is if the material composition can be structurally sound while minimizing weight and bulk. According to this spy report from The Full Signal, that’s exactly what Apple did — and, not surprisingly, they chose aluminum to make it happen:

New photos of Apple’s iPad 5 and iPad mini 2 have popped up online, showing off the rear shell for each device. While much of this similar to the leaks we’ve already seen for these tablets, the iPad 5 actually looks closer in size to the iPad mini, likely due to its thinner bezel.

Current rumors indicate that Apple’s iPad 5 will be both thinner and lighter than its predecessor, and will also include a faster processor. The newest tablets will run on Apple’s newest version of its ever popular operating system; iOS 7.

The iPad 5 and iPad mini 2 launch dates haven’t been pegged yet, but it’s likely we’ll see them both sometime this fall. It’s very unlikely that they’ll launch with the newest iPhone, so an October release is more likely — perhaps just in time for the holiday shopping season.

Head on over to The Full Signal’s report to take a closer look at the new iPad body shells. Of course, as spy reports go, you didn’t hear this from us.

16 08, 2013

Attention Criminals: When Not To Use Aluminum

2015-06-18T15:33:07+00:00August 16th, 2013|

At Taber Extrusions, we’re a major proponent of being creative when it comes to aluminum. Lightweight, strong, and flexible, it’s the perfect material for do-it-yourselfers and artists alike.

But credit card fraud? First off, we don’t recommend doing anything illegal. Second, we don’t have any idea where these men (appropriately from Jupiter, Florida) got the idea for their shenanigans. From WPTV.com:

Jupiter Police are investigating an attempted fraud at a Jupiter gas station Saturday afternoon.

Thieves allegedly used aluminum foil to try to get away with free merchandise.

Employees at the BP gas station on Indiantown Road say two men helped each other climb up the back of the gas station to get to the roof.

The men then targeted the satellite dishes that were once used to transmit credit card transactions.

The thieves covered the sensors on the dishes with aluminum foil with the goal of making bad or maxed out credit cards process, and be approved.

Little did the thieves know, the satellite dishes are no longer active.

Aluminum foil to disrupt satellite transmissions of encrypted credit card data – we might need to call in the Mythbusters to give us definitive proof that this wouldn’t work, but somehow, we think that the perpetrators don’t exactly have a degree in material science or electrical engineering.

8 08, 2013

New Patent Reveals Yet Another Aluminum-Body Phone

2017-01-26T23:37:29+00:00August 8th, 2013|

Is it time Samsung’s next-generation mobile devices join the aluminum-body movement? If leaked reports prove to be true, it appears that Samsung’s Galaxy S5 will follow recent design trends of moving to an aluminum frame rather than a plastic one. This topic has been rumored before, but some dedicated tech pundits have dug up a new patent filed by Samsung that shows that recent moves by HTC and Apple haven’t been ignored. From GottaBeMobile.com:

The patent shows that the frame of the phone would be constructed from a single piece, which would give the unit for strength. Additionally, there is a front cut out for the glass touchscreen display. A rear cutout panel would house the battery door, and from the appearance of the rendering, it looks like users can slide the panel down to reveal the battery underneath.

If this is correct, then that means that Samsung may be able to still deliver features like a removable battery and a micro SDXC memory card slot.

No other details were given from the patent filing, which was initiated in February 2012, so we don’t know exactly what the internal specs will be for.

It’s unclear if Samsung will use the design, or something closely resemble this design, in the Galaxy S5 that would launch in the first half of 2014 or on a future Galaxy S smartphone, but the design is not unattractive and is a departure from the plastic construction that Samsung has so far employed and has been criticized for.

In technology, the cutting edge rapidly becomes the norm. For mobile devices, the notion of aluminum bodies and frames has been a trendsetter over the recent generations. Today, it looks like more and more manufacturers realize its strength and weight benefits. Before you know it, an aluminum body will probably become the default in the ever-evolving mobile device industry.

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