28 09, 2011

iPhone’s New (Aluminum) Design Has the Potential to Change the Smartphone Market

2015-06-18T15:33:40+00:00September 28th, 2011|

It is rumored by a Wall Street analyst that the newly redesigned iPhone 5 will have an all-new aluminum back, replacing the existing glass back of the iPhone4.  The newly issued iPhone4 is also predicted to have a new uniform aluminum design.  Two key advantages to their use of this new material are its lightweight and durability. Beyond this- the cost to produce the phone will be dramatically reduced allowing Apple to see more profit based on their use of this new material.

“The two anticipated new iPhone models are expected by analyst Chris Whitmore with Deutsche Bank to push Apple’s smartphone sales even higher. He sees the so-called ‘iPhone 4S’ as a handset with a bill-of-material cost lower than $150, allowing Apple to sell it for between $300 and $350 without a carrier subsidy.”

Whitmore claims this cut in manufacturing cost will enhance Apple’s sales in the midrange smartphone market, possibly achieving margins up to 50 percent.  The lower cost of the materials will undoubtedly generate more profit for Apple and be a better product for consumers.

Initial reports concerning iPhone’s new design first came out in March of 2011 but for now exact details are still under wraps. One thing for sure, these reports suggest aluminum will be the key material that will change the “face” of the midrange smartphone market.

Click here to read the full article from Apple Insider.

15 09, 2011

Sustainable Transport Systems Reach a New (Green) Milestone

2015-06-18T15:33:40+00:00September 15th, 2011|

Sustainable transport systems have witnessed a milestone. Recently, Alcoa Jamalco Operations hauled 10 million tons of bauxite from its Mount Oliphant mine location to the rail station where the material was loaded and shipped to the company’s alumina refinery in Clarendon. Using a Rope Conveyor (RopeCon) system, a 2.11 mile cable conveyor system used to move bauxite through mountainous areas like Mount Oliphant with an elevation of 843 feet, the transport record was achieved in under two years.

“The RopeCon system is the only one in the Alcoa network, and we selected it primarily because of its sustainability features,” said Jerome Maxwell, managing director of Jamalco.

Sustainable transport systems are excellent methods for moving raw material and generating green energy. These systems can generate energy to power mines and power networks; the RopeCon system used at Alcoa Jamalco generates nearly 1,200 kW of braking (green) energy per hour. These green transport systems also save money; Alcoa has saved approximately $1.5 million on the cost of energy since it started using the conveyor system in 2007.

In order to transport alumina, the raw material used to produce aluminum, the RopeCon system was constructed with a belt of corrugated side walls and integrated wheel sets on fixed track ropes which are guided over 11 tower structures. The system is powered by two AC induction motors. When the conveying system is loaded with bauxite and begins making its way down the mountain, the drives begin using a continuous braking (regeneration) mode which produces the electrical power.

The system also provides environmental benefits in addition to providing and alternative energy course. Long distance conveyors can operate in mid-air, minimize space requirements and can effortlessly cross obstacles on the ground. The systems are also quiet, dust-free and use less land space than road transport which further reduces its environmental footprint.

For more on sustainable transport systems like RopeCon, read the original Yahoo Finance article here: http://yhoo.it/oidblN.

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

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.

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