20 10, 2011

“Aluminum Man” Video Goes Viral & We Like IT!

2017-01-26T23:37:32+00:00October 20th, 2011|

Dare I ask, Is the ‘Aluminum Man’ video good for the industry? While the video was created as a jovial stunt it does offer up facts about aluminum. Lyrics describe the main character, Aluminum Man, as “light as a feather” and “recyclable;” all positive descriptions of the material.

The video’s creator, Richard Heene, has made previous viral spoofs that garnered he and his family international public attention, not all of which has been entirely positive. But with estimates that aluminum stocks will rise in the 4th Quarter after what some might call a rough and unpredictable year, there’s little point in not bobbing along to the song which in its best moments praises the material for both its fanciful and practical purposes. So while the Huffington Post may not understand why Heene as contributed yet another stunt to his repertoire of joke videos and what the world could possibly learn from it- we’re bobbing along and yes…singing it praises.

CLICK HERE to read the original video and to watch the video or HERE to learn more about aluminum’s predicted stock gain in 2011’s 4th Quarter.

17 10, 2011

Evaluating Craft Beer’s Switch to Aluminum Cans

2017-01-26T23:37:32+00:00October 17th, 2011|

In “Is Craft Beer’s Move to Aluminum a Dirty Choice?” John Heylin weighs the pros and cons of the newest trend in craft beer packing: aluminum cans. Helyin argues that the move to aluminum packaging is a reflection of consumer demand, as more craft beer drinkers are active and prefer containers that do not break as easily as glass. Helyin also cites the unbreakable nature of aluminum as an additional benefit to the manufacturer, who often looses product when working with glass. And if this wasn’t enough, aluminum is of benefit to distributors as it’s lighter and less expensive to ship. So why is Helyin so against the industry’s new trend?

While Helyin feels the craft beer market established itself on a green, organic image which they are moving away from by using mainstream method’s of manufacturing, packaging and shipping, his main concerns were the processes used to acquire the material from the earth. But the fact remains that aluminum is better for beer. Seeing that it’s nearly 100% recyclable, cans costs less to manufacture than glass, have a longer shelf life – creating less waste and above all, are a better preserver of quality and taste, all seem to trump his environmental focus. While Helyin’s points should not be dismissed as it is always important to consider the costs of mining the earth, it is also necessary to consider what material is best suited for a product that will undoubtedly be around until the end of time. Watch Inc.’s “New Product Trend: Craft Beer in a Can” video below to learn about the first USA brewer to use aluminum and positive ways it has affected the production and use of the product.

CLICK HERE to read the original article and learn more about craft beer’s switch to aluminum cans.

CLICK HERE to watch Inc.’s video about the first brewing company in America to use aluminum cans and the many ways it’s benefiting to the industry.

7 10, 2011

Predicted Demands for Aluminum Encourage Industry Growth

2015-06-18T15:33:40+00:00October 7th, 2011|

Canada’s top aluminum companies will be investing 15 billion in facility enhancement and job creation in Quebec over the next decade based on “rising global demand” for the material. The need for new transportation systems like buses and subway cars that can be recycled and repaired for less cost when made with aluminum, and the widening call for bridge repair in North America, have enticed Quebec companies to invest heavily in the future of the industry.

Many facts point to an increase in aluminum use in the next 10 years.  For starters there are approximately “250,000 older bridges in the United States and 3,000 in Quebec in need of repair.” In addition to that fact aluminum is more “cost effective [than] steel,” has a longer life cycle and when used in vehicles reduces their weight, therefore decreasing wear and tear on roads and bridges. In light of these details it will be easy market the material to current and future manufacturers as it is the greener alternative to other materials, like steel.

Canadian companies celebrate their “cheap hydroelectric energy costs and a trained workforce” as advantages that can only be further enhanced with their new investment. Ultimately the goal for the Canadians is to retaining industry expertise in the province and there’s no doubt their headed in the right direction.

CLICK HERE to read the original article and learn more about the expanded demand for aluminum.

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.

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.

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