1 03, 2021

Taber: Microextrusions For Defense and Aerospace

2021-03-01T20:55:09+00:00March 1st, 2021|

Two images side-by-side, on left: long-range radar antenna used to track space objects and ballistic missiles. On right: A military radar antenna which rotates steadily, used for aircraft detection.

Like conventional aluminum extrusions, microextrusions are pushed through a die. Unlike conventional extrusions, the entire extrusion process is performed at a submillimeter level. In other words, the resulting product’s cross section can fit through a 1-millimeter square. Since microforming was first explored in 1990, several microextrusion processes have been developed and found to be especially valuable in the defense and aerospace industries.

“Taber was originally recognized for our large shapes and now we are establishing ourselves as microextruders. Since we’ve added microextrusions, friction stir welding, and billet casting, we’re pretty much spanning the gamut of aluminum extrusion competence,” says Jason Weber, VP of Sales and Marketing at Taber Extrusions. “We were already well-versed within the defense and aerospace markets but adding miniature aluminum extrusions to our capabilities has allowed us to become a one-stop shop for our customers in those industries. Our diversification has opened the door wide for our customers.”

Three side-by-side images illustrating how strikingly small microextrusions are. Various aluminum profiles are lined up creatively next to measuring rulers.

Taber Extrusions has experienced many evolutions since its founding in the early 1970s. Established in Russellville, AR, Taber pioneered a process for extruding rectangular billet, able to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Since then, the Gulfport, MS facility was added, which increased Taber’s billet capacity, alloy range, and ability to reuse materials. Within the last decade, fabrication capabilities were upgraded, friction stir welding was added, and of course, microextrusions became an offering.

MICROEXTRUSIONS FOR DEFENSE AND AEROSPACE

For which type of end-use applications are Taber’s microextrusions being utilized?

 

Defense

 

Precision is a must for military, defense, and firearms manufacturing – requiring strength, complexity, and tight tolerances. Aluminum’s high strength-to-weight ratio makes it the ideal material for many defense product applications such as:

 

  • Communications systems
  • Electronics thermal management/enclosures
  • Guidance systems
  • Radar systems
  • Weapons systems
  • Firearms components and accessories
A U.S. Air Force T-38 Talon, British Royal Air Force Eurofighter Typhoon, French Air Force Dessault Rafale, and U.S. Air Force F-22 fly in formation above the clouds on a sunny day.

Aerospace

 

From the Wright brothers to NASA, aluminum has helped make it possible for humans to fly above the Earth onward to explore other galaxies. Aluminum’s minimal maintenance, lightweight with high strength, flexibility at low temperatures, and ability to engineer a wide range of functionality into components, makes it an obvious choice for solutions in aircraft and aerospace.  For the most part, microextrusions function out of site and you’ll never know they are all around you. However, they serve a crucial role in aerospace:

 

  • Interior aircraft systems
  • Supplemental oxygen systems
  • Electrical/Communication Systems
  • Passenger Comfort Systems
  • Coolant radiators
  • Oil coolers
  • Transmission coolers
  • Intercoolers
  • AC condensers
  • Passenger service systems
  • Other fluid/gas systems

As aluminum has played an important role in the defense and aerospace applications for many years, a new generation of aluminum-lithium alloys are offering aircraft manufacturers even more savings when it comes to weight and fuel. Beyond aluminum’s high strength-to-weight ratio and excellent formability, its anticorrosive properties make it a top choice. When aluminum is exposed to air, it forms a hard microscopic oxide coating, sealing it from the environment. This tight oxide bond is a compound not found in nature, but an aluminum alloy created to provide a long-lasting protective solution. These unique properties allow microextrusion manufacturers like Taber Extrusions to furnish extremely strong, precise, and long-lasting miniature extrusions to end users in a wide range of markets.

Taber’s Miniature Extrusion Capabilities

  • Up to 0.8 In2 cross sectional area
  • Special cases down to 0.075 In2
  • Profile circle size up to 3″
  • Minimum wall thickness possible to 0.010” (select cases)
  • Key characteristic tolerances possible ±0.001” (select cases)
: The word “microextrusions” reflects on a metal ruler up to the 4-inch mark, with 3 sizes of square hollow-shaped miniature extrusions lined up against the 1-2-inch marks.

More About Taber Extrusions: 

Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billet which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS, in 1995 which houses a new state-of-the-art cast house and two additional presses, microextrusion capabilities, and the fabrication area has been expanded multiple times.

Taber continues to extrude billet in a wide range of alloys and sizes and has diversified its markets beyond military since its inception to include aerospace, automotive, marine, infrastructure, and sporting goods, among many others. For these markets, the company supplies cast and extruded products in a variety of soft and hard alloys.

Today, Taber Extrusions has completed the addition of in-house friction stir welding capabilities, and carries on their offering of extruded aluminum components, value-added machining services, and raw material supply to the North American market – making them a vertically integrated supplier of FSW panels and assemblies never before seen in North America.

Follow Taber Extrusions

LINKEDIN: https://www.linkedin.com/company/8843183/

FACEBOOK: https://www.facebook.com/taberextrusions/

TWITTER: https://twitter.com/taberextrusions

Interested in becoming a part of the Taber Team?  Submit your resume to careers@taberextrusions.com.

Become a customer today! Visit us or request a quote: https://taberextrusions.com or call us at (888) 985-5319.

11 01, 2021

Industries That Use Friction Stir Welding

2021-02-11T20:06:29+00:00January 11th, 2021|

4 photographs: upper left – a high-speed white rail train with a red stripe zooming through a bright train station in a dynamic blur. Upper right – Fincantieri Marinette Marine Littoral Combat Ship plowing through a deep, dark ocean. Lower right – the view from a car roof as it speeds down the expressway towards a beautiful orange sunset. Lower left – A jet airplane high in the air creating stark white contrails against a clear turquoise sky.

Amid the screech of saws cutting through metal, the beeping of forklifts, and the clank of metal components, workers in modern shipyards are producing some of the largest vessels in the world. A similar cacophony of sounds as those heard in a shipyard can be heard around the country in automotive, construction, aerospace, and transportation factories.

Neatly organized assembly line workers with electric drills work on large metallic parts, bigger than the men working on them and resemble pvc pipe connectors with structures inside them. Behind them can be seen boxes with materials and in front of them are large metallic shelves for storage.

Yet, one traditional sound associated with industrial manufacturing may soon go silent: the loud cracking, buzzing, electric sound associated with MIG welding. Sometimes likened to the sound bacon makes while frying, the sounds of MIG welding may eventually come to be completely replaced by the low buzzing of the spinning rotating tool used in Friction Stir Welding (FSW).

As FSW becomes faster and more versatile, more industries than ever are moving toward this type of welding.

The Benefits:

FSW shows its high cast as a modern-form joining operation.

A computer operator wearing blue, noise-canceling headphones with a small microphone attachment, sits working in front of 6 computer monitor stacked three on top of three. Behind the monitor is a large structure, which nose-cone to the Orion spaceship, it appears to be a green cylinder surrounded by white pipes and tubes.

Unlike other forms of welding, FSW can be automated which increases precision and reduces manufacturing times. Manufacturing time is further decreased because FSW only takes one pass to weld metals and because there is no filler material nor melting, eliminating the need for post weld work, such as splatter cleaning.

FSW is also hyper-modern by being more environmentally friendly and less wasteful (it does not have consumable parts) and not producing nauseous gases during the process.

Other benefits of Friction Stir Welding include:

  • Increased strength (High tensile, fatigue & bend properties) ​
  • Improved sealing, completely void-free leak proof joints​
  • Reduced thermal distortion and shrinkage​
  • Improved repeatability​
  • The ability to join two different alloys​
  • Good for welding metals such as aluminum alloys that can be hard to weld
  • Cost effectivity

The top users: Marine and Transportation

Both of these gigantic industries – marine and transportation – incorporate FSW into their manufacturing operations. Public transportation alone has a market size of 75.6 billion dollars[i], and for shipbuilding, without considering the other sectors of the naval industry, the market size is 29 billion.

Other key sectors are also keen on taking advantage of FSW. Below we highlight just one benefit FSW gives each of the following sectors:

Air Transport:

The Benefit: Weight Reduction

The long underbelly of an airplane, which has two undulations for engines, and the landing gear down against a completely white backdrop giving the image a classic black & white feel.

One of the simplest ways to increase efficiency in transport vehicles is by reducing weight. Marine, air, and land transport vehicles are foregoing rivets, clinch nuts, or traditional MIG or TIG welding in their manufacturing processes in favor of FSW which doesn’t add any weight to the structure.

“Weight is one of the biggest challenges to aircraft manufacturers. Using FSW to join aluminum alloy stringers to skins for aircraft wings and fuselage structures will reduce weight by the removal of thousands of rivets, and any overlapping aluminum material. A leading aircraft manufacturer estimated that potential weight savings of approximately 2.2 lbs. per meter of FSW could be made.[i]

Aerospace:

The benefit: Easy welding of hard-to-weld alloys.

Space X’s Falcon 9 Flight 17's first stage attempting a controlled landing on the Autonomous Spaceport Drone Ship (ASDS) against an early evening sky as the fiery hot gasses are expelled toward the landing pad, creating a misty exhaust.

Some types of difficult-to-weld aluminums can frustrate traditional welding attempts. In addition, joining dissimilar aluminum alloys has always been a challenge due to the different chemical and physical properties of the metal.

Recently, aerospace companies have begun using FSW, a solid-state welding technique, to surpass these limitations. Today, some fuel tanks for spacecraft – made out of hard to weld aluminum alloys – are premanufactured using FSW[i].

Marine Ships:

The benefit: Better production habits, taking advantage of prefabrication, modular building, and assembly lines.

A scene with a backdrop of green hills covered with small shrubs and trees. On a waterway, a large white cruise ship with one smoke stack creates white foam as its hull breaks through the water.

As if a precursor of things to come, the first commercial use of FSW was on ships, specifically on hollow panels used for freezing fish on fishing boats.

Today, many ships use friction stir welded floors, decks, and bulkheads. By using FSW, shipyards reduce the amount of work needed to be done, shifting the work to assembly-line factories[i]. Many parts can be manufactured in production lines improving safety, accuracy, and efficiency. Not only that, the industry can take advantage of the best pre-fab and modular practices that will further decrease production times.

Today’s cruise ships are light weight structures which allow shipbuilders to build taller ships while keeping the center of gravity lower. Designed with all the heavy machinery at the bottom and lightweight aluminum materials at the top makes them inherently stable even as ship designs are getting taller and taller, demonstrating how sufficient safety can be achieved.

Ultimately this translates to one thing: bigger ships mean MORE FUN!

Whether it’s the freighters that carry the goods from our globalized economy, the military vessels that keep our oceans safe, or the cruise-lines that give families unforgettable vacations, all these sectors are seeing cost and efficiency saving with FSW.

Trains:

The benefit: Safety

a long, white high speed train with orange trim at the bottom. The train disappears into the distance as it rests at an empty platform with tile floors and a metal roof with a long row of lights and a skylight running down the middle on the roof.

This industry in particular has honed in on the advantages FSW offers in crash safety. FSW is the best welding process for creating safe designs:

“Modern passenger rail cars are increasingly produced from longitudinal aluminium extrusions with integrated stiffeners.

This design approach can enhance the crashworthiness of vehicles […] Large aluminum extrusions with complicated shapes are [being used].[i]

Freight Trailers:

The benefit: Stability

Underneath a fiery red sky, a blue lorry and trailer travel along a paved highway road followed by a car while on the other side of the double yellow line, two empty lanes extend off into the distance.

Anyone traveling behind an 18-wheeler on highways knows just how the wind and road shakes the trailers. By using FSW on the floorboard of their trailers, some freight companies argue that their trailers have become more stable than ever. “The aluminum extrusions become one at the molecular level, making the floor a single-piece of rigid aluminum.[i]” The end result? Less wear on the tires and better fuel mileage.

Other industries:

Other industries taking advantage of friction stir welding include the automotive, construction, and defense industries, among others. It has even been incorporated to make stronger snowmobiles and lighter coolant systems.

The strong, lightweight welds that can be used on hard-to-weld alloys have every industry that uses aluminum and aluminum extrusions looking to gain a competitive advantage.

Companies that have specialized in aluminum and aluminum extrusions are the front line for delivering FSW benefits to customers. For more information, please visit Taber Extrusions. With a long tradition of proving aluminum and aluminum extrusion solutions, Taber Extrusions provides companies all the advantages of FSW in one location.

Industries Served by Taber Extrusions:

 

  • Distributors
  • Government | Military Contracts | Department of Defense
  • Aircraft | Aerospace
  • Marine | Shipbuilding
  • Infrastructure | Platforms | Decking
  • Electrical | Power Transmission | Electronics
  • Transportation
  • Sporting Goods
  • Industrial, Agricultural, and Mining Equipment
  • Structural Components
  • Specialty Architectural

About Taber Extrusions: 

Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billet which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS., in 1995 which houses a new state of the art cast house and two additional presses, micro-extrusion capabilities, and the fabrication area has been expanded multiple times.

Taber continues to extrude billet in a wide range of alloys and sizes, and has diversified its markets beyond military since its inception to include aerospace, automotive, marine, infrastructure, and sporting goods, among many others. For these markets, the company supplies cast and extruded products in a variety of soft and hard alloys.

Today, Taber Extrusions has completed the addition of in-house Friction Stir Welding capabilities, and carries on their offering of extruded aluminum components, value-added machining services and raw material supply to the North American market – making them a vertically integrated supplier of FSW panels and assemblies never before seen in North America.

Follow Taber Extrusions

LINKEDIN: https://www.linkedin.com/company/8843183/

FACEBOOK: https://www.facebook.com/taberextrusions/

TWITTER: https://twitter.com/taberextrusions

Interested in becoming a part of the Taber Team?  Submit your resume to careers@taberextrusions.com.

Become a customer today! Visit us or request a quote: https://taberextrusions.com or call us at (888) 985-5319.

 

______

 

i https://www.ibisworld.com/industry-statistics/market-size/public-transportation-united-states

ii https://www.twi-global.com/who-we-are/who-we-work-with/industry-sectors/aerospace/joining-of-airframe-structures/friction-stir-welding-of-airframe-structures

iii https://www.twi-global.com/technical-knowledge/published-papers/industrialisation-of-friction-stir-welding-for-aerospace-structures-december-2001

iv https://www.twi-global.com/who-we-are/who-we-work-with/industry-sectors/aerospace/joining-of-airframe-structures/friction-stir-welding-of-airframe-structures

v https://www.twi-global.com/technical-knowledge/published-papers/creating-a-stir-in-the-rail-industry-november-2001

vi https://www.ttnews.com/articles/fontaine-brings-friction-stir-welding-revolution-trailer

 

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21 12, 2020

Taber Extrusions: Our Friction Stir-Welding Timeline

2020-12-16T04:23:04+00:00December 21st, 2020|

: Infographic that illustrates Taber’s friction stir-welding timeline: 1. March 2019 2. April 2019 3. July 2020 – ending with a CTA that reads, “Learn more about friction stir-welding capabilities like you’ve never seen HERE!’’

 

Full-service provider of aluminum extrusions, Taber Extrusions, has completed the addition of in-house FSW capabilities, making them a vertically integrated supplier of FSW panels and assemblies never seen before in North America.

Friction Stir-Welding Capabilities Like You’ve Never Seen

Adding to their legacy of innovation, Taber’s new FSW capabilities include simultaneous two side welding, double wall hollow extrusions up to 6.25 inches tall, 32 inches wide, and accepting lengths up to 65 feet long. Taber’s friction stir-welding production cell is capable of creating panel assemblies 200 inches wide by 65 feet long, with integrated pre-joining profile trimming. With profile widths up to 31 inches, lengths up to 65 feet, and an ability to weld up to 3/4 of an inch in a single pass, Taber has an operational envelope that is unmatched within the industry.

Friction stir-welding is commonly used in the rail, automotive, marine & shipbuilding industries, military & defense, commercial & industrial construction, infrastructure, and aviation & aerospace sectors.

 

TABER EXTRUSIONS HISTORY AND RECENT GROWTH

Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billet which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS in 1995 which houses a cast house and two additional presses, and multiple expansions of value added fabrication services. Taber continues to extrude billet in a wide range of alloys and sizes, including 7″ billet molds, and has diversified its markets beyond military since its inception to include aerospace, automotive, marine, infrastructure, and sporting goods, among many others. For these markets, the company supplies extruded products in a variety of soft and hard alloys. In 2018, Taber added ultra-precision® extrusions to their capabilities allowing them to further serve customers in electronics, computer, and medical industries. Taber recently announced yet another exciting launch into friction stir-welding, positioning them as a vertically integrated supplier of FSW panels and assemblies never seen before in North America.

Thank you for your continued support of Taber Extrusions, LLC. If you have any questions please visit taberextrusions.com or contact one of Taber’s Regional Sales Managers.

Follow Taber Extrusions

LINKEDIN: https://www.linkedin.com/company/taberextrusions/

FACEBOOK: https://www.facebook.com/taberextrusions/

TWITTER: https://twitter.com/taberextrusions

17 02, 2020

Taber: Advanced Friction Stir Welding Capabilities

2020-02-17T19:42:22+00:00February 17th, 2020|

Something big is happening at Taber: Friction Stir Welding has been added to their already extensive portfolio of capabilities. #TheShapeOfEndlessPossibilitiies #Taber #Aluminum Extrusions #FSW

11 02, 2020

Taber’s Friction Stir Welding Capabilities: Going Vertical

2020-05-11T21:05:07+00:00February 11th, 2020|

Taber’s Friction Stir Welding Capabilities Infographic

Taber is is AS9100, NADCAP, and ABS certified. Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billet which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS., in 1995 which houses a cast house and two additional presses, and multiple expansions of value-added fabrication services. Taber continues to extrude billet in a wide range of alloys and sizes, including 7”billet molds, and has diversified its markets beyond military since its inception to include aerospace, automotive, marine, infrastructure, and sporting goods, among many others. For these markets, the company supplies extruded products in a variety of soft and hard alloys. In 2018, Taber added micro-extrusions to their capabilities allowing them to further serve customers in electronics, computer, and medical industries. Today Taber is proud to announce yet another exciting launch into Friction Stir Welding. To learn more about how we can be of service visit: https://taberextrusions.com/

Follow Taber Extrusions

LINKEDIN: https://www.linkedin.com/company/8843183/

FACEBOOK: https://www.facebook.com/taberextrusions/

TWITTER: https://twitter.com/taberextrusions

1 02, 2020

Aluminum Extrusion Leader Taber Extrusions Looks Ahead

2020-02-01T20:39:14+00:00February 1st, 2020|

“2020” written in shiny, silver-colored metal – with the inverted gold Taber Extrusions logo positioned underneath.

As Taber Extrusions launches into 2020, we thought we’d take a look back at the last several years and the many ways Taber has progressed within the aluminum extrusion industry. Among many changes, Taber added an upgraded casthouse, expanded into micro extrusions; received various awards, began friction stir welding, and brought on a new business director. This has been a very exciting time, and we invite you to learn more about the innovations that are shaping endless possibilities in 2020 and beyond.

Aluminum Casthouse

Not long ago in 2017, Taber upgraded to their aluminum casthouse in Gulfport, MS. which integrates casting, extrusion, and in-house fabrication services. With this upgrade, Taber opened up opportunities in a variety of markets, with the sale of cast billet to outside extruders.  With this casthouse, Taber is targeting aerospace, automotive, and defense industries, all of which utilize aluminum at an accelerated rate. Taber’s new products are suitable for current and future U.S. infrastructure projects, such as the construction and improvement of bridges, decking, flooring, and railing for mass transportation projects.

A 3D rendering of a yellow aluminum billet crane suspending 3 freshly casted shiny silver billets. Beside the image it reads: “currently Taber offers 7″, 8″, 9″, 11″, 16″, 20″ & 10″x 20″ rectangular billet molds.”

Partnering with Almex USA, Taber developed a customized solution to meet Taber’s unique requirements and specifications. Almex supplied new equipment, including a casting line with a degassing and melt purification system, billet and slab tooling, automation technology, and a complete homogenizing line, as well as a new cooling water system.

Benefits to Taber’s aluminum casthouse upgrade:

  • Increased Production. The CASTRIGHT II™ casting machine and new billet and slab tooling stations were adapted to fit the circular pit, and the casting tables were modified to have an oval shape with unique headbase configurations. Excel™ and Optima™ billet mold systems were installed for various sized billets. The quantity of billet produced with each cast has been enlarged, allowing increased production per drop.
  • Quality Control. A large part of Taber’s consideration during this upgrade was quality control. Taber now has a level pour (or, hot-top) mold table distribution system and a way to optimize mold lengths for consistent billet quality. Taber’s goal was safety and alloy versatility for high performance and yield, from conventional to the most demanding alloys. For the larger diameter aerospace grade products, Almex installed specialized water wiping technology in order to manufacture difficult to cast materials without the formation of stresses or cracks. With the new casting line, Taber increased monitoring and automation, and now has computer control of all critical casting and degassing parameters. Operators now interact with the system through an integrated SCADA control panel installed on the plant floor in order to monitor the correct mixture of several ingredients that make up the casting recipe. At the end of each cast, the system automatically generates a complete report of the heat number for reference and archival by quality control personnel. With this new system, Taber has not only achieved a greater level of quality control, but process transparency and product traceability.
  • Accuracy and Precision. An internally guided and double acting platen cylinder was installed, which has more loading capacity, guiding accuracy, and precision speed control (needed for hard alloys).
  • Consistency and Strength. The new casting line also includes a LARS® in-line degassing and purification system that refines and cleans the melt prior to casting. The LARS system mixes inert argon gas and a halogen gas into the molten aluminum through Almex’s patented in-situ gas preheating disperser system. This significantly reduces hydrogen and other impurities commonly found in liquid aluminum, including inclusions, nitrides, oxides, and alkali metals and also increases recovery through a minimal amount of dross creation. This high quality of the molten metal is, thus, dependably strong and consistent.
  • Environmentally Friendly. Taber rebuilt and integrated its water management system, which provides increased visibility of the water flow, temperature, quality, and maintenance. Water is discharged in a safe and controlled manner.

16 fresh aluminum billets atop Taber’s casting table engineered to fit the existing circular casting pit.

Ultra Precision® Extrusions

In 2018, Taber added micro extrusion capabilities into their portfolio. Micro-extrusions are used in a number of industries, such as electronics, aerospace, medical, industrial, and military. The addition of small precision profiles will allow Taber to better serve existing customers and future partners such as – defense contractors, commercial aerospace engineers, and electronics designers.

A 3D rendering of am 8-inch ruler with a variety of micro extrusion shapes fitting elegantly inside roughly a 1-inch white square, and the words “The Shape of Endless Possibilities, Ultra Precision® Extrusions, Taber”

The micro-extrusion manufacturing lines have a production envelope with a circle size of 3 inches or less and a weight per foot of 1 lb. or less. Unlike traditional extrusion presses, these micro-extrusion presses are built in such a way to allow for the production of extrusions with wall thicknesses of 0.010 inches and tolerance capabilities of +/- 0.001 inches. This allows designers and engineers the freedom to engineer profiles that are impossible to extrude through conventional presses.

The addition of  ultra precision® extrusions allows the company to enhance its business to provide a wider range of profile sizes and competencies which blend beautifully with the various sectors already being served by Taber.

2018 NMLP Safety Award

Taber Extrusions took home National Material L.P.’s 2018 Safety Excellence Award for exceptional safety management at their Russellville, Arkansas facility.

Russellville Plant Manager Gavin Butterworth, Taber President Eric Angermeier, and Gulfport Plant Manager Mike Keenan standing with the NMLP Safety Award trophy during the 2018 holiday party.

Taber’s safety management system includes:

  • Perpetual assessment & evaluation of existing safety policies
  • Process & workflow analysis
  • Establishment of safety work procedures
  • Safety training & meetings
  • Safety inspections
  • Maintenance regimens of plants, equipment, and processes
  • Identification of hazards & hazard analysis
  • Facilitation of occupational health programs
  • Emergency preparedness
  • Documentation control & management reviews

2019 Taber Extrusions Recognized by Russellville for Energy Savings Excellence

Taber Extrusions employees stand alongside Entergy and CLEAResult personnel in front of the Taber sign at their Russellville location. They are holding an extra-large check for $31,748 – representing Taber’s energy savings.

Taber Extrusions created a plan to reduce power consumption by implementing energy efficient measures while participating in the Entergy Arkansas Energy Solutions Program assisted by CLEAResult consulting company.

“I couldn’t be happier to assist Arkansas businesses reduce their power consumption by energy efficient measures. Every project that CLEAResult assists a customer with is a positive step in their energy reduction,” says Taylor Dumas, West Regional Account Manager at Entergy Arkansas Energy Solutions Program. “The Taber Extrusions project is one that greatly reduced power consumption, increases machine efficiency, and makes Taber Extrusions a ‘greener’ business by completing this project.”

Taber’s commitment to energy savings still holds strong as they push forward into the future, making environmental accountability part of their company culture.

Friction Stir Welding Technology

In 2019, Taber  installed a new friction stir welding (FSW) line at its Russellville, Arkansas, manufacturing facility. Sometimes described as more of a forging process than actual welding – FSWis a solid-state joining technique used to join metals not easily fused with traditional welding. It is used in the aerospace, rail, automotive, marine, transportation, and other industries that use metals such as aluminum, copper and other metal alloys. The new FSW line that welds large, double-sided thick profiles, uses minimal cycles of the machine, which make it both efficient and precise. FSW also makes possible very high-quality welds with minimal distortion.

The addition of friction stir welding illustrates how Taber has proven itself to be dedicated to the technological advances in the industry, economic development, and job production. The line enables the company to be a vertically integrated supplier of FSW panels and assemblies in North America, with capabilities including aluminum extrusions, fabrication, billet casting, and micro-extrusions.

Already known for their wide range of capabilities, both broad and unique, the mayor of Russellville, Richard Harris, thanked Taber for choosing Russellville as their location, “The fact that you chose to expand and add new technology here is the highest compliment you can give the city and citizens where you live and work. Economic development and job creation is one of our top priorities. We congratulate Taber on this advancement.”

Jeffrey Bladow: Director of New Business Development

Photographic portrait of Jeffrey Bladow, Director of New Business Development, Taber Extrusions

Taber’s rapid growth initiated the presence of Jeffrey Bladow, the company’s recently appointed Director of New Business Development. Hired to help lead business growth and assist in building strategy, Bladow has spent over 25 years in automotive design and manufacturing. He also has experience in structure design, high strength steel applications, and the launch of large capital projects. Like Taber, Bladow is comfortable solving multi-faceted problems. In his management style, Bladow encourages “critical thinking, continuous improvement, and a no-fear approach to growing and entering new markets.”  Taber feels lucky to have Jeffrey Bladow ushering us into a new decade.

At Taber we believe the possibilities are endless.  We believe in the future.

About Taber:

Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billet which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS., in 1995 which houses a cast house and two additional presses, and multiple expansions of value added fabrication services. Taber continues to extrude billet in a wide range of alloys and sizes, including 7″billet molds, and has diversified its markets beyond military since its inception to include aerospace, automotive, marine, infrastructure, and sporting goods, among many others. For these markets, the company supplies extruded products in a variety of soft and hard alloys. In 2018, Taber added ultra-precision extrusions to their capabilities allowing them to further serve customers in electronics, computer, and medical industries. Today Taber is proud to announce yet another exciting launch into friction stir welding. Call us at (888) 984-9866, or request a quote today!

15 01, 2020

Joining Aluminum Extrusions Through Friction Stir Welding

2020-01-15T19:32:51+00:00January 15th, 2020|

Dramatic in-flight photo of two F-22 Raptor military aircraft speed through the sky on a clear day.

What is Friction Stir Welding?

 

Friction stir welding is the method of joining two pieces of metal with no extra filler or material by subjecting the components to heavy plastic deformation, at elevated temperatures, that are still lower than the melting point. A rotating tool is thrusted between the components and, as friction heat is generated, the tool produces a severe plastic deformation under high pressure, at which time the weld interfaces are stirred together, and a homogenous structure is formed, creating a defect-free bond.

Why Friction Stir Welding?

FSW is a method of welding that is being used as an alternative method to fusion welding and other types of arc welding.

FSW vs. Fusion Welding  –  FSW offers three key benefits over fusion welding: metallurgical, environmental, and energy. The metallurgical benefits include: low distortion of workpiece (fine      microstructure, absence of cracking), good dimensional stability, and no loss of alloying elements. The environmental benefits include: no shielding gas required, no surface cleaning required, elimination of solvents required for degreasing, and consumable materials savings.  The energy benefits include: improved material use (joining different thickness), only 2.5% of energy needed for a laser weld, and decreased fuel consumption in light     weight, automotive, and ship applications. FSW is then, specifically because of its environmental and energy benefits, a more cost-effective method of welding. It is also a more economical choice due to low set up and training costs.

Close angle of a shiny drill-like instrument, also known as a friction stir welder cone.

FSW vs. Other Types of Arc Welding  –  The joining of aluminum extrusions in friction stir welding is a process that can be easily automated, making it an ideal solution for industrial use in manufacturing services such as the marine, aerospace, automotive, transportation, and rail industries. FSW welds have effectively been used in the marine industries in the fish freezer panels of ships, on the deck panels of helicopter landing platforms on ships, and it has been used in various amphibious assault ships. In aerospace, FSW has been used for structures such as the fuselage, fins, and wings that require high-strength aluminum alloys. In the automotive industries, FSW is used for aluminum engine cradles and suspension struts, as well as rear seats and exhaust gas recirculation coolers. The railway industry has utilized FSW to make roof and floor panels, as well as heat sinks for cooling the high-power electronics of locomotives.

An aerial view of an amphibious assault ship with a landing and launchpad for fighter jets on the ocean.

In military and defense, aluminum alloys are used as armor due to the combination of high ballistic performance and static strength that traditionally use MIG, gas metal arc, and tungsten arc welding. The reasons for the transition to FSW over the aforementioned arc welds are many — MIG welds cause stress corrosion at the weld toe, exfoliation occurring in the solution treatment, low ductility in butt welds, and liquidation due to the formation of low-melting point grain boundary. FSW welds are also more likely to pass the ballistic shock test.

Why FSW at Taber? New Aluminum Joining Techniques at Taber

 

In April of 2019, Taber Extrusions of Russellville, AR and Gulfport, MS announced the addition of Friction Stir Welding, “FSW,” capabilities to our existing portfolio which currently includes aluminum extrusions, fabrication, billet casting, and micro-extrusions. With the addition of in-house FSW capabilities, Taber is now a vertically integrated supplier of FSW panels and assemblies.

Taber’s engineering and manufacturing teams collaborated with Bond Technologies to create a custom Linear Seam machine. Taber’s new FSW machine is capable of welding large, double-sided thick profiles with minimal cycles of the machine; less cycles means greater efficiency and more precise results.

 

Taber offers quality custom extrusion design and advanced microextrusion capabilities and we are committed to providing our clients durable products that are both ecologically sound and cost effective. We chose FSW as a high-tech, alternative method to ensure a fast turn-around time, thereby reducing time to market.

About Taber:

Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billet which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS., in 1995 which houses a cast house and two additional presses, and multiple expansions of value added fabrication services.

Taber continues to extrude billet in a wide range of alloys and sizes, including 7″billet molds, and has diversified its markets beyond military since its inception to include aerospace, automotive, marine, infrastructure, and sporting goods, among many others. For these markets, the company supplies extruded products in a variety of soft and hard alloys. In 2018, Taber added ultra-precision extrusions to their capabilities allowing them to further serve customers in electronics, computer, and medical industries. Today Taber is proud to announce yet another exciting launch into Friction Stir Welding.

1 10, 2019

Friction Stir Welding In The Shipbuilding Industry

2019-11-01T14:28:43+00:00October 1st, 2019|

Friction Stir Welding In The Shipbuilding Industry Infographic containing most common applications of thermal management, helideck, wall panels, bulkheads, hull, decking, and honeycomb panels

Taber Extrusions wants to lead the way in FSW development and be a part of its growth in the future. Taber Friction Stir-Welding Capabilities are second to none. With profile widths up to 31 inches, lengths up to 65 feet,

and ability to weld up to ¾ of an inch in a single pass, Taber has an operational envelope that is unmatched within the industry. To learn more about how we can be of service visit: https://taberextrusions.com/

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12 09, 2019

What is Friction Stir Welding?

2019-09-12T18:36:18+00:00September 12th, 2019|

This image depicts a friction stir-welding machine joining two large, cylindrical aerospace vehicle components.

What is friction stir welding?

As the name suggests, “friction stir welding” (FSW) is a metal joining technique that uses friction heat to unite metal structures. In traditional welding, high levels of heat are applied thereby melting two metal parts into one another. By contrast, FSW is a solid-state joining technique that takes advantage of metal atom’s cohesive forces that cause them to diffuse into each other. The friction generates temperatures below the melting point, but high enough where the plasticized material can move around.

How does friction stir welding work?

The key in FSW is the non-consumable rotating tool. The tool, that looks similar to a drill bit, is made up of two components: a probe, a small cylinder which will penetrate into the width of the metals at their joint; and a shoulder, a larger cylinder which will spin along the surface of the metal pieces. The rotating tool supplies both the heat and the pressure needed for the weld.

The metal pieces are clamped tightly in a butt or lap joint configuration, and the mechanical rotating tool is programmed to run along the joint. The spinning tool inserted between the tightly clamped metal creates enough friction heat for the atoms of the two metals to move around. The plasticized metal moves around the probe and then fills the cavity behind the tool before coalescing into a single piece of metal.

Close up image of the drill bit-like rotating tool on a friction-stir welding machine.

What are the advantages of friction stir welding’s solid state joining for aerospace, shipbuilding, rail, aerospace, automotive industries?

There are various advantages to using FSW for metal joining:

  1. Flexibility: FSW allows efficient welding for difficult projects. FSW can be used on high-strength aluminum that can be difficult to join using conventional welding. Companies such as Taber use FSW to create aluminum extrusions in a wide array of profiles and sizes ranging from micro extrusions to 65-foot long extrusions.
  2. High strength welds: Traditional welding can introduce corruption into metals during the welding process, as it can manifest solidification cracks and porosity problems. Solid-state joining creates joints that are as strong as the metal from which they are created and are a good choice for high-strength aluminum.
  3. High quality welds: Characteristics of FSW welded metal include low distortion, reduced weight (no filler material), and excellent bonding properties.
  4. Green welding: Traditional welding consumes electrodes, energy, shielding gas, and produces noxious fumes. FSW with its non-consumable rotation tool eliminates waste.

Limitations of friction stir welding for metal joining:

The FSW spin tool must resist heat and corrosion as it moves the metal around it. Therefore, FSW best works with malleable materials with low welding temperatures.

Four, large cross-sectional profiles of aluminum parts with different patterns, shapes, and widths, and underneath an aluminum tablet with micro-aluminum profiles.

Therefore, aluminum continues to be one of the most important metals used in FSW. Aerospace, shipbuilding, rail, aerospace, automotive industries all look to aluminum FSW for high-precision aluminum extrusions and aluminum welds of high strength and quality. Aluminum FSW is particularly important because high-strength aluminum can be difficult to join using traditional methods and FSW precision allows almost infinite variety in shape and size in aluminum extrusions.

More on Taber Extrusions 

Founded in 1973, Taber Extrusions originally pioneered a process for extruding rectangular billets which enables the company to extrude solid profiles up to 31 inches wide or hollows up to 29 inches. Taber expanded with the purchase of an extrusion facility in Gulfport, MS in 1995 which houses a cast house and two additional presses, with a fabrication area that has been expanded multiple times. Besides their recently expanded capabilities to include micro-extrusions and 7” billet molds, Taber Extrusions is proud to announce friction stir-welding technology. The addition of in-house FSW capabilities creates a vertically integrated supplier of FSW panels and assemblies never before seen in North America.

Connect: Call Us Today! (888) 984-5279

10 09, 2019

Taber Presents Friction Stir Welding Capabilities at Aluminum USA 2019

2019-09-12T18:34:22+00:00September 10th, 2019|

Stunning evening view of the Nashville city skyline along the water featuring a colorful reflection of the bright downtown lights reflecting off the water giving the entire scene a magical glow.

Aluminum industry professionals are gearing up for The Aluminum USA Tradeshow on September 12th-13th in Nashville, Tennessee, where Taber Extrusions will be showcasing their in-house friction stir welding capabilities creating a vertically integrated supplier of FSW panels and assemblies never before seen in North America.

Aluminum USA is hosted biannually as a “weeklong leading industry event covering the entire value chain from upstream (mining, smelting) via midstream (casting, rolling, extrusions) to downstream (finishing, fabrication). ALUMINUM USA is the ideal event for end-users from application industries such as automotive, aerospace, construction, packaging and electrical & electronics”. Special events surrounding the tradeshow kick off with Nissan tours on Wednesday, September 11th, and continue with an array of face-to-face opportunities including technology-based networking events and an industry meet & greet. This year’s tradeshow is bigger and better than ever, featuring an expanded show-floor.

Jason Weber who currently serves as Taber Extrusion’s VP of Marketing and Sales, will be hosting a presentation at EDU ’19, which is part of the broader Aluminum USA tradeshow on September 12th and 13th  that “gives a forum to leading suppliers and industry professionals to come together for face-to-face meetings, exhibition, cutting-edge conference, and educational programming.” Aluminum USA EDU ’19  features educational presentations covering aluminum extrusion design, applications, and technology. In addition to speaking at the EDU ’19 forum, guests are welcome to visit Jason Weber and other Taber Extrusions team members at Booth #546 during the tradeshow.

A headshot of an attractive smiling Caucasian man with slightly silvering hair, wearing an ocean blue polo shirt and a white, zip-up sweater.

Jason Weber’s presentation titled, “Joining Aluminum Extrusions through Friction Stir Welding” will present industry experts and end-users with information on Friction Stir Welding (FSW). The presentation will cover the “basics of what FSW is, current products that are Friction Stir Welded, general design practices for extrusions incorporating FSW features, and typical performance of FSW joints versus other joining technologies”.

Sometimes described as more of a forging process than actual welding – Friction Stir Welding is a solid- state joining technique used to join metals not easily fused with traditional welding. Ideal for metals such as aluminum, copper, and other metal alloys, FSW is commonly used in the aerospace, rail, automotive, shipbuilding, transportation, and marine industries. Friction Stir Welding makes possible very high-quality welds with minimal distortion. It is also a process that can be easily automated, making it an ideal solution for industrial use.

The EDU ’19 forum gives a chance for Weber to share inside knowledge of the process which the company now offers in its extensive menu of services. “As a leader in the Aluminum Industry, Taber works with clients in military, government, aircraft and aerospace, shipbuilding, infrastructure – and so much more. The aluminum extrusion shapes they are creating for these clients are absolutely ideal for Friction Stir Welding technology,” said Dave Hofferbert, President of Bond Technologies, Inc.

A close-up of a futuristic looking, metal spinning tool inserted between the metal ends of two large cylindrical spaceship parts.

Jason Weber, Vice President of Sales & Marketing for Taber Extrusions, has 20+ years of global manufacturing experience helping innovate product and service offerings. Jason is an active member of the Aluminum Extruders Council (AEC) and is the leader of the Council’s Marketing/Industry Promotion Team.

About Taber: 

Founded in 1973, Taber has become a leading supplier of high quality aluminum extrusions. By ensuring that every process and procedure, from billet procurement and final shipment, fulfills all ISO9001 and AS9100 standards, Taber maintains preferred supplier ratings. In 2018, Taber added ultra-precision extrusions to their capabilities allowing them to further serve customers in electronics, computer, and medical industries. In 2019, Taber announced their launch into Friction Stir Welding.

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