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.

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

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.

31 07, 2013

Houses Use Aluminum To Withstand Hurricanes

2017-01-26T23:37:29+00:00July 31st, 2013|

Over the past few months, we’ve all seen shocking images on news broadcasts of homes devastated by hurricanes across the country. But for one South Carolina home builder, a change in materials has them feeling confidant in the face of hurricane season. Meet Ray and Geoff Hawes, the father-and-son team behind Cat Five Houses. The Cat Five difference? Their home frames don’t use wood beams; instead, they chose aluminum. From Charleston’s Post & Courier:

As the most dangerous months of the hurricane season arrive, Ray and Geoff Hawes of Mount Pleasant aren’t worrying much.

That’s because the father and son entrepreneurs may have the strongest homes in the Lowcountry.

Both were built with an aluminum skeleton bolted together and connected to a heavy concrete foundation.

Both also cost a lot of money, a reality they acknowledge means that their approach isn’t for everyone.

But for those interested in paying a premium for a sturdy structure, the Hawes’ business, known as Cat Five Houses of Charleston, certainly would be worth looking into.

The aluminum is lighter and more portable than steel, and the frames can be quickly assembled and taken apart. The frames also can be placed on wheels and moved. And there’s one other advantage, too, says Quince Cody of Cat Five Houses.

“Aluminum has memory, where steel does not,” he says.

In other words, an aluminum structure can bend, then pop back in place, much like a soda can.

Hawes says the company isn’t looking to design or build homes, but it is looking to give architects, builders and their clients another choice, one that might cost more but that will stand the test of time.

“ ‘Built to last’ is our slogan, that’s what we’re trying to promote,” he says. “It’s a good way forward, not for everybody but for those who want to live here long term, and they don’t want to worry about the contents of their house, or their house.”

With the automobile industry rapidly getting behind the strength and durability of aluminum, it’s no wonder the construction industry is taking a closer look. Yes, it does cost more to use an aluminum skeleton, but in hurricane-prone areas, that price may have a value well beyond a dollar amount.

11 07, 2013

File Under Bad Idea: Stealing Aluminum Chicken Statues

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

Recycling aluminum is worth .78 cents per pound these days. So, if you had something weighing around, oh, 600 pounds or so, you could get about $468 for it.

Or you could go to jail in a story that’s equal parts The Onion and TV’s Cops.  You don’t often get headlines like this in the aluminum industry, but then again, things like “Darrin Edwards, Tyler Jones, James Smith Arrested For Stealing, Riding Aluminum Chicken In Florida” just don’t happen that often. From the Huffington Post:

Three men were charged with grand theft after allegedly stealing a purple, 9-foot, 600-pound aluminum chicken statue, First Coast News reports.

Darrin Luke Edwards, 19, Tyler Lee Jones, 21, and James Joseph Smith, 18, were arrested for hatching the plan on Wednesday in San Mateo, Fla. Ben Smith, the chicken’s owner notified authorities after hearing a ruckus outside around 6 a.m. Tuesday.

Smith told deputies that when he went outside, he saw the bird being dragged down the street behind a Chevrolet truck, News 4 Jax reported. One man allegedly mounted the chicken and rode its back about a mile down the road. They then unhooked it and fled.

Chances are, these fellows weren’t looking to turn the aluminum chicken in for a valuable return. Instead, this was probably more a case of misguided youth and a dare gone too far.  In any case, if you ever wondered what you could get charged with for stealing an aluminum chicken statue, now you know.

3 07, 2013

Service Truck Manufacturer Turns To Aluminum For Next-Gen Vehicles

2015-06-18T15:33:07+00:00July 3rd, 2013|

We’ve seen high-performance sports cars go to aluminum bodies. We’ve also seen mainstream American auto manufacturers turn to aluminum for lighter bodies. Now, specialized vehicle makers are joining in the trend.

 

Reading Truck Body, LLC provides vocational trucks designed for specific industry services. Their next-generation CSV model (Classic Service Van) has switched from traditional steel bodies to aluminum bodies. From PR Newswire:

 

The new CSV features welded design construction and utilizes formidable aluminum alloy and extrusions throughout, including the load space floor. It is 210 pounds lighter than previous generations, allowing for greater payload capacity, improved fuel efficiency and less wear and tear on the chassis. This new aluminum construction will pass through Reading’s exclusive E-Coat and powder coat process, making it the longest lasting finish in the industry. This all adds up to a positive impact on the owner-operator’s bottom line.

 

The CSV continues to exhibit many unique Reading features such as a seamless wheelhouse panel, shuttle panel pass through, flush mount floor to threshold channel, Reading’s patented hidden hinge technology with recessed and concealed hardware, LED lighting and a standard ten year limited warranty. The CSV will have optional security systems available – the master locking system or the exclusive Reading Latch-Matic® system. The body was designed with a universal understructure for GM and Ford cutaway chassis applications, which streamlines the manufacturing process, allows for shorter lead times and drives simplified inventory levels for the distributor. The next generation Aluminum CSV57 & CSV75 will be available with many optional value-added packages for specialized vocational markets.

 

With luxury cars, everyday commuter cars, and now specialty service vehicles all turning to aluminum, soon it won’t be news when this occurs – it’ll be the gold standard. Or, should we say, the aluminum standard.

26 06, 2013

Sony Taps Aluminum To Build New Smartwatches

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

Smartphones have come a long way in both style and substance since the nascent days of old Blackberry and Windows Mobile devices. Are watches in for the same evolution?

Sony thinks so. Last winter, they released the Sony SmartWatch, an Android-based wristwatch. While it didn’t garner much positive buzz, it did set the stage for the product’s evolution. Recently, Sony announced the SmartWatch 2. If you’re wondering why we’re talking about this, it’s because Sony decided to go the same route as many smartphone manufacturers and use a lightweight aluminum frame. From MobileSyrup:

The water- and dust-resistant timepiece aims to be an improved version of what many people considered a half-baked product when it was announced in early 2012. The SmartWatch 2, however, is based on much newer Android software, supports newer Bluetooth protocols, and is, frankly, a better, more fully-realized product overall.

It has a 1.6-inch 220×176 pixel display with three Android navigation buttons below its screen — back, home and menu. The SmartWatch 2 is compatible with a range of Android apps, and can function as a second screen for incoming calls and texts, and even be utilized as a camera remote.

The SmartWatch 2 also joins a number of recent Sony products in a consistent design approach; you can see the nicely-crafted aluminum power button on the right hand side, and the entire product has been built with a lot more care than its predecessor. Sony will offer a stainless steel black wristband if the included plastic one isn’t up to scratch, and the SmartWatch 2 is compatible with all 24mm straps.

Will connected watches take off the same way smartphones have? It’s hard to tell, but at the very least, manufacturers like Sony have picked a winning material for their product frames.

6 06, 2013

Airstream’s New Aluminum-Everywhere Trailer

2017-01-26T23:37:29+00:00June 6th, 2013|

For decades, Airstream has brought retro-modern sensibility to the camping experience. With the unique look of aluminum shells, an Airstream trailer quickly stands out whenever and wherever you see it. However, Airstream’s new International Sterling trailer takes this one step further, creating a one-of-a-kind experience that blends Airstream’s signature style and the latest amenities for both style and comfort.

What makes the International Sterling different? It doesn’t just have aluminum on the outside; veteran Airstream designer Christopher C. Deam found a way to have aluminum cover all of the International Sterling’s inner surfaces for a look that truly blends retro and modern. From GizMag:

Covering surfaces like the cabinetry and walls, the aluminum interior isn’t just designed for pure aesthetics but to enhance the overall experience and more seamlessly blend interior with exterior.

Deam at first worried that an aluminum interior would be too much, overwhelming the eyes and taking an established design cue too far. After years of tinkering with the idea, he decided that by contrasting the grained aluminum of the exterior with an anodized aluminum interior, Airstream could successfully go all metal.

“We put our heads down and analyzed the problem … how do we do something nobody else can do? How can we be authentically Airstream?” says Deam. “Aluminum’s a challenging material, but that’s what we wanted to show off – Airstream’s great skill and craftsmanship with it.”

The Airstream International Sterling is currently in production, so there’s no retail price to go with it yet. However, if camping with a trailer is still too rough for you, perhaps you’d like to check out our find from last week.

7 05, 2013

Aluminum Helps VW Achieve 261 MPG

2017-01-26T23:37:30+00:00May 7th, 2013|

Tesla’s Model S may have been 2012’s Car Of The Year, but the folks at Volkswagen think they’ve got another industry changer — and once again, aluminum is a big part of it. The Volkswagen XL1 is still an experimental vehicle, one that will see limited production over the 2013 calendar year, though it’s certainly notable for its eye-popping 261 MPG. That’s two gallons of fuel required to drive between the Bay Area and Los Angeles. It also features an all-electric mode that supports a range of 31 miles.

The XL1 weighs in at approximately 1700 lbs — in comparison, the Model S weighs in at 4600 lbs while the Toyota Prius comes in at 2900 lbs. This mass savings stems from a variety of design choices, including heavy use of aluminum and composite (carbon fiber-reinforced plastic) as primary materials construction. From Plastics Today:

A total of 21.3% of the new XL1, or 169 kg, consists of CFRP. In addition, Volkswagen uses lightweight metals for 22.5% of all parts (179 kg). Only 23.2% (184 kg) of the new XL1 is constructed from steel. The rest of its weight is distributed among various other polymers (e.g. polycarbonate side windows), metals, natural fibers, process materials and electronics.

Thanks to CFRP, the XL1 is not only light in weight but also very safe as well. This is due in part to the high-strength and yet lightweight CFRP monocoque. In an emergency, it provides driver and passenger with the necessary survival space. The intelligent design of the load paths, including the use of sandwich structures in the monocoque, is responsible for this. In addition, the aluminum structures of the front and rear sections absorb the majority of the impact energy.

These principles were likewise implemented in the design of the CFRP doors, where an aluminum absorbing beam is responsible for the absorption of the energy; moreover, a stiff CFRP door frame minimizes the intrusions into the CFRP safety cell. The rescue of the passengers was also given a great deal of attention: In case the XL1 overturns and comes to a rest on the roof, pyrotechnical separating screws facilitate the opening of the doors (swing doors).

Of course, the XL1 isn’t going to be available at your local VW dealer. Only 250 vehicles will be produced in 2013, primarily for the European market. Still, with the world’s focus on fuel efficiency, it makes sense that this concept car may go from a mid-2000s pipe dream to occupying dealership space at a lot near you…someday.

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