beyond basics: designing aluminum extrusion to meet product challenges

Beyond Basics: Designing Aluminum Extrusion to Meet

Product Challenges

q  This webinar will be available afterwards at www.designworldonline.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #DWwebinar

Before We Start

Moderator Presenters

Paul Heney Design World

Mark Telander Alexandria Industries

Joe Jackman ALMAG Aluminum

Beyond bars, T’s, and angles: Designing extrusions to meet product challenges

Presented by:

Presenting Sponsor

Beyond bars, T’s, and angles: Designing extrusions to meet product challenges

Mark Telander Inside Sales Representative Alexandria Industries

Joe Jackman Vice President, Sales and Marketing, ALMAG Aluminum

www.priesenterprises.com

Introduction

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The Shape is the Idea! Almost any shape can be produced using aluminum extrusion …

Introduction

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The right shape, utilizing the right alloy, can then be enhanced and perfected through additional fabrication and finishing to yield an effective product solution …

Introduction … whether for functional or decorative applications

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Today’s Agenda

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This presentation provides both a conceptual and a practical understanding of how to creatively address product challenges with aluminum extrusions •  Advantages of Aluminum and

Aluminum Extrusion - The Extrusion Process

•  Key Design Variables - Alloys - Shapes - Fabrication

•  Case Examples •  Additional Resources

Introduction

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Aluminum: a material with outstanding physical characteristics Aluminum Extrusion: often the most functional, cost effective and quickest path between function and form – Incredibly versatile, capable of converting

ideas to reality quickly and inexpensively – A near-net shape process for complex forms,

with close tolerances Together, the metal and the process optimize component and product designs!

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Advantages of Aluminum

• Lightweight

• Strong

• High Strength-to-Weight Ratio

• Resilient

• Corrosion-Resistant • Heat Conductive

• Reflective

• Electrically Conductive

• Non-Magnetic

• Non-Sparking

• Non-Combustible

• Cold Strength

• Fully Recyclable

Advantages of Extrusion

• Tailored performance – put metal where it is

needed

• Suitable for complex, integral shapes,

produced to close tolerances

• Attractive, wide range of finishes

• Virtually seamless

• Easy to fabricate

• Joinable by various methods

• Suitable for easy-assembly designs

• Produced with uniform quality

• Cost Effective

• Short production lead times

Why Aluminum Extrusions?

Strong Appropriately alloyed and tempered, aluminum can be stronger than some steels, with ultimate tensile strengths as high as 80,000 psi to 90,000 psi or more.


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High Strength-to-Weight Ratio The standard aluminum frame for the 2014 Corvette C7 is over 90 pounds lighter, yet 60% stiffer than the previous steel frame

Corrosion-Resistant Excellent corrosion resistance in a wide variety of environments and contact with a myriad of substances. It develops its own inert aluminum oxide film, which is self-protective, blocking further oxidation.


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Cold Strength •  Advantages are not impaired by cold. Aluminum gains

strength and ductility as temperatures are reduced, making it a preferred metal for cryogenic (low-temperature) applications.

•  Steel and plastics get brittle when the temperature drops… aluminum gets stronger and tougher!

Photo: ©Action Graphics, Inc.

Electrically Conductive Volume for volume, aluminum carries electricity about 62% as well as copper. On a weight basis, aluminum can be twice as conductive as copper, and aluminum is often the most economical choice.


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0 20 40 60 80 100

Heat Conductive Conducts – and dissipates - heat better than any other common metal on both a weight and cost basis.


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Sustainable & Fully Recyclable • Can be recycled over and over without degradation of

its innate properties • Recycling requires only 8% of the energy necessary to

produce virgin aluminum • Extrusions can contain as much as 80%, recycled content.

Actual feedstock in 2010 contained 53% recycled content.

• In 2012, North American extruders utilized ~ 1

Billion pounds of scrap

47%

5% 19%

29%

prime process scrap

post-ind. Scrap post-consumer

Source: Aluminum Association Life Cycle Assessment of Semi-Finished Aluminum Products in North America, Dec. 2013

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Feedstock: heated aluminum alloy “billet”

Source: Rio Tinto Alcan

Advantages of Aluminum Extrusion

Steel die and supporting tooling

Desired final “profile” or shape

The Extrusion Process

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The Extrusion Process – Handling Equipment


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The Extrusion Process - how are HOLLOW Shapes Extruded?

The PlayDoh flows through the opening between the part of the die that forms the outside diameter and the inside “mandrel” supported by two horizontal supports.

The PlayDoh SEPARATES into two tube halves and “welds” back together due to the pressure needed to make it flow through the annular opening into a tube shape.



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Produced to Close Tolerances • The ability to hold tight tolerances over the full

extruded lengths are routine and the ability of aluminum extruders to meet even more critical dimensions is keeping pace with advances in technology.

Suitable for Complex, Integral Shapes • Shapes can combine functions that would

otherwise require the production and joining of several different parts, reducing part counts and costs.

Welds

Screw bosses

Local thickening


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Suitable for a Wide Range of Finishes Aluminum accepts a great variety of finishes, colors and textures (anodize, alodine, wet or powder paint, applique, etc.)

Easy to Fabricate • Designing with aluminum extrusions can eliminate

much fabrication and assembly steps •.Parts can be easily cut, machined, finished, bent,

welded, fabricated and assembled.


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Joinable by Various Methods Aluminum extrusions can be joined to other aluminum products or to different materials by all major methods, including adhesive bonding, welding, soldering, brazing, bolts, rivets, clips, clinching and slide-on, snap-together or interlocking joints.

Hinge detail “Christmas tree” for joining with wood or plastic

Screw boss on leg Groove to accept printed circuit cards

Groove for screw or rivet Groove for rubber moulding

Drill groove

Slot for location of nut or bolthead

Screw boss Fluted surface for appearance

Groove to accept printed circuit cards

Dovetail assembly

Snap fit spring assembly

“Heat sink” cooling fin

Patterned surface for appearance

Suitable for easy-to-assemble designs Aluminum extrusions with integral connection points have been widely used for elaborate framing, such as the scaffolding for the Statue of Liberty renovation and the recent repair of the Washington Monument

Process Typical Part Tooling Cost ($)

Aluminum Extrusion $500 to $5000

Stampings $5000 and up

Injection Molding $25,000 and up

Die Castings $25,000 and up

Roll Forming $30,000 and up


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Cost-effective • The diversity of shapes permitted by the extrusion process

cuts down or eliminates many machining and joining operations.

• Tooling costs are modest in comparison with other

processes.

Time-effective • Extrusion’s modest tool costs, with short lead times

facilitate the use of custom shapes to create a signature design solution with differentiation and enhanced function.

0 4 8 12 16 20

Typical Tooling Lead Time (weeks)

Choices of Alloy, Geometry (or shape), Tolerances and Fabrication offer design flexibility …

• To tailor component performance • To inexpensively incorporate functional details that simplify assemble,

reduce part counts, and enhance utility …but, there are some limitations • Circle Size (the circumscribing circle that the profile could fit through) • Weight/Ft (Too heavy? Too light?) • Shape Constraints – High tongue ratios – Somewhat balanced wall thicknesses – Other

Key Design Variables

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Availability of various profile circle size / area / weight combinations

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Circumscribed Circle Size in inches Corresponding Profile weight (lbs/ft)

Cross Section Area in sq inches <1 1 to 7 8 to 10 11 to 14 >14

Min Max <.050 L L x x x - 0.06

.050 to .100 G G L x x 0.06 0.12 .100 to 1.0 W W L x x 0.12 1.18 1.0 to 2.5 x W W L x 1.18 2.94 2.5 to 10 x W W G L 2.94 11.76

>10 x x W G L 11.76 -

x Not available L Limited Availability

G Generally Available W Widely Available

Key Design Variables: Practical Considerations Practical Considerations: Aluminum extrusions offer outstanding design flexibility … but there are some limitations

Alloy

Major Alloying Elements and Alloy Characteris=cs

1000 Series

Minimum 99% Aluminum High corrosion resistance. Excellent finishability. Easily joined by all methods. Low strength, poor machinability. Excellent workability. High electrical conducDvity.

2000 Series

Copper High strength. RelaDvely low corrosion resistance. Excellent machinability. Heat treatable.

3000 Series

Manganese Low to medium strength. Good corrosion resistance. Poor machinability. Good workability.

4000 Series

Silicon Not available as extruded products

5000 Series

Magnesium Low to moderate strength. Excellent marine corrosion resistance. Very good weldability.

6000 Series

Magnesium & Silicon Most popular extrusion alloy class. Good strength. Good corrosion resistance. Good machinability. Good weldability. Good formability. Heat treatable.

7000 Series

Zinc Very high strength. Poor corrosion resistance. Good machinability. Heat treatable.

Typical Extrusion Tempers

Descrip=on

F Extruded and air cooled

O Fully annealed

H112 Strain-‐hardened; used for nonheat-‐treatable alloys

T1 Cooled from an elevated temperature/naturally aged

T4 SoluDon heat-‐treated and naturally aged

T5 Cooled from an elevated temperature/arDficially aged

T6 SoluDon heat-‐treated and arDficially aged

Key Design Variables: Alloys

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Aluminum extrusions can be produced in different alloys and processed to different tempers to achieve desired mechanical properties.

Broadest applicability

Strength is one key consideration … 6XXX alloy series

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1.3 1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1

0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

% Si

% Mg

6082

6063 6060

6005A 6061

6063 6060

6082

6063 6060 6061

6005A 6061

6063

6061

6082

6063

6061 6005A

6082

6063

6061 6060

6005A

6082

6063

6061

Increasing strength


Trim components Heat sinks Electronics housings Window/Façade systems

Auto Intrusion Beams Bumper Beams Auto Chassis/Structural

Auto Chassis/Structural Solar racking systems

Typical Applica=ons

… as is Extrudability and Conversion Cost S

treng

th**

(ksi

)

Extrudability index 0 50 100 150

Yield Tensile

3003

6060/63*

6082* 7020

7075

Al 99.5

6005A*

0

90

80

70

60

50

10

40

30

20


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* T6, except 6005A @ T61 **typical properDes

Mild steel

Mild steel

Source: Rio Tinto Alcan

Yield Strength

(min)

Surface Quality Bending Machining (based on

chips, finish)

Joining Extrudability/Processing/

Cost

6060/63 25 ksi Excellent finish & corrosion resistance

Good in T6, VG in T1/T4

C B 100 - Superior extrudability, easy quench

6005A 38 ksi Superior corrosion resistance

Good in T6, VG in T1/T4

C : continuous chip, good finish

C 95 - Superior extrudability & quench vs. 6061/6082

6061 38 ksi Good corrosion resistance

Manageable in T6511, VG in T1/T4

C B 80 - Good extrudability, quench demanding

6082 38 ksi Good corrosion resistance

Manageable in T6511

C B 80 – Good extrudability, very quench demanding

7005 44 ksi Zn precludes good anodize Stress corrosion

Acceptable in T53

B : curled chip, good-exc. finish

D 50 - ½ speed; quench, special ageing

25 Source: Rio Tinto Alcan


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(Launched 2009)

Key Design Variables: Alloys There is often more than one “right” answer

Lotus used profile geometry to offset a lower strength alloy Key Design Variables: Geometry/Shapes

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Shape Classifications (per Aluminum Association)

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Solids

Semi-hollow

Hollows

Class I Class II

Class I (Balanced

round int. > 1”)

Class II (< 5”, > 0.11”)

Class III

Key Design Variables: Geometry/Shapes

Good Design Practices

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• Balance walls • Avoid/minimize hollows • Generous tapers

Uniformity

This! This! Not this!

Not this!

Smooth Transitions

This! Not this!

This! Not this!

Symmetry

This! Not this!

• Practice symmetry/minimize asymmetrical detail • Use grooves, webs, and ribs • Minimize perimeter/cross-section ratio

Enhance visual surfaces

This! Not this!


Extrusion Design Hint Where possible, reduce deep narrow “tongues” by re-designing the profile

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Not this! This!

Key Design Variables: Geometry/Shapes x

y

Tongue raDo: y:x

Extrusion Design Hint Where possible, consider re-designing the profile with a secondary “bend to gap” step

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Where possible, consider re-designing the profile with a removable tab


Extrusion Design Hint Screw slots are often simple to incorporate in the profile

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Screw slots can often eliminate the need for a more expensive hollow die (which also extrudes more slowly, further increasing cost)

Self tapping screw Thread cutting screw

Not this!

This!


Extrusion Design Hint Where possible, re-design the profile to reduce cost (for example, a single void hollow die with smoothed transitions vs. a multiple void hollow die)

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This! Not this! This! Not this!

Or, in this case, 10% less cost, lighter, and less likely to have die breakage.


Extrusion Design Hint Complex hollow dies can be simplified by splitting single profile into multiple profiles

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1

2


SOLID HOLLOW

1 2

3 4

5 7

6

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Key Design Variables: Geometry/Shapes But … sometimes it makes sense to “break the rules” For example, sometimes a “complex hollow die” will yield a superior solution

Tolerances

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Tolerance tables, are available in Aluminum Standards & Data published by The Aluminum Association.

Source: The Aluminum Association

Key Design Variables: Tolerances

Tighter than standard tolerances will

often be required applications, and

can be achieved by many extruders.

Solids -‐ Defini=on The key – which are the critical dimensions? •  These?

Wall Thickness

Base of Gap Dimensions


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Hollow/Gap Defini=on … or these •  Hollow/Gap Dimensions - Column 4-9

Hollow Dimension Gap Dimension


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Fabrication & Assembly Extrusions can be machined, formed and assembled with a wide variety of familiar technologies. Yet some processes – particularly bending and welding – benefit from prior extrusion fabrication experience

Key Design Variables: Fabrication

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Key Design Variables: Fabrication

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Fabrication • Sawing • Punching/piercing/drilling • Machining • Bending • Welding • Milling • Tumbling

•  Capable of complex bending to create unique shapes

•  Multiple bending technologies: Stretch bending, CNC bending, chain bending

•  Can be bent in both T4 and T5 conditions

Key Design Variables: Fabrication Bending

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Joining The rapid increase in automoDve aluminum content – and in mulD-‐material soluDons – has led to a dynamic evoluDon in material joining technology. In response, a comprehensive Aluminum Joining Manual, has recently been developed.

Key Design Variables- Fabrication

The manual addresses: •  Adhesive Bonding •  Beam Welding •  Brazing •  Mechanical Joining •  Resistance Welding •  Fusion •  Combined Joining •  Joining Dissimilar Materials

To access, go to: www.aec.org/library/joining_manual.cfm 42

Case Examples Often, we end up breaking (or at least bending) the “rules” to meet particular product challenges, striving to meet multiple objectives. Yet Aluminum is often costlier* than alternate materials per pound, e.g.:

Assessment q  Weight reducDon q  Packaging efficiency q  Cost reducDon q  Build process/ Manufacturability q  Serviceability q  Quality

Realistic economic comparisons should consider: •  Aluminum’s lower density (1/3 that of steel) and offsets from: •  Weight reduction, including that of secondary elements •  Reduced processing & assembly costs from “designed-in” functionality •  Maintenance savings •  End-of-life costs/credits

*e.g. June 2014; Source: ycharts.com; Worldsteelprices.com

•  Global Carbon Steel Price : $714/MT •  Aluminum (LME): $1,838/MT

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Steel Beam & Channel vs. Custom Aluminum Profile Case Examples

Source: Werner Extrusion SoluDons

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Case Example: Medical

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Accuray TomoTherapy System for radiation oncology •  Issue – 64 mechanical “leaves”, coupled to a

pneumatic actuator, open and close to deliver the prescribed radiation dosage. Occasional breakage of the machined steel couplings caused machine shut down.

•  Objectives - redesign the couplings for improved system up-time - reduce part cost and manufacturing complexity. Existing steel couplings were machined using EDM, requiring multiple manufacturing steps and yielding a relatively high cost

Case Example: Medical

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•  Approach - Replace EDM steel coupling with an aluminum extrusion, 6063 alloy, machined and hard coat anodized - Tweak part design for improved strength and durability - Laser etch identification on each part for traceability

•  Results - No failures through 10 million cycle test regimen - “snap fit” assembly cut labor by 30 to 60 minutes per assembly; eliminated a tool used for assembly - Component manufacturing cost cut by nearly 90%; production time cut by 75%

Coupling as extruded

Aber fabricaDon

~1.5”


Credits: Alexandria Industries

Case Example: Building & Construction

Edith Green-Wendell Wyatt Federal Bldg Portland, OR Renovate this 35 year old, 520,000 sq. ft. federal office building to achieve dramatic reductions in energy use and water consumption.

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Photos: Nic Lehoux

Architect: Cutler Anderson Façade: Benson Industries

Case Example: Building & Construction Results: 55-60% reduction in energy use vs. pre-retrofit •  “Reedlike” aluminum extrusions shade direct

sunlight on the West façade •  Vegetation being grown on the “reeds” for

additional shading •  Roof mount PV – provides 15% of energy need •  Double glazed windows, “smart” lighting

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Case Example: Automotive Lincoln MKZ Panoramic Retractable Roof

•  10,000 per year • Existing design in steel, 28 parts, stamping intensive, requiring high investment

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Objectives:

•  Cost neutral •  25% weight reduction •  Part count reduction for reduced labor cost

Approach & Results

•  6 pieces only – 2 extrusions + 4 small aluminum stampings •  20% weight savings •  Cost neutral with investment reduction for volume •  22 piece part reduction; reduced labor cost

Case Example: Automotive

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Case Example: Lighting

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Center Mount LED Ligh=ng Fixture •  Issue -‐-‐ Develop a heat sink for a new,

array-‐style center mount LED light fixture for Medical/ExaminaDon applicaDons. This applicaDon requires dimming from 10% to 100%, a 3700 lumen output, 60,000 hour life and electromagneDc compaDbility

•  Objec+ves -‐ reduce mass -‐ preserve, or improve heat dissipaDon effecDveness -‐ source in North America for supply chain efficiency Original heat sink

Case example: Lighting

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•  Approach -‐ Replace solid center hub with hollow secDon with uniform wall center web to ensure structural performance -‐ Replace solid secDons to be drilled for screw akachment with integral screw bosses -‐ UDlize 6360 alloy for thermal conducDvity, and to facilitate high tongue raDos and Dght tolerances

•  Results -‐ 47% weight reduc/on -‐ 4% increase in surface area, for improved heat dissipa/on -‐ elimina/on of secondary drilling opera/ons, reducing total cost and speeding manufacturing

1.4” 0.4”

Credits: Almag Aluminum

Original part Original heat sink

Redesign


Case example: Medical

53

Hercules Pa=ent Posi=oning System™ •  Issue

When caregivers have to reposiDon a hospital or nursing home paDent, it oben causes discomfort to the paDent … and possible discomfort or injury to the caregivers. There is also a loss of dignity for the paDent and a drain on mulDple caregivers’ Dme.

•  Objec+ves Develop a system that could be used with exis/ng hospital beds that would allow a single caregiver to reposiDon a paDent in 10 seconds! With the push of a bukon

Case example: Medical

54

•  Approach -‐ Develop a compact drive assembly – the Hercules PaDent ReposiDoning System™ -‐-‐ that can be added to exisDng hospital beds; when acDvated, the drive draws a special sheet into its aluminum housing, thereby gently reposiDoning the paDent. -‐ UDlize 7 custom extrusions to create the assembly, maintaining a minimal footprint while handling 600 in/lbs of torque

•  Results -‐ Ready acceptance by hospitals -‐ Winner, 2014 Medical Design Excellence Award -‐ Winner, 2014 ET FoundaDon Aluminum Extrusion Design CompeDDon, Professional Category

1.4”

0.2” Assessment q  Weight reducDon q  Packaging efficiency q  Cost reducDon q  Build process/ Manufacturability q  Serviceability q  Quality

Case Example: Automotive

Mercedes SL Floor Assembly

• Weight reduction was a major objective for the most recent redesign of the Mercedes SL, precipitating a shift to an aluminum-intensive (89% of the bodyshell) design with a resulting 300 lb (140 Kg) weight reduction

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Case Example: Automotive Mercedes SL Floor Assembly

• Weight reduction was a major objective for the most recent redesign of the Mercedes SL, precipitating a shift to an aluminum-intensive (89% of the bodyshell) design with a resulting 300 lb (140 Kg) weight reduction

Results: Extruded Floor Panel

•  3 multi-void hollows, characterized by variable wall thicknesses

•  Joined by Friction Stir Welding •  Weight reduction of 6.4 lbs •  Height reduction providing additional interior

space

56


Conclusion

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Aluminum extrusions provide a great resource for your next product design

•  They are lightweight, strong, corrosion resistant, fully recyclable . . . a sustainable material

•  They utilize tailored alloys, accommodate complex shapes, can incorporate multiple functions and are easy to fabricate, providing a custom design response quickly and at minimal cost -- making aluminum extrusions the cost effective solution

•  While there are important nuances to the extrusion process, available fabrication/finishing options, alloy selection, and extrusion design details, there are a wealth of resources to help you push the envelope and make superior product design decisions

•  Take advantage of the available resources and contact an aluminum extrusion expert as early in your design process as possible

For more Information and Training Additional Resources

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Purchase the Aluminum Design Manual 2010 edition from the Aluminum Association (aluminum.org) Reference other resources available from the Aluminum Association Aluminum Standards and Data: nominal and specified chemical compositions of alloys; typical mechanical and physical properties; mechanical property limits; definitions, and dimensional tolerances for semi-fabricated products

Utilize ASCE Aluminum Design Manual training

– go to www.asce.org/distancelearning; click on “View a complete list of ASCE courses”,

scroll down to “Aluminum Structural Design with the 2010 Aluminum Design Manual”

For more Information and Training

Additional Resources

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• Utilize the Aluminum Extruders Council website (aec.org) for webinars or other key information

•  Find an Extruder search •  Extrusion Applications •  Extrusion Design Resources •  Sustainability Info •  And more!

About AEC: The Aluminum Extruders Council (AEC) is an international trade association dedicated to advancing the effective use of aluminum extrusion in North America. AEC is committed to bringing comprehensive information about extrusion's characteristics, applications, environmental benefits, design and technology to users, product designers, engineers and the academic community. Further, AEC is focused on enhancing the ability of its members to meet the emerging demands of the market through sharing knowledge and best practices.

AEC Aluminum Extrusion Manual

(www.AECmanual.org)

AEC Buyers’ Guide (www.AECguide.org)

Thanks to Our Presenting Sponsors …

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… and to all the members of AEC To find an extruder: go to aec.org and choose “Find an Extruder”

www.priesenterprises.com

ABC Aluminium Solutions Aerolite Extrusion Company Akzo Nobel Coatings Inc. Albarrie Canada Limited Alcoa Forgings and Extrusions Alcoa Primary Metals Alexandria Industries Alexin LLC Almag Aluminum Inc. Almex USA, Inc. Al-Taiseer Aluminium Factory Aluminio de Centro America Aluminium Bahrain B.S.C, Aluminium Products Co. Ltd. Aluminum Shapes LLC AMCOL Corporation APEL Extrusions Limited Apex Aluminum Extrusions Ltd. Arabian Extrusions Factory Astro Shapes Inc. A.t.i.e. uno Informatica SrL Azon USA Inc. BCI Surface Technologies Belco Industries Inc. Bonnell Aluminum Briteline Extrusions, Inc. Butech Bliss Capral Aluminium Cardinal Aluminum Co. CASTOOL Tooling Systems Cometal Engineering S.p.A.

Compes International Crown Extrusions Inc. Crystal Finishing Systems Inc. Custom Aluminum Products Inc. Dajcor Aluminum Ltd. Danieli Corporation Dienamex Drache USA Inc. Dubai Aluminium Co. Ltd. Emmebi ETS-Exco Tooling Solutions EXCO Extrudex Aluminum Ltd. Foy Inc. Frontier Aluminum Corp. Futura Industries Corp. Gateway Extrusions Ltd. General Extrusions Inc. GIA Clecim Glencore Ltd. Granco Clark Inc. Gulf Extrusions Company LLC Houghton Metal Finishing Company Hulamin Extrusions Hydro Aluminum North America Inc. ILSCO Extrusions Inc. iNOEX LLC International Extrusions Jordan Aluminum Extrusions, LLC Kennametal Extrude Hone Corp. Keymark Aluminum Corporation Light Metals Corporation

Magnode Corporation Marx GmbH & Co. KG Matalco Inc. M-D Building Products Metal Exchange Corporation Metra Aluminum Inc. MI Metals Inc. Mid South Extrusion Die Co. Mid-States Aluminum Corp. Nanshan America Co. National Aluminium Ltd. Nizi International (U.S.) Inc. Noranda Aluminum Inc. Non-ferrous Extrusion Ohio Valley Aluminum Co. LLC OMAV S.p.A. PanAsia Aluminium Limited Peerless of America Inc. PengCheng Aluminum Penn Aluminum International Inc. Pennex Aluminum Company Postle Extrusion PPG Industries Inc. Presezzi Extrusion North America Pries Enterprises Inc. Profile Extrusion Co. Republic Chemical Co., Inc. Reliant Aluminum Products LLC Richardson Metals Rio Tinto Alcan R.L. Best Company Sapa Extrusions

Service Center Metals Sierra Aluminum Silver City Aluminum Corp. SMS Meer Service Inc. Spectra Aluminum Products Ltd. Spectrum Metal Finishing Inc. Superior Extrusion Inc. Taber Extrusions LLC Tecalex USA Technoform Tecnoglass S.A. Tellkamp Systems Inc. Thumb Tool & Engineering Tower Extrusions, LLC Tri City Extrusion Inc. Tubelite Inc. Turla S.r.L. Ube Machinery Inc. Valspar Corporation Vidrieria 28 de Julio S.a.C. Vitex Extrusion Wagstaff Inc. Walgren Company WEFA Cedar Inc. Werner Co. Werner Extrusion Solutions, LLC Western Extrusions Corp. Whitehall Industries YKK AP America Inc. Youngstown Tool & Die Co. Inc.

Questions? Paul Heney Design World [email protected] Twitter: @DW_Editor

Mark Telander Alexandria Industries [email protected] Phone: 800-568-6601

Joe Jackman ALMAG Aluminum [email protected] Phone: 888-457-9480 Twitter: @ALMAGAluminum

Ron Gish Alexandria Industries [email protected]

Thank You q  This webinar will be available at

designworldonline.com & email

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Proper Use of the Presented Information

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The Aluminum Association (AA), Aluminum Extruders Council (AEC), the authors and contributors of this overview provide information and resources about aluminum products and aluminum-related technology as a service to interested parties. Such information is generally intended for users with a technical background and may be inappropriate for use by lay persons.

This presentation does NOT attempt to thoroughly discuss all load types, materials, profiles, design requirements, etc.

The purpose is to provide an overview of topics/issues to consider when utilizing aluminum extrusions for designs

Full understanding and adherence to the Aluminum Design Manual (Aluminum Association 2010) and all documents referenced by it is required for proper design

In all cases, users should not rely on this information without consulting original source material and/or undertaking a thorough scientific analysis with respect to their particular circumstances. Information presented here does not replace the independent judgment of the user or of the user’s company and/or employer.

AA AND AEC EXPRESSLY DISCLAIM ANY AND ALL GUARANTEES OR WARRANTIES WITH RESPECT TO THE INFORMATION PROVIDED HERE. AA AND AEC FURTHER DISCLAIM ANY LIABILITY IN CONNECTION WITH THE USE OR MISUSE OF ANY INFORMATION PROVIDED OR IN CONNECTION WITH THE OMISSION OF ANY INFORMATION.

Photos, illustrations, and graphics used in this PowerPoint courtesy of: Accuray, Akzo Nobel Coatings Inc./Bill Hanusek, Gossamer Innovations, GM, Hydro Aluminum North America Inc., Light Metal Age Magazine, MAADI Group, SAPA Extrusions, Skylne Solar, Taber Extrusions, Werner Co., Werner Extrusion Solutions, LLC