metal quality & technology in europe means aded value?

8/14/2019 Metal Quality & Technology in Europe means Aded Value?

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Metal Quality and Technologyin Europemeans Added Value ?

Gary Mahon

[email protected]


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Innoval Technology LtdIP07-047, Slide 3

Scope

The European Industry Landscape

Evaluating Billet Quality

Innovative Scrap Processing

Global R&D Trends

Managing Knowledge Assets

Does Europe have a Sustainable Advantage ?


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EU-25 Aluminium Flow Chart (2005)

Sustainability of the European Aluminium Industry 2006,European Aluminium Association.


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Primary Aluminium Regional Balances


Expect more Billet from these regions


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Geometric Tolerances Weight per metre

Dimensional accuracy

Bow

Flatness

Other

Corrosion resistance

Welded Properties

Surface Properties Reflectivity

Topography

Uniformity

Anodising Response

Mechanical Properties

Strength

Toughness

Formability

Fatigue

Defects

Die lines

Speed tears

Stains

Pick-up

Scratches

Blisters

Marks

Extruded Metal Quality

Influenced by billet quality


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Examples of Composition Control on Quality

0

10

20

30

40

50

6070

80

90

100

0.40 0.45 0.50 0.55 0.60 0.65

wt.% Si

%

Alpha

0.03 Mn

0.06 Mn

0.09 Mn

Brassard et al

AlcanET04

0

25

50

75

100

125

0.40 0.45 0.50 0.55 0.60 0.65

wt.% Si

Exit

Speed(m/min)

Pick-up

OK

0.03 Mn

0.06 Mn

0.09 Mn

Intermetallics Surface Pick-up


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Metal Cleanliness with Prefil: Pressure Filtration

0

200

400

600

800

1000

1200

1400

0 30 60 90 120 150

Time (s)

Weight(g)

CLEAN(High Flow Rate)

High

InclusionContent

(Low Flow Rate)

Increasing InclusionContent

N-Tec


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PrefilMetallographic Inclusion Analysis

Aluminium

Inclusion band

Filter grains

Wide Inclusion BandMany Inclusions

N-Tec

Smelter

Melter

Transfer

Holder

Launder

Degasser

Filter

Casting

Al4C3(TiV)B2

Al Borocarbides

Al2O3 films & particles

MgO films & particlesSpinel films & particles

AlN

Refractory particles

Fe Mn oxidesBone ash

Note this is not a comprehensive list

Defect Mapping


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Evaluation of Billet Quality Intermetallics

Red superimposed image of Mg2Si

0

5

10

15

20

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

App. Conc. Si

App.Conc.Fe+Mn

Alpha: %

Beta: %

46

54Alpha Standard

Beta Standard

50

55

60

65

70

75

80

85

90

95

100

Edge Mid radius Center Edge Mid radius Center Edge Mid radius Center

%

alpha

Bottom TopMiddle


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Evaluation of Billet Quality

Billet is the critical starting point for extrusion Quality

Expect new Billet Suppliers from developing Countries

Evaluation techniques exist to measure billet quality

Technical Audit of Suppliers

Need to insist that billet suppliers are meeting your requirements


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Growth of Old Scrap (Post Use)

0

2000

4000

6000

8000

10000

12000

14000

16000

1950 1960 1970 1980 1990 2000 2003 2004 2010 2020

Oldscrap(thousandto

nnes)

Other

Consumer Durables

Engineering

Packaging

Building

Other Transport

Automotive

Global Aluminium Recycling Committee2005


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Up-Cycling of Light Alloys from Recycled Scrap

Aim to prevent down-grading of wrought-alloy Old Scrap into casting alloys.

Deliver Value-Added products for Recyclers

Based on Melt Conditioning by high shear of liquid metal.

Family of technologies developed at Brunel University.

1.2M over three years from UK Technology Strategy Board

Innoval is Lead Partner and Technical Manager.

Started March 2007.


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High-Shear Twin-Screw Melt-Conditioning

Feeding DC Caster

Centre Edge

Mg-alloy AZ31 60mm billet


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Examples of Potential of Melt Conditioning

0

2

4

6

8

10

12

0.4 0.6 0.8 1 1.2

Fe Content (wt.%)

Elongation(%

MC

HPDC

Mg-Alloy AZ91D

Fe tolerance increased by 0.37wt%

LM25 (Al-10.3Si-0.3Cu-0.16Mn)

0

50

100

150

200

250

300

100%Scrap 50%Scrap Primary

Yield,

UTS(MPa)

0

1

23

4

5

6

7

8

Elo

ngation(%)

Yield UTS Elongation

Quality unaffected by scrap recycling


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Impact of Technology Development not always in Europe

SMEs

Entrepreneurs

Development usually

undertaken intechnologically advancedregions

If necessary, will licence

globally to get return oninvestment

Independent

Investing in long-termsustainability of theiroperations

Need to protect andenforce IPR position toprevent copying

Developer has first moveradvantage, but for limitedlifetime

Global Companies

Usually invest most intechnology development

Make financially drivendecisions to satisfyshareholders

Often put plant in lowest

cost region regardless ofwhere technologydeveloped

Needs a continuous through-put of ideas and innovations


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R&D Policy Response

EU Framework 7

Collaborative and International

50% funding (75% for SMEs)

Focus on science, technology development and exploitation for benefit of EU

UK Technology Strategy Board

Collaborative within UK

50% funding

Need supply chain in place for exploitation

University Education EU is continuing to invest in producing a high number of science and

engineering graduates.


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Value-Added Opportunities

FinishingOperations

NewAlloys

New Profiles &

Processes

Product Differentiation

Technically demandingproducts

High Strength AerospaceAlloys

Weldable medium strength6000-series Alloys

Metal Matrix Composites

Design

Die Coatings

Cost Reduction to enablepenetration into new markets


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World Labour Costs by Region


Investing in State-of-the-Art Equipment


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Managing Knowledge Assets

Important to maximise the knowledge that exists in existing employees

Staff with valuable knowledge which is not exploited

Loss of long-serving, knowledgeable employees

Share knowledge of manufacturing to improve product quality

Determine gaps in the knowledge base (R&D programme)

Standardise operations and develop Best Practice

Knowledge Management using K-Maps

Based on The Voice of the Customer or QFD (Quality Function Deployment)

Team-based Workshop approach involving

Manufacturing Technology

Sales


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Knowledge Mapping Matrix

How to Build a K-Map

Assemble those with knowledge

Define Product Attributes

Define the Process Stages

Define the strength of relationship

Develop content via Intranet


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K-Map Summary Level


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K-Map Case Study - Enthovens Pb Battery Recycling

Actual Standard Operating Practice captured andagreed by all shifts for the Refinery.

14% increase in output.

3% reduction in fuel use.

Improved Team Work throughout Plant.

Currently using P-Map to compare Key PerformanceIndicators and develop Best Practice across 10European sites.


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Innoval Technology Ltd

Summary

European extruders currently have a technical advantage

To keep this advantage we need to

Keep a robust manufacturing infrastructure

Maintain high quality throughout the supply chain

Invest in innovation and new technology

Fund dynamic and exciting aluminium R&D programmes

Manage highly qualified and innovative European nationals

[email protected]

metal quality & technology in europe means aded value?

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