aerospace aluminum
Transcription
aerospace aluminum
AEROSPACE ALUMINUM YOUR PARTNER IN ALUMINUM SOLUTIONS We believe that it’s a win-win to enable our customers’ progress. Quality. Accountability. Integrity. These things are non-negotiable. When we collaborate with customers to find solutions, we’re contributing to their success and creating a better world. 2 www.aleris.com THINK BEYOND At Aleris, aluminum isn’t just our work — it’s our passion. It represents opportunity, innovation and game-changing solutions to create a better world. With Aleris Aerospace Aluminum, Aleris provides customers with the people, the tools and the resources that they need to realize the value that aluminum offers. GLOBAL REACH becomes more important in business every minute of every day. Aleris is helping our customers meet international demand through global assets such as our newly built world-class plate mill in China, which allows us to serve fast-growing Asian markets. TECHNICAL PROGRESS is what drives our people. We’re not satisfied with today’s solutions. By always striving to develop new and innovative aluminum products for our customers, we ensure that we’re providing them the best materials to meet tomorrow’s challenges today. SUSTAINABILITY is important to us. As a leading aluminum recycler with a safety-focused culture, Aleris looks after the environment the same way that we look after our people. CONSISTENCY in our quality, reliability and creativity come together to make Aleris the preferred choice for our customers, and as a result, a leading global producer of aircraft aluminum products. www.aleris.com 3 PLANT KOBLENZ Our success is founded in offering innovative, customized solutions for our customers and maintaining long-term partnerships within the aerospace industry. The Aleris plant in Koblenz, Germany, is one of the world’s leading rolled products mills for high-quality rolled aluminum plate. The plant produces plates, sheets and coils in more than 100 different alloys, which are used in applications for engineering, transportation, aerospace and other modern industrial segments. Through highly innovative and efficient operations, the Koblenz plant delivers more than 150,000 tons of semi-finished aluminum to Aleris customers around the globe every year. This has enabled Aleris Koblenz to supply the global aerospace industry with innovative aluminum materials of the highest quality, which meet not only the highest standards but also all conceivable individual customer specifications. Both experience and know-how have been applied to develop special various alloys – like ultra thick aluminum aircraft plates, millfinished and polished aluminum aircraft sheets, as well as aluminum aircraft segments in customized sizes – which fully satisfy the requirements of the aerospace market. 4 www.aleris.com BUILT FOR THE FUTURE, ROOTED IN HISTORY With a heritage going back more than 50 years, the Koblenz plant embodies Aleris’ commitment to permanent quality improvement, a culture of systematic process optimization and a constant investment in modern equipment. Since its inception, more than 450 million euros have been invested in Koblenz to expand the facility and its capabilities. Today, the plant is known for its innovation and quality. Through continued investment in modern production and the ability to meet the highest standards of organization, working environment, health, safety and environmental quality, the Koblenz plant is well-positioned to successfully serve the industrial needs of today’s global marketplace. MAJOR CAPABILITIES CAST HOUSES SCALPER 160“ HOT ROLLING MILL 128“ HOT ROLLING MILL 148“ COLD ROLLING MILL SAWING CENTERS (WIDE PLATE, CNC, SEGMENT, LINER PLATE SAW) HORIZONTAL HEAT-TREATMENT FURNACE, PLATE- AND VERTICAL FURNACES STRETCHER UP TO 8,000 T PLATE TESTING EQUIPMENT (E.G. ULTRASONIC TESTING, EDDY CURRENT TESTING) CERTIFICATIONS CERTIFIED FOR QUALITY MANAGEMENT AEROSPACE: EN 9100 AUTOMOTIVE: ISO/TS 16949 GENERAL ROLLED PRODUCTS: DIN EN ISO 9001 CERTIFIED FOR DIN EN ISO 14001 ENVIRONMENTAL MANAGEMENT SPECIALIZED COMPANY ACC. TO “WASSERHAUSHALTSGESETZ” EMAS CERTIFIED FOR AEROSPACE NADCAP – HEAT TREATING NADCAP – NON-DESTRUCTIVE TESTING CERTIFIED FOR MANUFACTURE OF PRESSURE EQUIPMENT DIRECTIVE 97/23/EC CE MARKING FOR CONSTRUCTION EN 15088 CERTIFIED FOR SHIPBUILDING BUREAU VERITAS DET NORSKE VERITAS GERMANISCHER LLOYD KOREAN REGISTER OF SHIPPING LLOYD´S REGISTER RULES ABS www.aleris.com 5 PLANT ZHENJIANG We’re using innovative technology and personalized service to make high-end, high-quality aluminum products available for customers in Asia and all over the world. Aleris Zhenjiang, China, was established to meet growing regional and global demand for aerospace and commercial plate products. The new plant, which spans 271,330 m2 represents a $350 million greenfield investment in technologically advanced aluminum plate production. It is one of only a handful of state-of-the-art aluminum plate facilities in the world – and the first to be built outside of the U.S. and Europe. SUPPORTING TOP PLAYERS AND FAST-GROWING INDUSTRIES IN ASIAN MARKETS The Zhenjiang plant benefits greatly from the rich experience and expertise of its sister plants in other regions, specifically the Aleris facility in Koblenz, Germany. As a result, the Zhenjiang plant is able to deliver: Innovative technology Through a technology transfer agreement with the Koblenz plant, the Zhenjiang plant benefits from more than 50 years of operational innovation to invest in its own quality improvements, systematic process optimization and modern equipment. 6 www.aleris.com State-of-the-art equipment The twin Zhenjiang and Koblenz plants share nearly the same set of cutting-edge equipment for highly specialized products, which are used in applications for all modern industrial market segments. This primarily comprises aluminum plate for integrally machined structural components used in the aerospace industry. Typical alloys are 2024, 2124, 7075, 7175, 7475 and 7050 in various tempers. Established expertise In addition to sharing similar technology, processes and equipment, the plant in Koblenz transferred key managerial staff and technical engineers to Zhenjiang. Gaining this expertise complements the efforts of Zhenjiang engineers and supports the plant’s overall technology, quality and operation. As one of the first state-of-the-art plate mills in Asia, the Zhenjiang plant provides aluminum products for leading industry players in China and throughout Asia, including fast-growing industries in the region. Working closely with our engineering and transportation strategic partners overseas, Aleris aims to produce aerospacequality products and introduce them for all technically-demanding aluminum applications worldwide. MAJOR CAPABILITIES CAST HOUSES SCALPER 160“ HOT ROLLING MILL HORIZONTAL HEAT-TREATMENT FURNACE STRETCHER UP TO 6,000 T PLATE SAWING CENTERS PLATE TESTING EQUIPMENT (E.G. ULTRASONIC TESTING, EDDY CURRENT TESTING) CERTIFICATIONS CERTIFIED FOR QUALITY MANAGEMENT AEROSPACE: EN 9100 GENERAL ROLLED PRODUCTS: DIN EN ISO 9001 CERTIFIED FOR AEROSPACE NADCAP – HEAT TREATING NADCAP – NON-DESTRUCTIVE TESTING CERTIFIED FOR MANUFACTURE OF PRESSURE EQUIPMENT DIRECTIVE 97/23/EC CERTIFIED FOR SHIPBUILDING BUREAU VERITAS DET NORSKE VERITAS KOREAN REGISTER OF SHIPPING RULES ABS IN PROGRESS GERMANISCHER LLOYD LLOYD´S REGISTER www.aleris.com 7 ALUMINUM AEROSPACE PLATE Ultra thick plate Cut-to-size shapes Pre machined parts In order to help the aircraft Original Equipment Manufacturers (OEM) to develop and build light and cost efficient passenger and cargo aircrafts with lower fuel burn, reduced emissions and larger ranges, it has become increasingly important for suppliers to technically support their programs. One major aspect of these programs is the substitution of assemblies and built-up structures by so-called integral or monolithic structures. The major challenge for a supplier of semifinished aluminum is that, that the property combination of the raw material should not limit the performance of the integral structure when compared to a classical assembly. Therefore a number of limitations of aluminum plates have to be overcome: The maximum thickness of conventional aluminum plates have to be increased in order to allow machining of very heavy sections. An assembly usually consists of a number of formed sheets and extruded, forged and/or machined parts, which are riveted together or joined otherwise, whereby the entire structure integrates the function of all individual components. Several key properties of the plate material – such as fatigue resistance, toughness and ductility – have to be improved in order to compete with properties of other product forms like forgings. Additionally the residual stress level of the plate material have to be controlled to an extremely low level to achieve practically distortion free machinability even with the large dimensions and the high aspect ratios involved. 8 www.aleris.com ADVANTAGES OF DAMAGE TOLERANT ALUMINUM PLATES: •thickness up to 280 mm (11”) •no significant porosity •excellent fatigue performance •extreme low level of residual stresses •practically no distortion after machining •high strength •high ductility •excellent toughness Aircraft plate dimensional capabilities CUT-TO-SIZE SHAPES WITH IMPROVED BUY-TO-FLY RATIO The state-of-the-art CNC sawing center allows a variety of plate cuts to saw tailormade contours as well as the most difficult special shapes. The individual manufactu red plate cuts can additionally be provided with fixing holes of 6 to 45 mm (0.24 to 0.177”) provided as passage holes or bag holes with or without a thread. They serve as the fast attachment of ring bolts and fixing devices. Plate pre-machining can be offered to optimize cost savings and to minimize scrap handling at the customer site. Thickness up to 11” up to 280 mm Width up to 130” up to 3,300 mm Length up to 945” up to 24,000 mm Other dimensions on request The cut-to-size and pre-machined parts are delivered to customers all over the world; all of the resulting scrap is being recycled in our own recycling companies. MAJOR CAPABILITIES 2014 2214 6061 7050 7150 7175 AMS 4029 BS 2 L.93 TH 5.313 AIR 9048 CR 1.1.031 AIR 9048 AMS 4025 AMS 4026 AMS 4027 AMS-QQ-A-250/11 DAN 422 WL 3.3214 AIMS 03-02-019 AIMS 03-02-022 AIMS 03-02-029 ABM 3-1029 ABM 3-1030 AIR 9048 AMS 4050 AMS 4201 BAEM 1213 BAMS 516-001 BAMS 516-003 BMS 7-323 Type I BMS 7-323 Type III DAN 422 DGQT 1.1.0.97 DGQT 1.1.0.0098 DMS 2233 DMS 2459 EN 3982 EN 3983 KMB-SK2102 LMA-M7050 MEP02-014 MEP02-036 MFM 0017 MMS 1420 MMS 1439 M3184 MM3184 OFWN 4029 OFWN 4037 OFWN 4040 STD 113643 STM 0887 TSM 42.03.69 TSM 42.03.70 WL 3.4144 ABM 3-1031 AMS 4252 BAEM 1219 BAMS516-006 DMS 2308 AIMS 03-02-008 ASN-A3050 CR 1.1.0.88 OFWN 4033 SMS 003 7075 7475 AIR 9048 AMS 4045 AMS 4078 AMS-QQ-A-250/12 AMS-QQ-A-250/13 AMS-QQ-A-250/24 BS 2 L.95 DAN 422 EN 2126 MMS 159 STD 113627 TH 5.316/3 TH 5.316/5 WL 3.4364 AIMS 03-02-009 AIR 9048 AMS 4089 AMS 4090 AMS 4202 BAMS 516-002 DAN 422 DMS 2184 DMS 2234 FMS-3004 MEP 02-013 Std. Type MEP 02-013 Type I MM0565 M3188 MM3188 OFWN 4057 STD 113637 TSM 42.03.68 WL 3.4384 2219 2024 AIMS 03-02-004 ABM 1-1005 AIR 9048 AMS 4037 AMS 4041 AMS-QQ-A-250/4 AMS-QQ-A-250/5 ASN-A3011 BS 2 L.97 BS 2 L.98 CMS-AL-103 DGQT 1.1.0.0036 DAN 422 MEP02-035 SMS 3204 TH 5.312 WL 3.1354 2124 AIMS 03-02-032 AMS 4101 AMS-QQ-A-250/29 FMS 3002 FMS 3008 MMS 149 MEP 02-029 A5-SA-121-1039 A5-SA-133 1100-C-0019MTA AMS 4295 AMS 4600 AMS 4613 AMS-QQ-A-250/30 DSN 1719.01 MPS/2219/S&P/01 SA-MU-42.549.04 55 LV 09 003 2618 ABM 1-1006 AIMS 03-02-021 AIR 9048 ASN-A 3355 BAEM 1103 DAN 422 MEP02-020 WL 3.1924 7010 ABM 3-1029 ABM 3-1030 AMS 4204 AMS 4205 ASN-A3098 ASN-A3101 BAEM 1213 BAEM 1218 DAN 422 DGQT 1.1.0.87 D.T.D. 5120 D.T.D. 5130 EN 2684 EN 2687 MM0533 OFWN 4017 OFWN 4038 SM 9102 SMS 3206 STD 113644 TSM 42.03.66 TSM 42.03.67 TSM 42.03.71 WL 3.4394 7020 AIR 9048 www.aleris.com 9 ALUMINUM AEROSPACE SHEET Wide sheet Wide coil sheet Standard coil sheet Aleris Koblenz supplies sheet and plate material for fuselage components, mainly for European, Asian, North American and South American customers. Traditionally, the aluminum alloys used for these applications were conventional 2xxx and 7xxx series alloys like 2024, 7075 and 7475 but also 5xxx and 6xxx series alloys for welded applications. In order to supply optimum products and materials for light-weight fuselage constructions the sheet portfolio comprises the following different product forms: •standard coil sheet •wide coil sheet up to 2,600 mm (102’’) width •wide sheet up to 3,460 mm (136’’) width As part of the strategic plan to develop cost effective materials with highest quality property performance in extreme dimensions for various development projects, investment programs as well as other activities have been carried out enabling the plant in Koblenz to become one of the most important suppliers of semi-finished aluminum products to the aerospace industry and a strong partner of the major airframe manufacturers. HIGH QUALITY STANDARDS COMBINED WITH UNIQUE STATE-OF-THE-ART EQUIPMENT MAKE IT POSSIBLE: 10 www.aleris.com •extreme size range •excellent surface capabilities (mill finished, bare, one side clad, both sides clad, polished skin quality) •high formability •best chemical milling quality •MRS-quality MAJOR CAPABILITIES 2024 BARE 2219 BARE 6061 BARE ALCLAD 7075 AMS 4035 AMS 4037 AMS-QQ-A-250/4 AMS 4031 AMS 4295 AMS-QQ-A-250/30 AMS 4025 AMS 4026 AMS 4027 AMS-QQ-A-250/11 AMS 4048 AMS 4049 AMS-QQ-A-250/13 AMS-QQ-A-250/25 ALCLAD 2024 ALCLAD 2219 AIMS 03-04-009 AIMS 03-04-010 AIMS 03-04-011 AIMS 03-04-012 AIMS 03-04-013 AIMS 03-04-014 AMS 4040 AMS 4041 AMS-QQ-A-250/5 AMS 4096 7075 BARE ALCLAD 7475 5024 BARE AMS 4044 AMS 4045 AMS-QQ-A-250/12 AMS-QQ-A-250/24 AIMS 03-04-029 DMS 2234 AIMS 03-04-055* * Qualification complete, customer paperwork pending Aircraft sheet dimensional capabilities Wide sheetO/F-Temper Thickness T-Temper 0.100”– 0.472” 2.5 –12.00 mm 0.100”– 0.472” 2.5 –12.00 mm Width up to 136” up to 3.460 mm up to 130” up to 3.300 mm Length up to 500” up to 12.700 mm up to 500” up to 12.700 mm 0.032”– 0.126” 0.8 – 3.2 mm Standard coil sheet and wide coil sheetO/F-Temper Thickness 0.032”– 0.158” 0.8 – 4.00 mm T-Temper Width 36”– 102” 914 – 2.600 mm 36”– 89” 914 – 2.250 mm Length 39”– 472” 1.000 – 12.000 mm 39”– 472” 1.000 – 12.000 mm Other dimensions on request www.aleris.com 11 PLANT DUFFEL Billets Drawn / extruded rods and bars Small and intermediate profiles Hard aluminum alloys play a major role in complex applications in airplanes and automobiles. Particular emphasis should be given to the AlEco62Sn alloy, a 100 % leadfree alloy for machining applications. Aleris Duffel (Belgium) is specialized in hard alloys in round and flat bar shape for complex machining and milling applications for products such as steering valves, landing gear parts (high-load structural components), fuel adaptors and heat exchanger parts. Using its indirect 50 MN press, the Ebner horizontal solution annealing furnace and the 800-t stretcher, Aleris Duffel offers optimum production conditions for these tasks. Modern ageing furnaces allow the closest tolerances thereby guaranteeing high-end products. With its extraordinary drawing force, the 800-t stretcher helps to minimize residual stresses for all hard alloys in order to achieve close dimensional tolerances after machining. These facilities enable international customers to procure aluminum profiles and bars with outstan ding technological properties. 12 www.aleris.com ALERIS DUFFEL IS EQUIPPED WITH THE FOLLOWING INFRASTRUCTURE: •Cast house •50 MN heavy press (indirect) •16 MN press (modernization 2010) •Ebner horizontal solution annealing furnace •Various drawing benches •800-t stretcher •Short-length sawing installation In addition to its technological competence, customer proximity and a consistent focus on customer requirements are strong advantages offered by Aleris Duffel, resulting in customized products with a consistant high degree of verifiable quality – in many cases developed in cooperation with our customer. Aleris complies with these requirements for its customers worldwide as a reliable partner with a high delivery performance. QUALITY PRINCIPLES AND CUSTOMER APPROVALS QUALITY PRINCIPLES The quality principles is an essential element of the company policy. Its objectives are a continuous improvement in the quality of the products, the services and to fulfill all customer requirements. The quality principles are formulated by the company management, implemented and known within the corporation. To ensure these quality principles, a documented quality system has been implemented. The quality system will be continuously updated and expanded in scope. The demand of the quality system are based among other requirements on the international standard EN 9100. Process control ensures that production takes place under controlled conditions. Quality inspections are continuously carried out in various production facilities. In laboratories with state-of-the-art equipment, chemical tests ensure the proper composition of alloys and their resistance to corrosion. Mechanical tests on strength and fracture toughness, fatigue testing as well as metallographic examination on the structure of the material can also be provided. ALERIS ALUMINUM DUFFEL BVBA CUSTOMER APPROVALS (ALPHABETIC LISTED) QUALITY PHILOSOPHY ALERIS ROLLED PRODUCTS GERMANY GMBH PLANT KOBLENZ CUSTOMER APPROVALS (ALPHABETIC LISTED) Our quality philosophy ”means zero defects”. The quality system takes into account the customer’s continuously rising requirements and quality standards such as EN 9100 and Nadcap. Legislation and regulatory measures will also factor into our quality philosophy. ENVIRONMENT, HEALTH AND SAFETY PRACTICES In terms of environment, health and safety practices, we have ISO 14001 in both European plants and EMAS for the Koblenz plant. Aleris wide we have our Safety and Environment Policy and Principles implemented and update this continuously. • Airbus • BAE Systems-MAS • Boeing • Lockheed Martin • Messier Dowty Serck Aviation • Mettis Aerospace • Raytheon Aircraft • etc. • Airbus •BAE Systems • Boeing • Bombardier • Cessna • EADS • Embraer • Gulfstream • Lockheed Martin • Raytheon Aircraft • etc. www.aleris.com 13 THE BASIS FOR INNOVATION AND QUALITY With intensive, permanent, focused research and development work we ensure that our products and processes are continually improved and meet the highest quality standards. This is how we build on our technological position in the aerospace industry. Our investment and consistent focus on research and development is directed at those innovations which meet the needs and goals of our customers. We develop tailor-made strategic processes, products and applications. And of course we support our customers’ activities in key market areas. Improvements relating to quality, costs and the environment always take center stage. To fulfill these requirements our organizational structure are continuously refined and adapted to current demands. The same applies to field engineering support, product and process technology (PPT), classic research and development (R&D) and intellectual property. 14 www.aleris.com FIELD ENGINEERING SUPPORT In addition to excellent material supply, it is one of our strategic goals to provide our customers with comprehensive engineering support. Aleris field engineer can help develop solutions together with our customers, using new technologies and proces ses to meet your requirements and to improve your products. They are the technological link betw een the customer needs and our production capabilities, and we view this activity as mutually beneficial, joint development. Our customer engineering team can provide technical consulting, product and material training, problem solving in the field, providing direct technical support services based on the experience Aleris has gained. Aleris’ broad metallurgical knowledge allows for the rapid transfer of new customer requirements or applications into defined alloy properties and fabrication processes. Airbus PRODUCT AND PROCESS TECHNOLOGY CORE RESEARCH AREAS The work of product and process technology is to ensure that Aleris products go through a robust and simultaneously efficient metallurgical mass production process. The core research areas for Aleris in the aerospace industry include hard alloys like AA7181, reduced-density alloys such as AlMgSc and also aluminum-lithium alloys, which are both light and strong and resistant to corrosion and fatigue. Aleris can develop and test all major production and processing stages as pilot processes at the production scale. Furthermore, all inno vation centers use the latest analysis techniques, microscopes, x-ray machines, testing and measurement apparatus, partly in cooperation with external partners. The special aerospace equipment in Koblenz includes a trial casting machine, which makes it possible to cast industrial-scale ingots for test programs. The laboratory area here not only serves to approve production: new testing equipment is continuously added for physical and chemical testing to particular customer specifications. This enables research into the materials themselves, their properties and their applications in the aerospace industry to be optimized – from alloy development, casting, rolling and processing through to the performance of the finished product. Aleris can thus provide its customers reliably and comprehensively with all the information they need to manufacture an optimal product. RESEARCH AND DEVELOPMENT Aleris has concentrated its research and development work in three innovation centers, whereby the center at the Koblenz plant is specifically responsible for R&D in the aerospace sector. In Aachen there is another innovation center for more bluesky, fundamental and cross-sector research purposes. The engineers there are responsible for developing new aluminum products with improved properties under laboratory conditions, which includes experimental trials and theoretical simulations. They also carry out small-scale testing of alloys and processes. As well as its good geographic location, Aachen offers close connections to the research facilities of RWTH Aachen University, one of the most respected higher education centers in the world. Aleris is one of the partners in the AMAP (Advanced Metals and Processes) cluster, working closely with university institutes and other industry partners on pre-competitive advanced solutions. www.aleris.com 15 Global Headquarters Aleris International, Inc. 25825 Science Park Drive Suite 400 Cleveland, Ohio 44122 · USA T +1 216 910 3400 info@aleris.com European Head office Aleris Switzerland GmbH Balz Zimmermann-Straße 7 8058 Zürich Airport · Switzerland T +41 44 828 1400 info.europe@aleris.com Asian Head office Aleris (Shanghai) Trading Co., Ltd. Suite 2804, Wheelock Square No.1717 Nanjing Road West Shanghai 200040 · China T +86 21 2231 8000 info.china@aleris.com Plant Koblenz Aleris Rolled Products Germany GmbH Carl-Spaeter-Straße 10 56070 Koblenz · Germany T +49 261 891 7479 Plant Duffel Aleris Aluminum Duffel BVBA A. Stocletlaan 87 2570 Duffel · Belgium T +32 15 30 2237 Plant Zhenjiang Aleris Aluminum (Zhenjiang) Co., Ltd. No. 1 Cai Jia Road Jingkou Industrial Park Zhenjiang, 212141 Jiangsu · China T +86 511 8530 7220 Picture used by courtesy of Airbus. www.aleris.com Download any QR reader and scan. Charges may apply. © 2014, Aleris Corporation Issue 6/14 · 8th release