EP3986629B1 - Reliable high extrusion rate production method for high corrosion resistance powdercoated recycle friendly aluminum soft alloys - Google Patents

Reliable high extrusion rate production method for high corrosion resistance powdercoated recycle friendly aluminum soft alloys Download PDF

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Publication number
EP3986629B1
EP3986629B1 EP21731160.4A EP21731160A EP3986629B1 EP 3986629 B1 EP3986629 B1 EP 3986629B1 EP 21731160 A EP21731160 A EP 21731160A EP 3986629 B1 EP3986629 B1 EP 3986629B1
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Prior art keywords
extruded
soft alloy
aluminum soft
alloy
die
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German (de)
English (en)
French (fr)
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EP3986629A1 (en
EP3986629C0 (en
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Dimitri Fotij
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C29/00—Cooling or heating work or parts of the extrusion press; Gas treatment of work
    • B21C29/006—Gas treatment of work, e.g. to prevent oxidation or to create surface effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/002—Extruding materials of special alloys so far as the composition of the alloy requires or permits special extruding methods of sequences
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/03—Making uncoated products by both direct and backward extrusion
    • B21C23/035—Making products of generally elongated shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/05—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions

Definitions

  • the present invention relates to a reliable high extrusion rate production method for recycle friendly aluminum soft alloy of the type 6060X, which besides Al ,Mg and Si contains important amounts of Cu , Zn, Fe and Mn as alloying elements, followed by an pretreatment with an alkaline or acid etching of at least 1,0 preferably 2 gram/m2 yielding powdercoated aluminum profiles with a very high corrosion resistance after powder coating for the most common conversion (Ti, Ti,Zr,preanodisation, etc) - powdercoating systems available in the market.
  • Aluminum soft alloys are typically used for the production of components with a high surface quality for use in decorative applications, by shaping the alloy into a wide variety of forms using extrusion.
  • Aluminum soft alloys are further suitable for use in a wide variety of non-structural, non-critical applications such as architectural applications, extrusions like frames for windows and doors, curtainwalls, storefronts, skylight architectural applications, doors, shop fittings, irrigation tubing, sports equipment, non-structural applications in aircraft industry, road transport, rail transport etc. house buildings and other buildings.
  • Aluminum soft alloys offer good corrosion resistance, good machinability, good weldability, good formability and acceptable strength. They are heat treatable and may be artificially aged.
  • the aluminum soft alloy is subjected to etching and anodization.
  • Aluminum soft alloys may also be subjected to powder coating or to any other suitable surface treatment.
  • Components or parts made of aluminum soft alloys typically take the shape of sheets or plates, wires, rods, bars, extrusions, structural shapes, tubing, pipe, forgings, foil, etc.
  • Main alloying elements contained in aluminum soft alloys may include Mg, Fe, Si, Cu, Mn, Cr, Zn, Ti.
  • the most common aluminum soft alloy in Europe is the 6060 alloy, which contains Mg and Si as alloying elements and has a minimal tensile strength of 215 MPa. Tensile strength and other mechanical properties to which these 6060 soft alloys must respond are described in Extrusion Norm (EN) EN 755-1 and EN 755-2.
  • An EN AW 6060 aluminum alloy which responds to the European EN 573-3 in relation to its composition may typically contain the following alloying elements in the indicated concentrations (in wt. % with respect to the weight of the alloy composition):
  • An EN AW 6063 aluminum alloy which responds to the European norm in relation to its composition may typically contain the following impurities in the indicated concentrations (in wt. % with respect to the weight of the alloy composition):
  • the concentration of Fe in soft alloys of these types is restricted to a maximum of 0.22 wt.% , preferably below 0,19 wt. % , because of its negative impact on extrusion rate or speed and negative impact on the surface quality of extruded products due to the presence of heavy pick-ups at higher iron levels.
  • the concentration of Mn is generally restricted to a maximum of 0.04 wt. % , preferably below 0,01 wt. %, because Mn is known to interfere in aluminum re-crystallization during extrusion, and to give rise to the formation of large grains with an irregular shape and/or a fiber structure and a dull surface after anodization.
  • the concentration of Cu is generally restricted to a maximum of 0.02 wt.% , preferably below 0,01 wt. % to minimize the risk to the occurrence of corrosion problems, which may deteriorate the surface quality and give rise to colour or gloss problems after anodizing.
  • Cu is also known to have a negative impact on extrusion speed.
  • the concentration of Zn is generally restricted to a maximum of 0.02 wt.% , preferably below 0,01 % , in view of its negative impact on the anodization behavior of the soft alloys, due to preferential grain etching.
  • D2 further discloses the etching and neutralisation or desmutting.
  • Recycled aluminum may originate from a variety of alloys, which in turn may originate from a fairly wide variety of applications.
  • Recycled aluminum may for example originate from cast products typically made from 4XXX- alloys which usually have a high Si content, from rolling products typically made from 5XXX - alloys which usually contain rather high percentage of Mg, from extruded profiles made from other alloys such as 2XXX-alloys with a high Cu content, from 3XXX-alloys with a high Mn content or from 7XXX-alloys which usually containing high percentage of Mg and Zn. Often, at the end of their life cycle, these products are collected all together and usually a detailed sorting of different aluminum alloys is not carried out.
  • Recycling may therefore lead to higher levels of certain elements in the recycled aluminum, such as Mg , Si ,Zn, Cu, Fe, Mn, etc. Furthermore, upon recycling of demolished products which contain aluminum parts, like parts taken from buildings or vehicles, the recycled parts may show increased levels of Fe, Mn, Cu and Zn. As a consequence these elements risk to end up in applications which make use of recycled aluminum, even when employing performant sorting techniques.
  • the recyclefriendly soft alloys typical contains alloying elements in the below examplified ranges, with especially the trace element at the higher end of the tolerance field (in wt. % with respect to the weight of the alloy composition) when compared to the Restricted alloys (supra):
  • the first big deviation in trace alloying elements is iron. Due to recycling these values can be far above 0,22 wt. % and as a result we expect a very negative impact on the extrusion rate. It is also known if Iron is in alpha condition ( round form ) and not in beta condition ( needle ) the negative impact on extrusion speed is neglectable. As known from WO 98 / 42884 Publication date 1 October 1998 . It is recommended that Mn is optimal 0,04 - 0,07 wt % to achieve optimal beta -alpha conversion during the homogenisation process to avoid tearing or reduction in extrusion rate during extrusion. At these Mn values the negative impact of Fe is of minor importance.
  • One of the parameters controlled by the press operator is the temperature of the extruded aluminum part that has left the extrusion die.
  • This temperature control is absolute necessary seen the fact that due to the higher concentrations of trace elements there are a lot of intermetallic particles in these recyclefriendly alloys , in particular low melting particles , that can cause incipient melting and may lead to a strong drop in extrusion speed.
  • Measurement of the temperature of the extruded aluminum part that has left the extrusion die is rather complex. Mechanical contact temperature measurements are very cumbersome and not possible without damaging the profile. Theoretical calculations of the temperature by energy input of the process by finite elements, such as the CADEX system of SMS, are not reliable and were no success.
  • Infrared measurements without contact are very difficult due the high emissivity of the aluminums, although there has been a lot progress the last years which made this new and innovative solution possible. Further you need to find the hottest point (hot spot) of the profile which is very often in the interior of the profile where it is impossible to measure. That is the main reason that today it is still the operator who is responsible for the settings of the most important press parameters.
  • the process of the present invention comprises the steps of creating an inert atmosphere at the die exit and of monitoring the and maintaining the temperature of the extruded aluminum at the exit of the die in a temperature range of between 500 and 600°C, preferably between 550 and 595°C, followed by an etching pretreatment with an alkaline or acid.
  • a low-grade etching of at least 1,0 preferably 2 gram / mm 2 is already sufficient to obtain an aluminum soft alloy with excellent surface qualities and free from surface problems like filiform corrosion upon powder coating.
  • the present invention relates to a process for producing an extruded part, wherein an amount of an aluminum recyclefriendly 6060X alloy having a composition as described herein before, is heated to a softening temperature which is below the melting temperature of the aluminum soft alloy with the purpose of softening the alloy, after which the softened alloy is forced through an extrusion die at an extrusion temperature until it exits the extrusion die at an extrusion die outlet so that an extruded alloy part is produced.
  • the process of the present invention is amongst others characterized in that the extruded alloy part is contacted with a flow of an inert gas at the position where it exits the die, and in maintaining the temperature at the die exit within the herein prescribed range.
  • the inert gas used in the process of the present invention may be any inert gas considered suitable by the skilled person, for example nitrogen, helium, argon etc or mixtures of two or more hereof. More preferably use is made of liquid nitrogen seen the massive expansion of liquid nitrogen when it comes in contact with the extrudate.
  • a further improvement of this invention is to force the flow of the inert gas as close as possible to the exit by drilling holes or slots in the support plate of the die and to force the inert gas in the immediate neighborhood of the die exit.
  • the present invention permits producing products from aluminum alloys with the conventional mechanical properties required by the intended applications for example the building or construction industry regardless of the presence of otherwise unwanted elements like Fe, Mn, Zn and Cu which are assumed to adversely affect the visual quality and extrusion speed.
  • extruded parts with a desired surface quality and desired mechanical properties may be produced.
  • high extrusion speeds conventionally used in the art may be maintained, regardless of the presence of high trace alloying elements in the aluminum soft alloy composition of this invention.
  • the obtained surface quality of these aluminum soft alloys which may contain recycled aluminum, having a chemical composition as described above and executed with production methods as described above is completely within the norms as described in Qualanod (2017) and Qualicoat (2013).
  • the die surfaces at the profileforming area's (bearing) should comprise a compound or white layer (such as a gas nitride dies with a nitride layer or CrN coated dies with a Cr-N hard coat) of minimal 5 ⁇ m, preferably of about 8 ⁇ m with a diffusion layer of about 0,15 to about 0,30 mm.
  • a compound or white layer such as a gas nitride dies with a nitride layer or CrN coated dies with a Cr-N hard coat
  • a compound or white layer such as a gas nitride dies with a nitride layer or CrN coated dies with a Cr-N hard coat
  • the billet preferably has an iron beta -alpha conversion of at least 90%, and is free from hard particle inclusions, such as Al 2 O 3 , TiB, Fe 2 O 3 , Al 2 O 3 , SiO 2 , etc, with a maximum particle size of 50 ⁇ m.
  • the TTT after extrusion preferably comprises a single or two step aging protocol, comprising a cooling speed of about 3°C / sec and maintaining the extruded profile at a temperature of about 160 to about 180°C for at least 8h; in one embodiment at about 175°C for about 8 hours; in another embodiment at about 165°C for about 12 hours.
  • a cooling speed of about 3°C / sec and maintaining the extruded profile at a temperature of about 160 to about 180°C for at least 8h; in one embodiment at about 175°C for about 8 hours; in another embodiment at about 165°C for about 12 hours.
  • proper pretreatment of the thus obtained 6060X soft alloy such as a state of art acid etching or alkaline etching ( at least 1,0 or preferably 2 gram/m2 ), and in case of alkaline etching followed by a standard acid desmutting to avoid enrichments of Zn, Cu,Mn on the surface.
  • This etching step of the inertized extruded alloy is preferably followed by deposition of a good stable conversion layer on Ti, Zr , Ti / Zr base or an anodisation layer of at least 4 ⁇ m is also used.
  • As final step a single or two layered powdercoating (very popular in the Netherlands) is placed of typical 70 ⁇ m.
  • the present invention is further provides a device 100 for manufacturing an of an aluminum recyclefriendly soft alloy having a composition as described above 10.
  • the device comprises a container 8, with container liners 7 in which the aluminum alloy or billet 2 to be extruded is pushed in. Often the container 8 will be heated to maintain the temperature of the aluminum soft alloy or billet 2 at a desired level.
  • the aluminum soft alloy or billet has been heated to softening temperature by a billet furnace.
  • the device comprises also a forwarding system 1 for forwarding the softened aluminum alloy or billet 2 from the container into, through and out of an extrusion die 3.
  • Forwarding systems used in this type of devices are generally known to the skilled person and usually comprise a hydraulic system with a hydraulic press 50.
  • a hydraulic press 50 As pressure is applied, the billet 2 is crushed against the die 3, becoming shorter and wider until its expansion is restricted by full contact with the container liner walls 7 wherein the billet 2 is contained. Then, as the pressure increases, the soft (but still solid) metal 2 has no place to go and begins to squeeze through the shaped orifice or die opening 33 of the die 3 to emerge on the other side from the die exit 23 as a fully formed profile 10.
  • the front part of the hydraulic system will usually comprise a ram 9 or a pusher, which forces the aluminum alloy or billet 2 through the die opening 33 into die cavity 43.
  • the extrusion die 3 comprises a die opening 33 in the shape of the part 10 to be extruded.
  • the extrusion die 3 may also comprise a die cavity 43 delimited by die backers 12 and die support parts 13. Depending on billet size and die opening 33, a continuous extrusion as much as +/- 50 meter may be produced with each stroke of the press.
  • the newly-formed extruded part 10 is supported on a runout conveyor or table 4 as it leaves the die 3.
  • an inert gas 15 is supplied from an inert gas supply 5 in such a way that the extruded aluminum alloy part 10 which emerges from the die opening 33 is contacted by or surrounded by an inert gas 15 to create an inert atmosphere in the die cavity 43, at least at the position where the freshly extruded still hot aluminum alloy leaves the extrusion die 3.
  • Suitable inert gases are well known to the skilled person and include nitrogen, helium, argon etc, but preferably nitrogen is used.
  • the device of this invention also comprises a device 5 for supplying an inert gas to die opening 33.
  • inert gas supply at the position of the die opening 33.
  • inert gas may be supplied along holes or slots in the support plate 13 and/or die backers 12 present behind the die opening (33) of the die 3 , towards and into the die exit 23.
  • the die surfaces at the profile forming area (bearings) should comprising a compound or white layer (such as a gas nitrided dies or CrN coated dies yielding repectively a nitride layer or Cr-N hard coating) of minimal 5 ⁇ m, preferably of about 8 ⁇ m with a diffusion layer of about 0,15 to about 0,30 mm.
  • a compound or white layer such as a gas nitrided dies or CrN coated dies yielding repectively a nitride layer or Cr-N hard coating
  • the extruded part 10 may be cooled after it has left the die 3, either by natural cooling in the environment or through the use of air or water quenches, to ensure that the desired metallurgical properties are obtained after aging.
  • the device of this invention may further preferably comprise a temperature sensor 6 for measuring the temperature of the extruded part 10 which has left the extrusion die 3 and ascertaining that the temperature of the extruded part is maintained in the range of between 500 and 600°C; in particular between 550°C and 595°C.
  • a temperature sensor 6 for measuring the temperature of the extruded part 10 which has left the extrusion die 3 and ascertaining that the temperature of the extruded part is maintained in the range of between 500 and 600°C; in particular between 550°C and 595°C.
  • various devices known to the skilled person may be used, for example an infrared camera.
  • TTT Temperature Time Treatment
  • the present invention further relates to a device for producing an extruded part of an aluminum soft alloy composition as described above, wherein the device may comprises an art known heating device 11 (such as a heating coil surrounding the container) for heating the container and maintaining the typically preheated and softened aluminum soft alloy at its elevated temperature, a pusher for pushing the softened alloy into an extrusion die for extruding the alloy into a desired shape, a device for supplying an inert gas at the exit of the die, a device for measuring the temperature of the extruded part which has left the extrusion die, and controlling the temperature of the extruded part in the range of between 500 and 600°C; in particular between 550°C and 595°C.
  • an art known heating device 11 such as a heating coil surrounding the container
  • a pusher for pushing the softened alloy into an extrusion die for extruding the alloy into a desired shape
  • a device for supplying an inert gas at the exit of the die a device for measuring the temperature of the ex
  • Table 1 provides a comparison between extrusion testruns of a series of tested alloys (Table 1A) including a primary classic aluminum soft alloy (Alloy 1) with two typical recyclefriendly soft alloys (Alloy 2 & 3) used in the method according to the invention.
  • Table 1B For each material two testrun conditions (Table 1B) were compared, respectively applying on the one hand temperature control according to the method of the present invention and on the other hand omitting this temperature control during the extrusion process.
  • Three parameters were monitored during these runs. Two of them relating to surface problems causing the production to stop either immediately (Direct Surface Problems) or before the target volume for surface problems is reached (Indirect Surface Problems).
  • the last parameter is the average ram speed that can be maintained without affecting the quality of the extruded aluminum soft alloy.
  • Billets were pressed through a die cavity as schematically shown in Figure 2 , comprising dies (3) having a Nitride layer with the following characteristics; - a compound layer or white layer of min 5 ⁇ m, preferably 8 ⁇ m; and - a diffusion layer of 0,15 mm preferably 0,30 mm.
  • the maximal exit temperature of the extruded profiles was determined after shrouding with liquid nitrogen at 1 m from die exit (Max. Ex.Temp. )
  • Extrusion conditions were the same as above, briefly billets were pressed with an average ram speed of 8 mm/sec through a die cavity as schematically shown in Figure 2 , comprising dies (3) having a Nitride layer with the following characteristics; - a compound layer or white layer of min 5 ⁇ m, preferably 8 ⁇ m; and - a diffusion layer of 0,15 mm preferably 0,30 mm.
  • AASS Acetic Acid Salt Spray test

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Extrusion Of Metal (AREA)
  • Powder Metallurgy (AREA)
EP21731160.4A 2020-06-15 2021-06-09 Reliable high extrusion rate production method for high corrosion resistance powdercoated recycle friendly aluminum soft alloys Active EP3986629B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP20180037 2020-06-15
EP2021051078 2021-01-19
PCT/EP2021/065484 WO2021254852A1 (en) 2020-06-15 2021-06-09 Reliable high extrusion rate production method for high corrosion resistance powdercoated recycle friendly aluminum soft alloys

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EP3986629A1 EP3986629A1 (en) 2022-04-27
EP3986629C0 EP3986629C0 (en) 2023-07-05
EP3986629B1 true EP3986629B1 (en) 2023-07-05

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EP21731160.4A Active EP3986629B1 (en) 2020-06-15 2021-06-09 Reliable high extrusion rate production method for high corrosion resistance powdercoated recycle friendly aluminum soft alloys

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EP (1) EP3986629B1 (pl)
ES (1) ES2954874T3 (pl)
HU (1) HUE062548T2 (pl)
PL (1) PL3986629T3 (pl)
WO (1) WO2021254852A1 (pl)

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3594133A (en) 1967-11-03 1971-07-20 Alcan Res & Dev Aluminum alloy
WO1998042884A1 (en) 1997-03-21 1998-10-01 Alcan International Limited Al-Mg-Si ALLOY WITH GOOD EXTRUSION PROPERTIES
JPH10306336A (ja) * 1997-05-01 1998-11-17 Sumitomo Light Metal Ind Ltd 陽極酸化処理後の表面光沢性に優れたアルミニウム合金押出材およびその製造方法
JP3776622B2 (ja) * 1999-03-25 2006-05-17 株式会社神戸製鋼所 押出急冷時の製品温度制御方法
NO20034731D0 (no) * 2003-10-22 2003-10-22 Norsk Hydro As Aluminiumslegering
KR101329555B1 (ko) * 2012-06-05 2013-11-14 주식회사 코레스 압출성형장치 및 그 제어방법
WO2017093304A1 (en) 2015-12-02 2017-06-08 Norsk Hydro Asa Aluminium extrusion alloy suitable for etched and anodized components

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EP3986629A1 (en) 2022-04-27
WO2021254852A1 (en) 2021-12-23
HUE062548T2 (hu) 2023-11-28
PL3986629T3 (pl) 2023-10-23
EP3986629C0 (en) 2023-07-05
ES2954874T3 (es) 2023-11-27

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