Defence Aluminium – Plate Products - Aleris

Defence Aluminium

Contents
Defence Aluminium
... Solutions from Aleris 3
... Plate Products 4
... Extruded Products 11
... Component Manufacturing
Customer Engineering Support ort
13
Research and Development
Quality Assurance
14 14
Approvals – Our Brand is Quality ality 15
Pictures used by courtesy of
General Dynamics European Land Systems - Germany
GmbH, Krauss - Maffei Wegmann GmbH &
Co. KG, Textron Marine and Land Systems, BAE
Systems, Hyundai Rotem Company, Doosan DST
Co., Ltd. and CEFA (France).
2
Defence Aluminium

Defence Solutions from Aleris
Aleris with its European headquarter in
Switzerland is among the world’s heading
suppliers of high-quality aluminium
rolled and extruded products, aluminium
recycling manufacturing top-quality cast,
wrought and magnesium alloys, as well
as custom-made components for the
defence industry.
As a result of more than fi ve decades
of experience and knowledge, gained
by being the principal supplier to many
industries, and continuous investment
in state-of-the-art production facilities,
research and development, quality assurance,
as well as ongoing education
and training of employees, Aleris products
are continuously improved.
This continuous improvement has enabled
Aleris, via defence specialized plants in
Koblenz, Bonn (both in Germany) and
Duffel (Belgium), to supply the international
defence industry with innovative
aluminium materials and components
of the highest quality, which fulfi l, not
only the highest industry standards but
also all conceivable individual customer
specifi cations with respect to their di-
mensions, properties and quality characteristics.
Aleris’ know-how has been applied in developing
niche products of various alloys
– like thick and extremely wide defence
aluminium plates or sections in customized
sizes and large extruded products,
as well as custom-made components –
which fully satisfy the requirements of
the worldwide defence industry.
A comprehensive quality management
system has been established for all speci-
fi ed material properties, continually con-
trolled and documented during the entire
fabrication processes, which guarantees
that the most stringent requirements of
both customers and governmental in-
stitutions worldwide are complied with.
It ensures highly consistent quality and
helps to continuously improve the product
quality.
If you need further data or more urgent
assistance, please contact us
using the information provided at the
back of this brochure or simply visit
our website at www.aleris.com.
Defence Aluminium 3

Defence Aluminium – Plate Products
Alloys and specifi cations
Aleris in Europe with its two entities Aleris
Aluminum Koblenz GmbH in Germany
and Aleris Aluminum Duffel BVBA
in Belgium operates two world-class
rolling mills with unique manufacturing
capabilities for fl at rolled semi-fi nished
products for e.g. the automotive, aerospace
and defence industry.
Traditionally, the aluminium alloys used
for armoured vehicles and other military
related applications are high strength,
heat-treatable 2xxx and 7xxx series alloys
but also low-density and cost effi
cient 5xxx series alloys with excellent
ballistic properties, good weldability and
outstanding corrosion resistance.
As part of Aleris’ strategic plan to de-
velop new aluminium plate materials and
solutions for armoured vehicles with the
highest property performance in extreme
dimensions – in particular with respect
to thickness and width – various development
projects, investment programs
as well as other activities have been
carried out, enabling Aleris (especially
the Koblenz plant) to become one of the
most important suppliers of aluminium
armour plate products into the world’s
defence industry.
4
Defence Aluminium
Aleris’ aluminium plates offer an optimum
solution for any kind of structural
application – with specifi c ballistic per-
formance, if required. They allow the
design of light-weight, reliable and cost
effi cient components for light armoured
civilian and tactical vehicles as well as
for heavy constructions like military
bridges. They improve strategic and
tactical mobility of defence components
e.g. by transport aircraft into combat or
disaster relief which gives aluminium a
comparative advantage over steel.
Aluminium armour plates with ballistic
requirements are being tested at certifi
ed testing laboratories such as BWB
(Germany), TNO (The Netherlands) or
APG (USA) with consideration of na-
tional and international regulations and
standards.
Aleris supplies defence aluminium plate
products based on the following alloys
and tempers according to the various
relevant material specifi cations:
With ballistic requirements
Alloy* Temper Specifi cation
AA 5083 H131 MIL-DTL-46027
EN AW 5083 TL 2350-0004
AA 5059 H131 MIL-DTL-46027
EN AW 5059
Alustar
TL 2350-0004
®
AA 5059 H136 MIL-DTL-46027
Alustar ®
AA 2519 T87 MIL-DTL-46192
AA 7017 T6 TL 2350-0004
EN AW 7020 T6 TL 2350-0004
AA 7039 T6 MIL-DTL-46063
* Other alloys on request
Without ballistic requirements
Alloy* Temper Specifi cation
AA 5456 H116 ASTM
AA 2024 O ASTM
AA 6061 T6 AMS-QQ-A
EN AW 6061 EN 485-2
EN AW 7020 T6 EN 485-2
EN AW 7022 T6 EN 485-2
* Other alloys on request

Basic material properties
In the following tables Aleris aluminium
armour plates with ballistic requirements
are characterized in detail and compared
to minimum values specifi ed in TL and
MIL standards.
Physical properties
Additionally, typical mechanical properties
after fusions welding and friction stir
welding (FSW) demonstrate the advantage
of Aleris the Alustar ® alloy in a cost
effi cient manufacturing process.
Chemical composition
Alloy* Chemical elements Other Other
Si Fe Cu Mn Mg Cr Zn Ti Zr V Individual Total
5083 Min. weight (%) 0.00 0.00 0.00 0.40 4.0 0.05 0.00 0.00 - - 0.00 0.00
Max. weight (%) 0.40 0.40 0.10 1.0 4.9 0.25 0.25 0.15 - - 0.05 0.15
5059 Min. weight (%) 0.00 0.00 0.00 0.6 5.0 0.00 0.4 0.00 0.05 - 0.00 0.00
Alustar ® Max. weight (%) 0.45 0.5 0.25 1.2 6.0 0.25 0.9 0.2 0.25 - 0.05 0.15
2519 Min. weight (%) 0.00 0.00 5.3 0.10 0.05 - 0.00 0.02 0.10 0.05 0.00 0.00
Max. weight (%) 0.25 0.30 6.4 0.50 0.40 - 0.10 0.10 0.25 0.15 0.05 0.15
7017** Min. weight (%) 0.00 0.00 0.10 0.10 1.7 0.00 4.0 0.00 0.10 - 0.00 0.00
Max. weight (%) 0.30 0.40 0.20 0.70 3.3 0.25 6.0 0.15 0.25 - 0.05 0.15
7020** Min. weight (%) 0.00 0.00 0.00 0.05 1.0 0.10 4.0 0.08 - 0.00 0.00
Max. weight (%) 0.35 0.40 0.20 0.50 1.4 0.35 5.0 0.20 - 0.05 0.15
7039 Min. weight (%) 0.00 0.00 0.00 0.10 2.3 0.15 3.5 0.00 - - 0.00 0.00
Max. weight (%) 0.30 0.40 0.10 0.40 3.3 0.25 4.5 0.10 - - 0.05 0.15
* According to AA or EN AW
** According to TL 2350-0004
Alloy* Density E-Modulus Coeff. of thermal expansion
20-100°C 68-212°F
Thermal conductivity
20°C 68°F
Electrical conductivity
20°C 68°F
g/cm3 lbs/in3 MPa 103 ksi µm/m K µin/in °F W/(m * K) btu/(ft h °F) m/(Ω · mm2 ) %IACS
5083 2.66 0.096 69,200 10.0 24.5 13.6 131 75.7 17 29.3
5059
Alustar
2.64 0.095 70,400 10.2 23.0 12.8 130 75.1 16 27.6
®
2519 2.82 0.102 71,000 10.3 22.0 12.2 140 80.9 19 32.8
7017 2.77 0.100 70,500 10.2 23.3 12.9 130 75.1 21 36,3
7020 2.77 0.100 71,000 10.3 23.1 12.8 137 79.2 20 34,5
7039 2.73 0.099 69,600 10.1 23.4 13.0 125 72.2 19 32,8
* According to AA or EN AW
Defence Aluminium 5

Mechanical performance
Minimum mechanical properties
Alloy Temper Specifi cation* Test
direction
Plate thickness
mm in
Tensile strength Rm MPa ksi
Yield strength Rp0.2 MPa ksi
Elongation A
%
AA 5083 H131 MIL-DTL-46027 L 6.35 - 12.67 0.250 - 0.499 310 45.0 241 35.0 8
(table VI) 12.7 - 50.8 0.500 - 2.000 310 45.0 255 37.0 8
50.83 - 76.2 2.001 - 3.000 303 44.0 241 35.0 9
EN AW 5083 H131 TL 2350-0004 LT 6.35 - 12.67 0.250 - 0.499 311 45.0 242 35.0 8
12.7 - 50.8 0.500 - 2.000 311 45.0 256 37.0 8
50.83 - 76.2 2.001 - 3.000 304 44.0 242 35.0 9
AA 5059 H131 MIL-DTL-46027 L 6.35 - 12.67 0.250 - 0.499 393 57.0 303 44.0 8
Alustar ® (table VI) 12.7 - 50.8 0.500 - 2.000 393 57.0 296 43.0 7
50.83 - 76.2 2.001 - 3.000 344 50.0 289 42.0 8
EN AW 5059 H131
Alustar
TL 2350-0004 LT 6 - 60 0.236 - 2.362 370 54.0 300 44.0 8
®
AA 5059 H136 MIL-DTL-46027 L 6.35 - 12.67 0.250 - 0.499 365 53.0 296 43.0 10
Alustar ® (table VI) 12.7 - 50.8 0.500 - 2.000 358 52.0 289 42.0 10
50.83 - 76.2 2.001 - 3.000 344 50.0 289 42.0 10
AA 2519 T87 MIL-A-46192 L 12.7 - 38.1 0.500 - 1.500 455 66.0 407 59.0 10
(table II) 38.1 - 50.8 1.501 - 2.000 455 66.0 407 59.0 9
50.8 - 76.2 2.001 - 3.000 462 67.0 414 60.0 8
76.2 - 101.6 3.001 - 4.000 469 68.0 421 61.0 7
AA 7017 T6 TL 2350-0004 LT 6 - 50 0.236 - 1.969 430 62.4 360 52.2 8
> 50 - 76 > 1.969 - 2.992 410 59.5 340 49.3 8
> 76 > 2.992 410 59.5 340 49.3 6
EN AW 7020 T6 TL 2350-0004 LT < 25 < 0.984 350 50.8 280 40.6 10
> 25 - 60 > 0.984 - 2.362 340 49.3 275 40.0 8
AA 7039 T6 MIL-DTL-46063 L < 38.1 < 1.5 414 60.0 352 51.0 9
(table II) > 38.1 > 1.5 393 57.0 331 48.0 8
* Mechanical properties according to table VI of MIL-DTL-46027 for standard dimensions up to 60” x 140” (width x length)
For wider plates with dimensions 60” < width < 100” mechanical properties are guaranteed according to MIL-DTL-46027 table II
Other dimensions on request
Minimum and typical mechanical properties
are measured in L-direction
as specifi ed in MIL standards, while
plates produced according to TL standards
are tested in LT direction. Properties
after welding are always measured
across the weld seam, typically
in the LT direction.
6
Defence Aluminium

Typical mechanical properties (based on actual production values)
Alloy* Temper Test
direction
Plate thickness
mm in
Tensile strength Rm MPa ksi
Yield strength Rp0.2 MPa ksi
Elongation A
%
5083 H131 L 6.35 - 12.67 0.250 - 0.499 345 50.0 285 41.3 10
12.7 - 50.8 0.500 - 2.000 330 48.0 275 40.0 10
50.83 - 76.2 2.001 - 3.000 320 46.4 265 38.4 11
5059 H131 L 6.35 - 12.67 0.250 - 0.499 405 58.7 360 52.2 9
Alustar ® 12.7 - 50.8 0.500 - 2.000 395 57.3 350 50.8 9
50.83 - 76.2 2.001 - 3.000 360 52.2 310 45.0 10
5059
Alustar
H131 LT 25.8 1.016 411 59.6 319 46.3 11
®
5059 H136 L 6.35 - 12.67 0.250 - 0.499 375 54.4 310 45.0 12
Alustar ® 12.7 - 50.8 0.500 - 2.000 380 55.0 320 46.4 11
50.83 - 76.2 2.001 - 3.000 355 51.5 295 42.8 12
2519 T87 L 12.7 0.500 484 70.2 455 66.0 12
25.4 1.000 488 70.8 464 67.3 12
38.1 1.500 484 70.2 458 66.4 12
7017 T6 LT > 6 < 50 0.16 - 1.97 445 64.5 385 55.8 11
7020 T6 LT > 4 < 25 0.16 - 0.98 360 52.2 300 43.5 13
> 25 < 60 1 - 2.36 355 51.5 295 42.8 11
7039 T6 L < 38.1 < 1.5 435 63.0 375 54.4 11
> 38.1 > 1.5 425 61.6 355 51.5 10
Typical values after fusion welding
Alloy* Temper Typical
fi ller wire
Typical plate
thickness
Tensile strength Rm Yield strength Rp0.2 alloy* mm in MPa ksi MPa ksi
5083 H131 5183 20 - 30 0.78 - 1.18 275 40.0 125 18.2
5059 H131 5183 20 - 30 0.78 - 1.18 300 43.5 160 23.2
Alustar ® 5556
5059 H136 5183 20 - 30 0.78 - 1.18 300 43.5 160 23.2
Alustar ® 5556
2519 T87 2319 101.1 4 280 40.6 204 29.6
7017 T6 5183
5356/5556
25 - 30 1 - 1.18 260 37.7 205 29.7
7020 T6 5183
5356/5556
25 - 30 1 - 1.18 275 40.0 205 29.7
7039 T6 5183
5356/5556
25 - 30 1 - 1.18 310 45.0 175 25.4
for comparison:
6061 T6 4043
5183
< 30 < 1.18 185 26.8 115 16.7
* According to AA or EN AW
All values are measured across the weld seam and rolling direction (LT-direction)
after friction stir welding (FSW)
Tensile strength R m
Yield strength R p0.2
MPa ksi MPa ksi
285 41.3 162 23.5
340 49.3 180 26.1
340 49.3 180 26.1
** ** ** **
** ** ** **
325 47.1 240 34.8
** ** ** **
252 36.5 162 23.5
** To be determined
Defence Aluminium 7

Ballistic performance
The following Milne de Marre graphs have
been generated to offer a design guide
to engineers and designers of armoured
vehicles, as well as to demonstrate the
ballistic performance and weight effi -
ciency of most commonly used Aleris
armour plate alloys.
They allow a simple estimation of the
weight of an aluminium plate under con-
sideration of the ballistic performance ac-
cording to the appropriate MIL standard
and the individual alloy density.
Milne de Marre graph for armour plate materials (according to MIL)
Projectile .30AP M2 0°
V 50 limit velocity
[m/s] [ft/s]
950 3,117
900 2,953
850 2,789
800 Example:
V = 800 m/s (2,625 ft/s)
50
2,625
750 Result:
2,461
Arial density = 115 kg/m2 (23.6 lb/ft2 )
700 2,297
650 2,133
70 80 90 100 110 120 130 140
(14.3) (16.4) (18.4) (20.5) (22.5) (24.6) (26.6) (28.7)
Projectile 20 mm FSP
V 50 limit velocity
[m/s] [ft/s]
950 3,117
850 2,789
750 2,461
650 2,133
550 1,804
450 1,476
350 1,148
70 80 90 100 110
(14.3) (16.4) (18.4) (20.5) (22.5)
Areal density [kg/m 2 (lb/ft 2 )] Areal density [kg/m 2 (lb/ft 2 )]
AA 2519 AA 5059 Alustar AA 2519
® AA 5059 Alustar ®
AA 7039 AA 7039
How to use the graph:
Requirement V 50 : 800 m/s 2,625 ft/s
Arial density AA 5059 Alustar ® : 115 kg/m 2 23.6 lb/ft 2
Assumed plate dimension: t x 2,000 x 3,000 mm t x 78.7 x 118.1 in
Assumed plate weight: 690 kg 1,521 lb
8
Defence Aluminium

Corrosion performance
The Aleris Alustar ® alloy was originally
developed for the challenging corrosion
requirements of the international ship-
building industry. Alustar ® has been
further developed to make it applicable
to the defence industry, where corrosion
performance is an essential operational
requirement.
Natural sea water test
Alloy* Temper Thickness
mm in
Test time
month
MIG welded
with fi ller alloy
Remarks
5059 H136 12.7 0.5 14 5183 insignifi cant attack on the water line, no visible attack on the weld seam
Alustar ® insignifi cant attack in the Heat Affected Zone (HAZ), pitting on the surface
2519 T87 13 0.51 3 2319 corrosion on the rolled surface, insignifi cant attack on the weld seam and in the HAZ
* According to AA or EN AW
AA 5059 H136
front side (fi nal weld pass)
For example, not only for amphibious
vehicles but also for other armoured
vehicles in corrosive environments due
to chemical / biological exposure or the
extreme environment conditions seen
through operational deployment throughout
the life time of such vehicles.
AA 5059 H136
back side (root pass)
Welded samples of AA 5059 and AA 2519 after natural sea water corrosion test
AA 2519 T87
front side (fi nal weld pass)
Today’s economic expectations are leading
to extended life cycles for current and
future military platforms requiring new
materials like Alustar ® with outstand-
ing corrosion resistance and excellent
ballistic protection.
AA 2519 T87
back side (root pass)
Defence Aluminium 9

Advantages
Based on Aleris’ unique manufacturing
technologies, such as the world’s most
powerful 160’’ (4,064 mm) wide hot rolling
mill and the 8,000 tons stretcher,
high performance plate products with
extraordinary dimensions can be produced,
leaving nothing to be desired.
All dimensional requirements in terms
of thickness covered by the relevant TL
Characteristics of aluminium armour alloys
Specifi c manufacturing capabilities
and MIL specifi cations can be fulfi lled
as a minimum. Moreover, armour plates
in extreme widths can be provided to
reduce the number of weld seams in a
cost effi cient manufacturing process –
a key manufacturing cost and design
integrity advantage.
Through Alustar ® Aleris offers the broadest
range and maximizes design fl exibility.
Alloy* Temper Specifi ed
thickness (MIL)
Specifi ed
thickness (TL)
Produced
thickness
Produced width
mm in mm in mm in mm in
5083 H131 76.2 3 76.2 3 76.2 3 2,540 100
5059
Alustar
H131 76.2 3 60 2.36 76.2 3 2,921 115
®
5059
Alustar
H136 76.2 3 - - 152.4** 6** 3,048 120
®
2519 T87 101.6 4 - - 101.6 4 2,032 80
7017 T6 - - 76 ~ 3 76.2 3 2,000 ~ 79
7020 T6 - - 60 2.36 60 2.36 2,870 ~ 113
7039 T6 101.6 4 - - 101.6 4 2,108 83
* According to AA or EN AW
** Without ballistic requirements; other dimensions on request
General dimensional
capabilities for armour plate*
mm in
Thickness up to 254 10
Width up to 3,300 130
Length up to 24,000 945
* Subject to alloy, temper and
thickness x width combination
Larger dimensions on request
Alloy* Temper Corrosion Weldability Ballistic requirements Spalling Mine Blast
resistance according to MIL standards
.30 AP M2 0° 20 mm FSP
5083 H131
5059 Alustar
not suitable excellent
® H131
5059 Alustar ® H136
2519 T87
7017 T6
7020 T6
7039 T6
* According to AA or EN AW
10
Defence Aluminium
Conclusion
Aleris offers a large variety of armour
plate materials for ballistic protection.
The product portfolio comprises high
strength, heat-treatable 2xxx and 7xxx
series alloys but also 5xxx series alloys,
such as Alustar ® with low density, excel-
lent weldability and corrosion resistance.
At the same time the ballistic protection
is comparable to the best performing
high strength alloys used in the industry
today.

Defence Aluminium – Extruded Products
Alloys and capabilities
Aleris in Europe operates a number of
extrusion plants, two of which are dedicated
to the manufacturing of high performance
extruded rod, bars and shapes
for the defence industry.
The extrusion plants Aleris Aluminum
Bonn GmbH (Germany) and Aleris Aluminum
Duffel BVBA (Belgium) are equipped
with sophisticated production equipment
utilizing all the necessary machinery for
the production of approved defence extruded
products.
In order to produce small, medium size,
wide and heavy extrusions, either as
open or hollow sections out of 5xxx, 6xxx
and 7xxx series alloys, various extrusion
presses are operating in direct or indirect
mode up to 90 MN.
Defence extrusion alloys*
2618A 6005A 7003 7022
5049 6060 7010 7049
5059 Alustar ® 6061 7020 7075
5083 6082 7021 7175
* According to AA or EN AW
All alloys are subject to profi le size and geometry
Other alloys on request
Weight of compact solids
Alloy mm in mm in mm in mm in mm in
du 40 1.57 60 2.36 89 3.50 225 8.86 560 22.05
2xxx / 5xxx / 7xxx Min. weight (kg/m; lbs/ft) 1.0 0.67 1.5 1.01 2.4 1.61 11.8 7.93 26.6 17.87
Max. weight (kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2
6xxx Min. weight (kg/m; lbs/ft) 0.6 0.40 1.0 0.67 1.5 1.01 7.6 5.11 10.0 6.72
Max. weight (kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2
High strength alloys are heat-treated in
one of the most modern horizontal solution-heat-treatment
furnaces, built by
Ebner with an annual capacity of about
4,900 tons. Based on a highly sophisticated
quenching system, as well as a
800 tons-stretcher for straightening and
stress relieving – Aleris’ new equipment
allows the production of complex shapes
with nearly no distortion. It increases
Aleris’ production capacity to a larger
range of sizes and shapes and brings
Aleris’ process capability to a higher
level for the entire product range.
Weight of wide compact solids
W
Alloy mm in mm in mm in mm in mm in
W x H 120 x 70 4.72 x 2.76 150 x 30 5.91 x 1.18 194 x 30 7.64 x 1.18 700 x 120 27.56 x 4.72 700 x 180 27.56 x 7.09
730 x 120 28.74 x 4.72
750 x 60 29.53 x 2.36
2xxx / 5xxx Min. weight
7xxx (kg/m; lbs/ft)
Max. weight
5.9 3.96 3.8 2.55 5.9 3.96 26.6 17.87 - -
(kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2 350.0 235.2
6xxx Min. weight
(kg/m; lbs/ft) 3.8
Max. weight
2.55 2.5 1.68 3.8 2.55 10.0 6.72 10.0 6.72
(kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2 350.0 235.2
d u
H
Defence Aluminium 11

Design guidelines
Minimum wall thickness of extruded hollows
Alloy* mm in mm in mm in mm in mm in
du < 100 < 3.94 < 200 < 7.87 < 300 < 11.81 < 400 < 15.75 < 490 < 19.29
5083 / 5049** 5.0 0.20 5.5 0.22 6.5 0.26 7.5 0.30 8.0 0.31
6060 / 6005A 1.0 - 1.5 0.04 - 0.06 2.5 0.10 3.5 0.14 4.5 0.18 5.0 0.20
6082 / 6061 2.5 0.10 3.0 0.12 4.0 0.16 5.0 0.20 6.0 0.24
7020 / 7021 / 7003 3.5 0.14 4.0 0.16 4.5 0.18 5.5 0.22 6.5 0.26
** The aluminium extruded hollows can only be manufactured by mandrel (no porthole or bridge dies)
Minimum wall thickness of open extrusions
Alloy* mm in mm in mm in mm in mm in mm in
du < 100 < 3.94 < 200 < 7.87 < 300 < 11.81 < 400 < 15.75 < 500 < 19.69 < 540 < 21.26
5083 / 5049 5.0 0.20 5.5 0.22 6.0 0.24 7.0 0.28 7.0 0.28 8.0 0.31
6060 / 6005A 1.0 - 1.5 0.04 - 0.06 2.0 0.08 3.0 0.12 4.0 0.16 4.5 0.18 5.0 0.20
6082 / 6061 1.8 0.07 2.5 0.10 3.5 0.14 4.5 0.18 5.5 0.22 7.0 0.28
7020 / 7021 / 7003 3.5 0.14 4.0 0.16 4.5 0.18 5.0 0.20 6.0 0.24 7.0 0.28
Minimum wall thickness of wide extruded hollows
Alloy* mm in mm in mm in
W x H 500 x 150 19.69 x 5.91 550 x 200 21.65 x 7.87 720 x 30 28.35 x 1.18
700 x 60 27.56 x 2.36
5083 / 5049 - - - - - -
6060 / 6005A 4.5 0.18 3.0 0.12 3.0 0.12
6082 / 6061 5.0 0.20 4.5 0.18 4.0 0.16
7020 / 7021 / 7003 6.0 0.24 5.5 0.22 5.0 0.20
Minimum wall thickness of wide open extrusions
Alloy* mm in mm in mm in
W x H 500 x 150 19.69 x 5.91 550 x 200 21.65 x 7.87 720 x 30 28.35 x 1.18
700 x 60 27.56 x 2.36
5083 / 5049 7.0 0.28 7.0 0.28 7.0 0.28
6060 / 6005A 3.5 0.14 3.0 0.12 2.8 0.11
6082 / 6061 4.5 0.18 4.0 0.16 3.0 0.12
7020 / 7021 / 7003 6.0 0.24 5.5 0.22 4.5 0.18
* Other alloys on request
Individual sections and specifi c designs on request
12
Defence Aluminium
W
W
d u
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H
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Defence Aluminium – Component Manufacturing
Aleris Aluminum Bonn GmbH is spe-
cialized in large extrusions and project
business. With Europe’s most modern
large 90MN extrusion press and extra
long run-out length the plant in Bonn is
well prepared to cope with the demands
coming from general engineering, electrical
power supply and distribution, railway,
waterway, road transport, and the
aircraft and defence industries.
Aleris’ key to success is to support the
OEMs with expertise and engineering
know-how in extrusions and components
manufacturing as part of the product
development with professional project
handling.
On-site aluminium welding facilities and
machining equipment are designed to
handle heavy duty profi les and over-
sized modular assemblies. Customers
appreciate a single point of contact before,
during and after the projects and
the ability to receive all goods from a
single partner.
Welding of assemblies
The applied welding processes are: MIG
for automated and MIG / TIG for manual
welding. The equipment for the auto-
mated welding of long panels like fl oors,
roofs, bulkheads, hulls, ramps, etc. has
a range of 26,000 x 3,600 mm.
Machining and milling
Aleris Bonn has two high performance
cutting CNC Machining Centers designed
for milling of tailor-made aluminium sections,
in particular for:
single main extrusions
for structural parts
welded subassemblies e.g.
fl oor plates, roofs, bulkheads, hulls.
Machine specifi cations
Type Axes Working area
Fooke 1 5 30,000 x 4,200 x 1,500 mm
(~ 1,180 x 166 x 59 in)
Fooke 2 5 25,000 x 4,000 x 1,250 mm
(~ 984 x 157 x 49 in)
Defence Aluminium 13

Customer Engineering Support
Research and Development
Customer Engineering Support
It is one of our strategic goals not only
to supply material to our customers but
also to provide them with comprehensive
engineering support. Our team of
Product Engineers and Process Specialists
will take any challenge to develop
together with our customers new
technologies and processes to improve
their products. They are the technological
link between customer demand and
our production capabilities.
The customer engineering team gives
support by technical consulting, product
and material training, problem solving in
their special fi eld of application as well
as service on the basis of experience
gained in different global industries.
Aleris metallurgical knowledge enables
the transfer of customer’s requirements,
specifi c applications and newly defi ned
properties into metallurgical fabrication
practices for both standard and new
products.
14
Defence Aluminium
Research and Development – Our New
Product and Technology Pipeline
Research and development is a collective
exercise and is based on a close
cooperation between R&D teams in our
customers, our plants and external parties,
e.g. a strategic cooperation with a
partner laboratory located in IJmuiden
(The Netherlands), which acts as a central
research facility for fundamental work,
with excellent facilities and highly qualifi
ed, motivated researchers.
The R&D activities focus on the devel-
opment of innovative technologies to
improve both processes and products
to exceed today’s and to shape tomorrow’s
requirements.
Areas of research:
alloy and technology development
casting technology
hot and cold rolling technology
optimization of heat treatment
processes
numerical and physical modelling
of processes and product
performance
NDT-technology
corrosion and surface technology
forming technology
welding technology
(e.g. LBW, FSW)
other joining techniques
(brazing, adhesive bonding,
mechanical joining)
high speed machining
product design support and
numerical simulation in close
cooperation with OEMs.

Quality Assurance
Approvals – Our Brand is Quality
The quality concept is an essential element
of the company policy. Its objectives
are a continuous improvement in the
quality of Aleris’ products and services
to fulfi l all customer requirements. The
quality principles are formulated by the
company management, implemented
and known on all levels and by all employees
within the corporation.
To ensure these quality principles, a
documented quality system has been
implemented. The fi rst quality manual
was established in 1979 based on the
Aleris Aluminum Koblenz GmbH
Defence related
BWB according to TL 2350-0004
Non defence related
DIN EN ISO 9001
ISO/TS 16949
Environment
DIN EN ISO 14001
Ballistic testing
Bundeswehr, Wehrtechnische
Dienststelle für Waffen und
Munition, Germany
TNO Prins Maurits Laboratory,
The Netherlands
U.S. Army Aberdeen Test
Center (APG), USA
requirements set by the aerospace in-
dustry. Since then the quality system
has been continuously up-dated and
expanded in scope.
Process control ensures that production
takes place under controlled conditions.
Quality inspections are regularly carried
out in various production facilities.
In-house laboratories with state-of-the-
art equipment control proper compo-
sition of alloys and their mechanical
performance.
Aleris Aluminum Bonn GmbH
Defence related
DIN 2303 Q2
Non defence related
DIN EN ISO 9001
ISO/TS 16949
DGR 97/23/EG
DIN EN 15085 CL 1
DIN V 4113-3
Environment
DIN EN ISO 14001
Certifi ed external testing laboratories
conduct ballistic testing of armour plates
according to national and international
standards and specifi cations.
The quality philosophy means “zero
defects”. The quality system takes into
account the customers continuously
rising requirements and specifi c quality
standards as well as legislative and
regulatory measures which may have
an additional effect.
Aleris Aluminum Duffel BVBA
Non defence related
EN ISO 9001
ISO/TS 16949
Environment
EN ISO 14001
Defence Aluminium 15

www.aleris.com
Aleris
European Headquarter
Aleris Switzerland GmbH
Balz Zimmermann-Straße 7
8058 Zurich Airport · Switzerland
T +41 44 828 1400
Care has been taken to ensure that this information is
accurate, but Aleris, including its subsidiaries, does not
accept responsibility or liability for errors or information
which is found to be misleading.
Defence Department
Aleris Aluminum Koblenz GmbH
Carl-Spaeter-Straße 10
56070 Koblenz · Germany
T +49 (0) 261 891 7479
Contact: T +49 (0) 261 891 7545 · info.europe@aleris.com · www.aleris.com © 2010, Aleris Switzerland GmbH
Issue 10/10 · 3rd release