Defence Aluminium – Plate Products - Aleris
Defence Aluminium – Plate Products - Aleris
Defence Aluminium – Plate Products - Aleris
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<strong>Defence</strong> <strong>Aluminium</strong>
Contents<br />
<strong>Defence</strong> <strong>Aluminium</strong><br />
... Solutions from <strong>Aleris</strong> 3<br />
... <strong>Plate</strong> <strong>Products</strong> 4<br />
... Extruded <strong>Products</strong> 11<br />
... Component Manufacturing<br />
Customer Engineering Support ort<br />
13<br />
Research and Development<br />
Quality Assurance<br />
14 14<br />
Approvals <strong>–</strong> Our Brand is Quality ality 15<br />
Pictures used by courtesy of<br />
General Dynamics European Land Systems - Germany<br />
GmbH, Krauss - Maffei Wegmann GmbH &<br />
Co. KG, Textron Marine and Land Systems, BAE<br />
Systems, Hyundai Rotem Company, Doosan DST<br />
Co., Ltd. and CEFA (France).<br />
2<br />
<strong>Defence</strong> <strong>Aluminium</strong>
<strong>Defence</strong> Solutions from <strong>Aleris</strong><br />
<strong>Aleris</strong> with its European headquarter in<br />
Switzerland is among the world’s heading<br />
suppliers of high-quality aluminium<br />
rolled and extruded products, aluminium<br />
recycling manufacturing top-quality cast,<br />
wrought and magnesium alloys, as well<br />
as custom-made components for the<br />
defence industry.<br />
As a result of more than fi ve decades<br />
of experience and knowledge, gained<br />
by being the principal supplier to many<br />
industries, and continuous investment<br />
in state-of-the-art production facilities,<br />
research and development, quality assurance,<br />
as well as ongoing education<br />
and training of employees, <strong>Aleris</strong> products<br />
are continuously improved.<br />
This continuous improvement has enabled<br />
<strong>Aleris</strong>, via defence specialized plants in<br />
Koblenz, Bonn (both in Germany) and<br />
Duffel (Belgium), to supply the international<br />
defence industry with innovative<br />
aluminium materials and components<br />
of the highest quality, which fulfi l, not<br />
only the highest industry standards but<br />
also all conceivable individual customer<br />
specifi cations with respect to their di-<br />
mensions, properties and quality characteristics.<br />
<strong>Aleris</strong>’ know-how has been applied in developing<br />
niche products of various alloys<br />
<strong>–</strong> like thick and extremely wide defence<br />
aluminium plates or sections in customized<br />
sizes and large extruded products,<br />
as well as custom-made components <strong>–</strong><br />
which fully satisfy the requirements of<br />
the worldwide defence industry.<br />
A comprehensive quality management<br />
system has been established for all speci-<br />
fi ed material properties, continually con-<br />
trolled and documented during the entire<br />
fabrication processes, which guarantees<br />
that the most stringent requirements of<br />
both customers and governmental in-<br />
stitutions worldwide are complied with.<br />
It ensures highly consistent quality and<br />
helps to continuously improve the product<br />
quality.<br />
If you need further data or more urgent<br />
assistance, please contact us<br />
using the information provided at the<br />
back of this brochure or simply visit<br />
our website at www.aleris.com.<br />
<strong>Defence</strong> <strong>Aluminium</strong> 3
<strong>Defence</strong> <strong>Aluminium</strong> <strong>–</strong> <strong>Plate</strong> <strong>Products</strong><br />
Alloys and specifi cations<br />
<strong>Aleris</strong> in Europe with its two entities <strong>Aleris</strong><br />
Aluminum Koblenz GmbH in Germany<br />
and <strong>Aleris</strong> Aluminum Duffel BVBA<br />
in Belgium operates two world-class<br />
rolling mills with unique manufacturing<br />
capabilities for fl at rolled semi-fi nished<br />
products for e.g. the automotive, aerospace<br />
and defence industry.<br />
Traditionally, the aluminium alloys used<br />
for armoured vehicles and other military<br />
related applications are high strength,<br />
heat-treatable 2xxx and 7xxx series alloys<br />
but also low-density and cost effi<br />
cient 5xxx series alloys with excellent<br />
ballistic properties, good weldability and<br />
outstanding corrosion resistance.<br />
As part of <strong>Aleris</strong>’ strategic plan to de-<br />
velop new aluminium plate materials and<br />
solutions for armoured vehicles with the<br />
highest property performance in extreme<br />
dimensions <strong>–</strong> in particular with respect<br />
to thickness and width <strong>–</strong> various development<br />
projects, investment programs<br />
as well as other activities have been<br />
carried out, enabling <strong>Aleris</strong> (especially<br />
the Koblenz plant) to become one of the<br />
most important suppliers of aluminium<br />
armour plate products into the world’s<br />
defence industry.<br />
4<br />
<strong>Defence</strong> <strong>Aluminium</strong><br />
<strong>Aleris</strong>’ aluminium plates offer an optimum<br />
solution for any kind of structural<br />
application <strong>–</strong> with specifi c ballistic per-<br />
formance, if required. They allow the<br />
design of light-weight, reliable and cost<br />
effi cient components for light armoured<br />
civilian and tactical vehicles as well as<br />
for heavy constructions like military<br />
bridges. They improve strategic and<br />
tactical mobility of defence components<br />
e.g. by transport aircraft into combat or<br />
disaster relief which gives aluminium a<br />
comparative advantage over steel.<br />
<strong>Aluminium</strong> armour plates with ballistic<br />
requirements are being tested at certifi<br />
ed testing laboratories such as BWB<br />
(Germany), TNO (The Netherlands) or<br />
APG (USA) with consideration of na-<br />
tional and international regulations and<br />
standards.<br />
<strong>Aleris</strong> supplies defence aluminium plate<br />
products based on the following alloys<br />
and tempers according to the various<br />
relevant material specifi cations:<br />
With ballistic requirements<br />
Alloy* Temper Specifi cation<br />
AA 5083 H131 MIL-DTL-46027<br />
EN AW 5083 TL 2350-0004<br />
AA 5059 H131 MIL-DTL-46027<br />
EN AW 5059<br />
Alustar<br />
TL 2350-0004<br />
®<br />
AA 5059 H136 MIL-DTL-46027<br />
Alustar ®<br />
AA 2519 T87 MIL-DTL-46192<br />
AA 7017 T6 TL 2350-0004<br />
EN AW 7020 T6 TL 2350-0004<br />
AA 7039 T6 MIL-DTL-46063<br />
* Other alloys on request<br />
Without ballistic requirements<br />
Alloy* Temper Specifi cation<br />
AA 5456 H116 ASTM<br />
AA 2024 O ASTM<br />
AA 6061 T6 AMS-QQ-A<br />
EN AW 6061 EN 485-2<br />
EN AW 7020 T6 EN 485-2<br />
EN AW 7022 T6 EN 485-2<br />
* Other alloys on request
Basic material properties<br />
In the following tables <strong>Aleris</strong> aluminium<br />
armour plates with ballistic requirements<br />
are characterized in detail and compared<br />
to minimum values specifi ed in TL and<br />
MIL standards.<br />
Physical properties<br />
Additionally, typical mechanical properties<br />
after fusions welding and friction stir<br />
welding (FSW) demonstrate the advantage<br />
of <strong>Aleris</strong> the Alustar ® alloy in a cost<br />
effi cient manufacturing process.<br />
Chemical composition<br />
Alloy* Chemical elements Other Other<br />
Si Fe Cu Mn Mg Cr Zn Ti Zr V Individual Total<br />
5083 Min. weight (%) 0.00 0.00 0.00 0.40 4.0 0.05 0.00 0.00 - - 0.00 0.00<br />
Max. weight (%) 0.40 0.40 0.10 1.0 4.9 0.25 0.25 0.15 - - 0.05 0.15<br />
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<br />
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<br />
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<br />
Max. weight (%) 0.25 0.30 6.4 0.50 0.40 - 0.10 0.10 0.25 0.15 0.05 0.15<br />
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<br />
Max. weight (%) 0.30 0.40 0.20 0.70 3.3 0.25 6.0 0.15 0.25 - 0.05 0.15<br />
7020** Min. weight (%) 0.00 0.00 0.00 0.05 1.0 0.10 4.0 0.08 - 0.00 0.00<br />
Max. weight (%) 0.35 0.40 0.20 0.50 1.4 0.35 5.0 0.20 - 0.05 0.15<br />
7039 Min. weight (%) 0.00 0.00 0.00 0.10 2.3 0.15 3.5 0.00 - - 0.00 0.00<br />
Max. weight (%) 0.30 0.40 0.10 0.40 3.3 0.25 4.5 0.10 - - 0.05 0.15<br />
* According to AA or EN AW<br />
** According to TL 2350-0004<br />
Alloy* Density E-Modulus Coeff. of thermal expansion<br />
20-100°C 68-212°F<br />
Thermal conductivity<br />
20°C 68°F<br />
Electrical conductivity<br />
20°C 68°F<br />
g/cm3 lbs/in3 MPa 103 ksi µm/m K µin/in °F W/(m * K) btu/(ft h °F) m/(Ω · mm2 ) %IACS<br />
5083 2.66 0.096 69,200 10.0 24.5 13.6 131 75.7 17 29.3<br />
5059<br />
Alustar<br />
2.64 0.095 70,400 10.2 23.0 12.8 130 75.1 16 27.6<br />
®<br />
2519 2.82 0.102 71,000 10.3 22.0 12.2 140 80.9 19 32.8<br />
7017 2.77 0.100 70,500 10.2 23.3 12.9 130 75.1 21 36,3<br />
7020 2.77 0.100 71,000 10.3 23.1 12.8 137 79.2 20 34,5<br />
7039 2.73 0.099 69,600 10.1 23.4 13.0 125 72.2 19 32,8<br />
* According to AA or EN AW<br />
<strong>Defence</strong> <strong>Aluminium</strong> 5
Mechanical performance<br />
Minimum mechanical properties<br />
Alloy Temper Specifi cation* Test<br />
direction<br />
<strong>Plate</strong> thickness<br />
mm in<br />
Tensile strength Rm MPa ksi<br />
Yield strength Rp0.2 MPa ksi<br />
Elongation A<br />
%<br />
AA 5083 H131 MIL-DTL-46027 L 6.35 - 12.67 0.250 - 0.499 310 45.0 241 35.0 8<br />
(table VI) 12.7 - 50.8 0.500 - 2.000 310 45.0 255 37.0 8<br />
50.83 - 76.2 2.001 - 3.000 303 44.0 241 35.0 9<br />
EN AW 5083 H131 TL 2350-0004 LT 6.35 - 12.67 0.250 - 0.499 311 45.0 242 35.0 8<br />
12.7 - 50.8 0.500 - 2.000 311 45.0 256 37.0 8<br />
50.83 - 76.2 2.001 - 3.000 304 44.0 242 35.0 9<br />
AA 5059 H131 MIL-DTL-46027 L 6.35 - 12.67 0.250 - 0.499 393 57.0 303 44.0 8<br />
Alustar ® (table VI) 12.7 - 50.8 0.500 - 2.000 393 57.0 296 43.0 7<br />
50.83 - 76.2 2.001 - 3.000 344 50.0 289 42.0 8<br />
EN AW 5059 H131<br />
Alustar<br />
TL 2350-0004 LT 6 - 60 0.236 - 2.362 370 54.0 300 44.0 8<br />
®<br />
AA 5059 H136 MIL-DTL-46027 L 6.35 - 12.67 0.250 - 0.499 365 53.0 296 43.0 10<br />
Alustar ® (table VI) 12.7 - 50.8 0.500 - 2.000 358 52.0 289 42.0 10<br />
50.83 - 76.2 2.001 - 3.000 344 50.0 289 42.0 10<br />
AA 2519 T87 MIL-A-46192 L 12.7 - 38.1 0.500 - 1.500 455 66.0 407 59.0 10<br />
(table II) 38.1 - 50.8 1.501 - 2.000 455 66.0 407 59.0 9<br />
50.8 - 76.2 2.001 - 3.000 462 67.0 414 60.0 8<br />
76.2 - 101.6 3.001 - 4.000 469 68.0 421 61.0 7<br />
AA 7017 T6 TL 2350-0004 LT 6 - 50 0.236 - 1.969 430 62.4 360 52.2 8<br />
> 50 - 76 > 1.969 - 2.992 410 59.5 340 49.3 8<br />
> 76 > 2.992 410 59.5 340 49.3 6<br />
EN AW 7020 T6 TL 2350-0004 LT < 25 < 0.984 350 50.8 280 40.6 10<br />
> 25 - 60 > 0.984 - 2.362 340 49.3 275 40.0 8<br />
AA 7039 T6 MIL-DTL-46063 L < 38.1 < 1.5 414 60.0 352 51.0 9<br />
(table II) > 38.1 > 1.5 393 57.0 331 48.0 8<br />
* Mechanical properties according to table VI of MIL-DTL-46027 for standard dimensions up to 60” x 140” (width x length)<br />
For wider plates with dimensions 60” < width < 100” mechanical properties are guaranteed according to MIL-DTL-46027 table II<br />
Other dimensions on request<br />
Minimum and typical mechanical properties<br />
are measured in L-direction<br />
as specifi ed in MIL standards, while<br />
plates produced according to TL standards<br />
are tested in LT direction. Properties<br />
after welding are always measured<br />
across the weld seam, typically<br />
in the LT direction.<br />
6<br />
<strong>Defence</strong> <strong>Aluminium</strong>
Typical mechanical properties (based on actual production values)<br />
Alloy* Temper Test<br />
direction<br />
<strong>Plate</strong> thickness<br />
mm in<br />
Tensile strength Rm MPa ksi<br />
Yield strength Rp0.2 MPa ksi<br />
Elongation A<br />
%<br />
5083 H131 L 6.35 - 12.67 0.250 - 0.499 345 50.0 285 41.3 10<br />
12.7 - 50.8 0.500 - 2.000 330 48.0 275 40.0 10<br />
50.83 - 76.2 2.001 - 3.000 320 46.4 265 38.4 11<br />
5059 H131 L 6.35 - 12.67 0.250 - 0.499 405 58.7 360 52.2 9<br />
Alustar ® 12.7 - 50.8 0.500 - 2.000 395 57.3 350 50.8 9<br />
50.83 - 76.2 2.001 - 3.000 360 52.2 310 45.0 10<br />
5059<br />
Alustar<br />
H131 LT 25.8 1.016 411 59.6 319 46.3 11<br />
®<br />
5059 H136 L 6.35 - 12.67 0.250 - 0.499 375 54.4 310 45.0 12<br />
Alustar ® 12.7 - 50.8 0.500 - 2.000 380 55.0 320 46.4 11<br />
50.83 - 76.2 2.001 - 3.000 355 51.5 295 42.8 12<br />
2519 T87 L 12.7 0.500 484 70.2 455 66.0 12<br />
25.4 1.000 488 70.8 464 67.3 12<br />
38.1 1.500 484 70.2 458 66.4 12<br />
7017 T6 LT > 6 < 50 0.16 - 1.97 445 64.5 385 55.8 11<br />
7020 T6 LT > 4 < 25 0.16 - 0.98 360 52.2 300 43.5 13<br />
> 25 < 60 1 - 2.36 355 51.5 295 42.8 11<br />
7039 T6 L < 38.1 < 1.5 435 63.0 375 54.4 11<br />
> 38.1 > 1.5 425 61.6 355 51.5 10<br />
Typical values after fusion welding<br />
Alloy* Temper Typical<br />
fi ller wire<br />
Typical plate<br />
thickness<br />
Tensile strength Rm Yield strength Rp0.2 alloy* mm in MPa ksi MPa ksi<br />
5083 H131 5183 20 - 30 0.78 - 1.18 275 40.0 125 18.2<br />
5059 H131 5183 20 - 30 0.78 - 1.18 300 43.5 160 23.2<br />
Alustar ® 5556<br />
5059 H136 5183 20 - 30 0.78 - 1.18 300 43.5 160 23.2<br />
Alustar ® 5556<br />
2519 T87 2319 101.1 4 280 40.6 204 29.6<br />
7017 T6 5183<br />
5356/5556<br />
25 - 30 1 - 1.18 260 37.7 205 29.7<br />
7020 T6 5183<br />
5356/5556<br />
25 - 30 1 - 1.18 275 40.0 205 29.7<br />
7039 T6 5183<br />
5356/5556<br />
25 - 30 1 - 1.18 310 45.0 175 25.4<br />
for comparison:<br />
6061 T6 4043<br />
5183<br />
< 30 < 1.18 185 26.8 115 16.7<br />
* According to AA or EN AW<br />
All values are measured across the weld seam and rolling direction (LT-direction)<br />
after friction stir welding (FSW)<br />
Tensile strength R m<br />
Yield strength R p0.2<br />
MPa ksi MPa ksi<br />
285 41.3 162 23.5<br />
340 49.3 180 26.1<br />
340 49.3 180 26.1<br />
** ** ** **<br />
** ** ** **<br />
325 47.1 240 34.8<br />
** ** ** **<br />
252 36.5 162 23.5<br />
** To be determined<br />
<strong>Defence</strong> <strong>Aluminium</strong> 7
Ballistic performance<br />
The following Milne de Marre graphs have<br />
been generated to offer a design guide<br />
to engineers and designers of armoured<br />
vehicles, as well as to demonstrate the<br />
ballistic performance and weight effi -<br />
ciency of most commonly used <strong>Aleris</strong><br />
armour plate alloys.<br />
They allow a simple estimation of the<br />
weight of an aluminium plate under con-<br />
sideration of the ballistic performance ac-<br />
cording to the appropriate MIL standard<br />
and the individual alloy density.<br />
Milne de Marre graph for armour plate materials (according to MIL)<br />
Projectile .30AP M2 0°<br />
V 50 limit velocity<br />
[m/s] [ft/s]<br />
950 3,117<br />
900 2,953<br />
850 2,789<br />
800 Example:<br />
V = 800 m/s (2,625 ft/s)<br />
50<br />
2,625<br />
750 Result:<br />
2,461<br />
Arial density = 115 kg/m2 (23.6 lb/ft2 )<br />
700 2,297<br />
650 2,133<br />
70 80 90 100 110 120 130 140<br />
(14.3) (16.4) (18.4) (20.5) (22.5) (24.6) (26.6) (28.7)<br />
Projectile 20 mm FSP<br />
V 50 limit velocity<br />
[m/s] [ft/s]<br />
950 3,117<br />
850 2,789<br />
750 2,461<br />
650 2,133<br />
550 1,804<br />
450 1,476<br />
350 1,148<br />
70 80 90 100 110<br />
(14.3) (16.4) (18.4) (20.5) (22.5)<br />
Areal density [kg/m 2 (lb/ft 2 )] Areal density [kg/m 2 (lb/ft 2 )]<br />
AA 2519 AA 5059 Alustar AA 2519<br />
® AA 5059 Alustar ®<br />
AA 7039 AA 7039<br />
How to use the graph:<br />
Requirement V 50 : 800 m/s 2,625 ft/s<br />
Arial density AA 5059 Alustar ® : 115 kg/m 2 23.6 lb/ft 2<br />
Assumed plate dimension: t x 2,000 x 3,000 mm t x 78.7 x 118.1 in<br />
Assumed plate weight: 690 kg 1,521 lb<br />
8<br />
<strong>Defence</strong> <strong>Aluminium</strong>
Corrosion performance<br />
The <strong>Aleris</strong> Alustar ® alloy was originally<br />
developed for the challenging corrosion<br />
requirements of the international ship-<br />
building industry. Alustar ® has been<br />
further developed to make it applicable<br />
to the defence industry, where corrosion<br />
performance is an essential operational<br />
requirement.<br />
Natural sea water test<br />
Alloy* Temper Thickness<br />
mm in<br />
Test time<br />
month<br />
MIG welded<br />
with fi ller alloy<br />
Remarks<br />
5059 H136 12.7 0.5 14 5183 insignifi cant attack on the water line, no visible attack on the weld seam<br />
Alustar ® insignifi cant attack in the Heat Affected Zone (HAZ), pitting on the surface<br />
2519 T87 13 0.51 3 2319 corrosion on the rolled surface, insignifi cant attack on the weld seam and in the HAZ<br />
* According to AA or EN AW<br />
AA 5059 H136<br />
front side (fi nal weld pass)<br />
For example, not only for amphibious<br />
vehicles but also for other armoured<br />
vehicles in corrosive environments due<br />
to chemical / biological exposure or the<br />
extreme environment conditions seen<br />
through operational deployment throughout<br />
the life time of such vehicles.<br />
AA 5059 H136<br />
back side (root pass)<br />
Welded samples of AA 5059 and AA 2519 after natural sea water corrosion test<br />
AA 2519 T87<br />
front side (fi nal weld pass)<br />
Today’s economic expectations are leading<br />
to extended life cycles for current and<br />
future military platforms requiring new<br />
materials like Alustar ® with outstand-<br />
ing corrosion resistance and excellent<br />
ballistic protection.<br />
AA 2519 T87<br />
back side (root pass)<br />
<strong>Defence</strong> <strong>Aluminium</strong> 9
Advantages<br />
Based on <strong>Aleris</strong>’ unique manufacturing<br />
technologies, such as the world’s most<br />
powerful 160’’ (4,064 mm) wide hot rolling<br />
mill and the 8,000 tons stretcher,<br />
high performance plate products with<br />
extraordinary dimensions can be produced,<br />
leaving nothing to be desired.<br />
All dimensional requirements in terms<br />
of thickness covered by the relevant TL<br />
Characteristics of aluminium armour alloys<br />
Specifi c manufacturing capabilities<br />
and MIL specifi cations can be fulfi lled<br />
as a minimum. Moreover, armour plates<br />
in extreme widths can be provided to<br />
reduce the number of weld seams in a<br />
cost effi cient manufacturing process <strong>–</strong><br />
a key manufacturing cost and design<br />
integrity advantage.<br />
Through Alustar ® <strong>Aleris</strong> offers the broadest<br />
range and maximizes design fl exibility.<br />
Alloy* Temper Specifi ed<br />
thickness (MIL)<br />
Specifi ed<br />
thickness (TL)<br />
Produced<br />
thickness<br />
Produced width<br />
mm in mm in mm in mm in<br />
5083 H131 76.2 3 76.2 3 76.2 3 2,540 100<br />
5059<br />
Alustar<br />
H131 76.2 3 60 2.36 76.2 3 2,921 115<br />
®<br />
5059<br />
Alustar<br />
H136 76.2 3 - - 152.4** 6** 3,048 120<br />
®<br />
2519 T87 101.6 4 - - 101.6 4 2,032 80<br />
7017 T6 - - 76 ~ 3 76.2 3 2,000 ~ 79<br />
7020 T6 - - 60 2.36 60 2.36 2,870 ~ 113<br />
7039 T6 101.6 4 - - 101.6 4 2,108 83<br />
* According to AA or EN AW<br />
** Without ballistic requirements; other dimensions on request<br />
General dimensional<br />
capabilities for armour plate*<br />
mm in<br />
Thickness up to 254 10<br />
Width up to 3,300 130<br />
Length up to 24,000 945<br />
* Subject to alloy, temper and<br />
thickness x width combination<br />
Larger dimensions on request<br />
Alloy* Temper Corrosion Weldability Ballistic requirements Spalling Mine Blast<br />
resistance according to MIL standards<br />
.30 AP M2 0° 20 mm FSP<br />
5083 H131<br />
5059 Alustar<br />
not suitable excellent<br />
® H131<br />
5059 Alustar ® H136<br />
2519 T87<br />
7017 T6<br />
7020 T6<br />
7039 T6<br />
* According to AA or EN AW<br />
10<br />
<strong>Defence</strong> <strong>Aluminium</strong><br />
Conclusion<br />
<strong>Aleris</strong> offers a large variety of armour<br />
plate materials for ballistic protection.<br />
The product portfolio comprises high<br />
strength, heat-treatable 2xxx and 7xxx<br />
series alloys but also 5xxx series alloys,<br />
such as Alustar ® with low density, excel-<br />
lent weldability and corrosion resistance.<br />
At the same time the ballistic protection<br />
is comparable to the best performing<br />
high strength alloys used in the industry<br />
today.
<strong>Defence</strong> <strong>Aluminium</strong> <strong>–</strong> Extruded <strong>Products</strong><br />
Alloys and capabilities<br />
<strong>Aleris</strong> in Europe operates a number of<br />
extrusion plants, two of which are dedicated<br />
to the manufacturing of high performance<br />
extruded rod, bars and shapes<br />
for the defence industry.<br />
The extrusion plants <strong>Aleris</strong> Aluminum<br />
Bonn GmbH (Germany) and <strong>Aleris</strong> Aluminum<br />
Duffel BVBA (Belgium) are equipped<br />
with sophisticated production equipment<br />
utilizing all the necessary machinery for<br />
the production of approved defence extruded<br />
products.<br />
In order to produce small, medium size,<br />
wide and heavy extrusions, either as<br />
open or hollow sections out of 5xxx, 6xxx<br />
and 7xxx series alloys, various extrusion<br />
presses are operating in direct or indirect<br />
mode up to 90 MN.<br />
<strong>Defence</strong> extrusion alloys*<br />
2618A 6005A 7003 7022<br />
5049 6060 7010 7049<br />
5059 Alustar ® 6061 7020 7075<br />
5083 6082 7021 7175<br />
* According to AA or EN AW<br />
All alloys are subject to profi le size and geometry<br />
Other alloys on request<br />
Weight of compact solids<br />
Alloy mm in mm in mm in mm in mm in<br />
du 40 1.57 60 2.36 89 3.50 225 8.86 560 22.05<br />
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<br />
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<br />
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<br />
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<br />
High strength alloys are heat-treated in<br />
one of the most modern horizontal solution-heat-treatment<br />
furnaces, built by<br />
Ebner with an annual capacity of about<br />
4,900 tons. Based on a highly sophisticated<br />
quenching system, as well as a<br />
800 tons-stretcher for straightening and<br />
stress relieving <strong>–</strong> <strong>Aleris</strong>’ new equipment<br />
allows the production of complex shapes<br />
with nearly no distortion. It increases<br />
<strong>Aleris</strong>’ production capacity to a larger<br />
range of sizes and shapes and brings<br />
<strong>Aleris</strong>’ process capability to a higher<br />
level for the entire product range.<br />
Weight of wide compact solids<br />
W<br />
Alloy mm in mm in mm in mm in mm in<br />
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<br />
730 x 120 28.74 x 4.72<br />
750 x 60 29.53 x 2.36<br />
2xxx / 5xxx Min. weight<br />
7xxx (kg/m; lbs/ft)<br />
Max. weight<br />
5.9 3.96 3.8 2.55 5.9 3.96 26.6 17.87 - -<br />
(kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2 350.0 235.2<br />
6xxx Min. weight<br />
(kg/m; lbs/ft) 3.8<br />
Max. weight<br />
2.55 2.5 1.68 3.8 2.55 10.0 6.72 10.0 6.72<br />
(kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2 350.0 235.2<br />
d u<br />
H<br />
<strong>Defence</strong> <strong>Aluminium</strong> 11
Design guidelines<br />
Minimum wall thickness of extruded hollows<br />
Alloy* mm in mm in mm in mm in mm in<br />
du < 100 < 3.94 < 200 < 7.87 < 300 < 11.81 < 400 < 15.75 < 490 < 19.29<br />
5083 / 5049** 5.0 0.20 5.5 0.22 6.5 0.26 7.5 0.30 8.0 0.31<br />
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<br />
6082 / 6061 2.5 0.10 3.0 0.12 4.0 0.16 5.0 0.20 6.0 0.24<br />
7020 / 7021 / 7003 3.5 0.14 4.0 0.16 4.5 0.18 5.5 0.22 6.5 0.26<br />
** The aluminium extruded hollows can only be manufactured by mandrel (no porthole or bridge dies)<br />
Minimum wall thickness of open extrusions<br />
Alloy* mm in mm in mm in mm in mm in mm in<br />
du < 100 < 3.94 < 200 < 7.87 < 300 < 11.81 < 400 < 15.75 < 500 < 19.69 < 540 < 21.26<br />
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<br />
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<br />
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<br />
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<br />
Minimum wall thickness of wide extruded hollows<br />
Alloy* mm in mm in mm in<br />
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<br />
700 x 60 27.56 x 2.36<br />
5083 / 5049 - - - - - -<br />
6060 / 6005A 4.5 0.18 3.0 0.12 3.0 0.12<br />
6082 / 6061 5.0 0.20 4.5 0.18 4.0 0.16<br />
7020 / 7021 / 7003 6.0 0.24 5.5 0.22 5.0 0.20<br />
Minimum wall thickness of wide open extrusions<br />
Alloy* mm in mm in mm in<br />
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<br />
700 x 60 27.56 x 2.36<br />
5083 / 5049 7.0 0.28 7.0 0.28 7.0 0.28<br />
6060 / 6005A 3.5 0.14 3.0 0.12 2.8 0.11<br />
6082 / 6061 4.5 0.18 4.0 0.16 3.0 0.12<br />
7020 / 7021 / 7003 6.0 0.24 5.5 0.22 4.5 0.18<br />
* Other alloys on request<br />
Individual sections and specifi c designs on request<br />
12<br />
<strong>Defence</strong> <strong>Aluminium</strong><br />
W<br />
W<br />
d u<br />
d u<br />
H<br />
H
<strong>Defence</strong> <strong>Aluminium</strong> <strong>–</strong> Component Manufacturing<br />
<strong>Aleris</strong> Aluminum Bonn GmbH is spe-<br />
cialized in large extrusions and project<br />
business. With Europe’s most modern<br />
large 90MN extrusion press and extra<br />
long run-out length the plant in Bonn is<br />
well prepared to cope with the demands<br />
coming from general engineering, electrical<br />
power supply and distribution, railway,<br />
waterway, road transport, and the<br />
aircraft and defence industries.<br />
<strong>Aleris</strong>’ key to success is to support the<br />
OEMs with expertise and engineering<br />
know-how in extrusions and components<br />
manufacturing as part of the product<br />
development with professional project<br />
handling.<br />
On-site aluminium welding facilities and<br />
machining equipment are designed to<br />
handle heavy duty profi les and over-<br />
sized modular assemblies. Customers<br />
appreciate a single point of contact before,<br />
during and after the projects and<br />
the ability to receive all goods from a<br />
single partner.<br />
Welding of assemblies<br />
The applied welding processes are: MIG<br />
for automated and MIG / TIG for manual<br />
welding. The equipment for the auto-<br />
mated welding of long panels like fl oors,<br />
roofs, bulkheads, hulls, ramps, etc. has<br />
a range of 26,000 x 3,600 mm.<br />
Machining and milling<br />
<strong>Aleris</strong> Bonn has two high performance<br />
cutting CNC Machining Centers designed<br />
for milling of tailor-made aluminium sections,<br />
in particular for:<br />
single main extrusions<br />
for structural parts<br />
welded subassemblies e.g.<br />
fl oor plates, roofs, bulkheads, hulls.<br />
Machine specifi cations<br />
Type Axes Working area<br />
Fooke 1 5 30,000 x 4,200 x 1,500 mm<br />
(~ 1,180 x 166 x 59 in)<br />
Fooke 2 5 25,000 x 4,000 x 1,250 mm<br />
(~ 984 x 157 x 49 in)<br />
<strong>Defence</strong> <strong>Aluminium</strong> 13
Customer Engineering Support<br />
Research and Development<br />
Customer Engineering Support<br />
It is one of our strategic goals not only<br />
to supply material to our customers but<br />
also to provide them with comprehensive<br />
engineering support. Our team of<br />
Product Engineers and Process Specialists<br />
will take any challenge to develop<br />
together with our customers new<br />
technologies and processes to improve<br />
their products. They are the technological<br />
link between customer demand and<br />
our production capabilities.<br />
The customer engineering team gives<br />
support by technical consulting, product<br />
and material training, problem solving in<br />
their special fi eld of application as well<br />
as service on the basis of experience<br />
gained in different global industries.<br />
<strong>Aleris</strong> metallurgical knowledge enables<br />
the transfer of customer’s requirements,<br />
specifi c applications and newly defi ned<br />
properties into metallurgical fabrication<br />
practices for both standard and new<br />
products.<br />
14<br />
<strong>Defence</strong> <strong>Aluminium</strong><br />
Research and Development <strong>–</strong> Our New<br />
Product and Technology Pipeline<br />
Research and development is a collective<br />
exercise and is based on a close<br />
cooperation between R&D teams in our<br />
customers, our plants and external parties,<br />
e.g. a strategic cooperation with a<br />
partner laboratory located in IJmuiden<br />
(The Netherlands), which acts as a central<br />
research facility for fundamental work,<br />
with excellent facilities and highly qualifi<br />
ed, motivated researchers.<br />
The R&D activities focus on the devel-<br />
opment of innovative technologies to<br />
improve both processes and products<br />
to exceed today’s and to shape tomorrow’s<br />
requirements.<br />
Areas of research:<br />
alloy and technology development<br />
casting technology<br />
hot and cold rolling technology<br />
optimization of heat treatment<br />
processes<br />
numerical and physical modelling<br />
of processes and product<br />
performance<br />
NDT-technology<br />
corrosion and surface technology<br />
forming technology<br />
welding technology<br />
(e.g. LBW, FSW)<br />
other joining techniques<br />
(brazing, adhesive bonding,<br />
mechanical joining)<br />
high speed machining<br />
product design support and<br />
numerical simulation in close<br />
cooperation with OEMs.
Quality Assurance<br />
Approvals <strong>–</strong> Our Brand is Quality<br />
The quality concept is an essential element<br />
of the company policy. Its objectives<br />
are a continuous improvement in the<br />
quality of <strong>Aleris</strong>’ products and services<br />
to fulfi l all customer requirements. The<br />
quality principles are formulated by the<br />
company management, implemented<br />
and known on all levels and by all employees<br />
within the corporation.<br />
To ensure these quality principles, a<br />
documented quality system has been<br />
implemented. The fi rst quality manual<br />
was established in 1979 based on the<br />
<strong>Aleris</strong> Aluminum Koblenz GmbH<br />
<strong>Defence</strong> related<br />
BWB according to TL 2350-0004<br />
Non defence related<br />
DIN EN ISO 9001<br />
ISO/TS 16949<br />
Environment<br />
DIN EN ISO 14001<br />
Ballistic testing<br />
Bundeswehr, Wehrtechnische<br />
Dienststelle für Waffen und<br />
Munition, Germany<br />
TNO Prins Maurits Laboratory,<br />
The Netherlands<br />
U.S. Army Aberdeen Test<br />
Center (APG), USA<br />
requirements set by the aerospace in-<br />
dustry. Since then the quality system<br />
has been continuously up-dated and<br />
expanded in scope.<br />
Process control ensures that production<br />
takes place under controlled conditions.<br />
Quality inspections are regularly carried<br />
out in various production facilities.<br />
In-house laboratories with state-of-the-<br />
art equipment control proper compo-<br />
sition of alloys and their mechanical<br />
performance.<br />
<strong>Aleris</strong> Aluminum Bonn GmbH<br />
<strong>Defence</strong> related<br />
DIN 2303 Q2<br />
Non defence related<br />
DIN EN ISO 9001<br />
ISO/TS 16949<br />
DGR 97/23/EG<br />
DIN EN 15085 CL 1<br />
DIN V 4113-3<br />
Environment<br />
DIN EN ISO 14001<br />
Certifi ed external testing laboratories<br />
conduct ballistic testing of armour plates<br />
according to national and international<br />
standards and specifi cations.<br />
The quality philosophy means “zero<br />
defects”. The quality system takes into<br />
account the customers continuously<br />
rising requirements and specifi c quality<br />
standards as well as legislative and<br />
regulatory measures which may have<br />
an additional effect.<br />
<strong>Aleris</strong> Aluminum Duffel BVBA<br />
Non defence related<br />
EN ISO 9001<br />
ISO/TS 16949<br />
Environment<br />
EN ISO 14001<br />
<strong>Defence</strong> <strong>Aluminium</strong> 15
www.aleris.com<br />
<strong>Aleris</strong><br />
European Headquarter<br />
<strong>Aleris</strong> Switzerland GmbH<br />
Balz Zimmermann-Straße 7<br />
8058 Zurich Airport · Switzerland<br />
T +41 44 828 1400<br />
Care has been taken to ensure that this information is<br />
accurate, but <strong>Aleris</strong>, including its subsidiaries, does not<br />
accept responsibility or liability for errors or information<br />
which is found to be misleading.<br />
<strong>Defence</strong> Department<br />
<strong>Aleris</strong> Aluminum Koblenz GmbH<br />
Carl-Spaeter-Straße 10<br />
56070 Koblenz · Germany<br />
T +49 (0) 261 891 7479<br />
Contact: T +49 (0) 261 891 7545 · info.europe@aleris.com · www.aleris.com © 2010, <strong>Aleris</strong> Switzerland GmbH<br />
Issue 10/10 · 3rd release