aluminium in commercial vehicles - European Aluminium Association

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Electrode Water cone short transverse direction 96 EUROPEAN ALUMINIUM ASSOCIATION ALUMINIUM IN COMMERCIAL VEHICLES CHAPTER VII 2.3.4. Plasma There are two plasma cutting techniques (Figure VII.4): • traditional plasma, with a draft of some 6°, • water VORTEX plasma, with a very small cutting draft, of the order of 2°. Plasmagen gas ‰ ‰ ‰ ‰ ‰ ‰ - ‰ FIGURE VII.4 PLASMA TECHNIQUES ‰ Vortex water inlet Compared to traditional plasma, water VORTEX plasmas facilitate greatly increased cutting speeds and reduce nuisance factors such as smoke, noise, ozone discharge. The process requires substantial amounts of power however. Plasmagen gas + Copper + ‰ ‰ - ‰ ‰ Electrode Cooling water Plasma column Plasma in vortex Plasma in free air Transverse direction FIGURE VII.5 FIBRE ORIENTATION Direction of rolling ‰ ‰ ‰ ‰ Longitudinal direction ‰ The plasma is formed in a special torch, and an inert gas (usually argon or nitrogen) moving at great speed is dissociated under the effect of an electric arc to attain the plasma state. Owing to its high cutting speed (several metres per minute), its quality and precision of cut and suitability for automation, a plasma cutting machine can be a highly profitable investment, even for short production runs. 2.3.5. Laser cutting This process is mainly used in the automotive industry. More information can be found in the Aluminium Automotive Manual (www.eaa.net/aam). Note: The width of the heat affected zone is less than 1 mm whatever the alloy and for all thicknesses. However cracking is sometimes observed in the short transverse dimension (Figure VII.5) that can attain a depth of some 2 mm. Whatever the thickness of the product, machining off 2 mm of material will restore the metal's original qualities. This is obviously unnecessary if the cut pieces are intended for use as welding blanks.
EUROPEAN ALUMINIUM ASSOCIATION ALUMINIUM IN COMMERCIAL VEHICLES CHAPTER VII 97 2.4. Edge rolling This shaping technique requires no special equipment for aluminium. The rollers must of course be clean and have smooth surfaces. Plasma cutting (Benalu) 2.5. Bending For multiple folds, holes should be used to mark the crossover points of the fold lines to avoid causing cracks when the folds are made. Aluminium does not require any special bending tools, and conventional table bending machines or presses are perfectly adequate provided the working parts of the tooling are free from unacceptable irregularities. The bending radii to be observed as a function of the thickness are given in standard EN485-2. 2.6. Non-machinable faces As with bending, one worthwhile precaution is to remove all score marks from the edges caused by cutting so as to prevent the formation of cracks at points of deep deformation. Shaping is carried out on the 5754, 5086 and 5083 grades (and on other alloys in the same family) in the annealed or H111 condition. In some cases shaping may call for inter-stage annealing4 , and this can be done as described before using an annealing torch and tallow as temperature indicator. Inter-stage annealing can be carried out several times in the course of the shaping operation; however care should be taken to avoid annealing a metal that is only slightly workhardened to prevent the risk of grain enlargement. 4. For 5000 alloys with Mg content above 3%, this must be done very carefully to prevent sensitization to intergranular corrosion. See also Chapter XI, section 2.2.6.
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ALUMINIUM IN COMMERCIAL VEHICLES
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Aluminium in Commercial Vehicles ha
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VII. FABRICATION . . . . . . . . .
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CHAPTER II ALUMINIUM IN TRANSPORT 1
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EUROPEAN ALUMINIUM ASSOCIATION ALUM
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CHAPTER III WHY USING ALUMINIUM 1.
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CHAPTER IV FREQUENTLY ASKED QUESTIO
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CHAPTER V ALUMINIUM ALLOYS FOR COMM
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CHAPTER XII CLEANING OF ALUMINIUM C
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CHAPTER XIII REPAIR OF ALUMINIUM CO
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