Metal Component Design ALUZINC

aluzinc 17/9/08 10:22 Page 1ALUZINC ®MetalComponentDesignDobelA competitive advantage. Immediately.

aluzinc 17/9/08 10:22 Page 2Fabricated in ALUZINC ®No further finishing necessary.Extremely long useful life. Designers and engineers often specify Aluzincfor producing a certain component because it builds in sustainability.Deep drawALUZINC ®Special forming substratesreadily available.Aluzinc can obviously be scratchedand damaged mechanically, but it will stillretain its excellent resistance to corrosion,it’s long useful life and it’s attractivesurface, owing to its “self-healing” ability.Spot weldingALUZINC ®Use most normalfabrication methods.Aluzinc components can be producedin exactly the same way as ordinarymild steel parts, using existing equipmentand conventional production methods.HandsomeALUZINC ®No need to post paint.Aluzinc sheet has a very attractive surfaceand can serve as a cost-effectivereplacement for cold reduced sheetwhich is to be painted.This bike rack was originally designed instainless steel, Aluzinc cut the cost by 75%.MAKE IT - FINISH IT - IN ALUZINC ®2

aluzinc 17/9/08 10:22 Page 3Finished in ALUZINC ®Get rid of all plating problems.By changing over to Aluzinc, you could eliminate the cost, headaches,bottlenecks and a sheer waste of time involved in separate zinc coating,yellow chromating or other finishing processes.No galvanising withALUZINC ®Get rid of galvanising.Beams, corner posts, support channelsand side panels are fabricated in Aluzinceliminating the need to galvanise.Roll formedALUZINC ®Completely finished.Making full use of Aluzinc’s reflectiveproperties. Aluzinc has a clean, naturaland bright silvery surface, which includessmall spangles giving a lustrousand striking appearance as lightconditions change.Screen printing onALUZINC ®With Easyfilm ® coating.Easyfilm also eliminates fingerprinting,bruising and chafing - perfect for multicomponent production.MAKE IT - FINISH IT - IN ALUZINC ® 3

aluzinc 17/9/08 10:22 Page 4Chassis in ALUZINC ®No need to paint your chassis.The clean dry feel of Aluzinc is perfect for a “one fab” finished chassis.Clean fabricationwith ALUZINC ®No degreasing.Aluzinc chassis with Easyfilm finishneeds no Further treatment.Just think, “finished as fabricated”.Consistent finishwith ALUZINC ®Component upgrade.Banish ugly and inconsistent “galv”spangles which quickly turn dark grey.Aluzinc retains its good look fromchassis to chassis, year upon year.Cost reductionALUZINC ®Take Stainless Steelout of production.You don’t need stainless steel forgood looks or long life in your chassis.Save up to 75% with Aluzinc.MAKE IT - FINISH IT - IN ALUZINC ®4

aluzinc 17/9/08 10:22 Page 5ALUZINC ® a natural for chassisA production manager’s bonus.Get your blanks, slit coil, sheet in Aluzinc and eliminate“rework” headaches. Make it in Aluzinc and the job’s finished.Press Braked inALUZINC ®Cut to size blanks alloweasy fabrication.Straight from “goods inwards” to the pressthen to assembly and the job is finished.C.N.C. Punched inALUZINC ®Machine flat sheetsease the way.Aluzinc fabricates like any other mild steelsheet, but your machine operators willlove working with its clean dry finish.Pressed Componentsin ALUZINC ®Hard surface prolongs tool life.Much of the surface of Aluzinc is aluminiumoxide. Much harder and more abrasionresistant than zinc or ferrous oxide ithelps prolong tool life.MAKE IT - FINISH IT - IN ALUZINC ® 5

aluzinc 17/9/08 10:22 Page 6Electricals in ALUZINC ®Get rid of oxide contact problems.All major and many smaller manufacturers of electrical cabinets rely on Aluzinc, they knowthat in all conditions Aluzinc will not contaminate electrical connections with oxide powder,which allows the internals of the cabinet to remain unpainted.Aluzinc makes a very good electrical connection.Electricalcompatibility withALUZINC ®Only good contacts achieved.It would be a mistake to ignore Aluzincif you’re fabricating within or for theelectrical industry.Cabinets inALUZINC ®Electrical componentperfection.D.I.N. rails and cabinets are a naturalin Aluzinc, its easy to see why majorcompanies have all exploredthe Aluzinc option.Slotted Componentsin ALUZINC ®Self healing Aluzinc ®has the edge.Aluzinc with Easyfilm “E” is the choicefor most manufacturers. The Easyfilmconforms to European Electrical Standardstowards the elimination of chrome andother metals from manufactured goods.MAKE IT - FINISH IT - IN ALUZINC ®6

aluzinc 17/9/08 10:22 Page 7Heatshields in ALUZINC ®Effective heat reflection combinedwith long corrosion protection.Aluzinc’s original design brief was to improve vehicle silencer life.Today many “original equipment” exhausts are Aluzinc, togetherwith a good number in the refit market.Effective heatreflection withALUZINC ®Put the heat whereyou need it.Aluzinc reflects heat very well and it staysbright and reflective throughout its long life,not dulling off unless its constant operatingtemperature exceeds 315 o c.Deep drawsubstratein ALUZINC ®Heatshield in complex form.Aluzinc in deep draw substrate was a naturalfor this exhaust heat shield for a motor cycle.The natural metallic appearance of Aluzincmade it a very effective component.ALUZINC ®back to its originsSeam welded tube exhausthas a long life in Aluzinc ® .Made for the refit market this exhaust usesboth the heat reflective and corrosionresistant properties to the full.MAKE IT - FINISH IT - IN ALUZINC ® 7

aluzinc 17/9/08 10:22 Page 8Building with ALUZINC ®Get a 25 year warranty.Aluzinc has long been used in the building industryfor roofing, cladding and component manufacture.Coping system inALUZINC ®Corrosion resistanceguarantees long life.As Aluzinc can last more than ten times aslong as galvanised in varying environmentsit becomes the natural choicefor roofing components.Architects loveALUZINC ®Architectural innovationin ALUZINC ® .Used for its natural metallic beauty withthe advantage of solar reflection.Aluzinc contributes to the environmentallowing diminished use of air conditioning.Roofing inALUZINC ®Cost effective optionsfor seaside roofs.Aluzinc exposed on a beach on the Englishsouth coast had no visible rust on edges orface after fifteen years. Proof that Aluzinc willperform in the harshest of environments.MAKE IT - FINISH IT - IN ALUZINC ®8

aluzinc 17/9/08 10:22 Page 9Pressed or Laser Cut ALUZINC ®All modern fabrication works with ALUZINC ® .Component manufacturers clinch, lasercut, press, fold, waterjet,spot weld, pressfix and lockform Aluzinc.Repetitive formingeasier withALUZINC ®Choosing the right substrate.Together with Aluzinc’s hard surface meancomponents are formed thousand bythousand without tool adjustmentand less tool wear.Easyfilm ® on Aluzinc ®lubricates pressformtoolingImprove ejectionrates lower tool wear.It’s easy with Easyfilm on Aluzinc,lubrication and component ejectionare facilitated using Aluzinc and Easyfilm.Laser cuttingenhances edgeprotection of Aluzinc ®Unexpected, surprising but true.Clients found that the laser cut edges on thickercomponents improved the edge protection.This was confirmed by tests metallurgically.MAKE IT - FINISH IT - IN ALUZINC ® 9

aluzinc 17/9/08 10:22 Page 10Automotive ALUZINC ®Enlightened manufacturers choose Aluzinc ® .Many automotive componets including electrical connectors,car horns, wiper motor chassis and bulb holders are made from Aluzinc.Connectingelectrically withALUZINC ®Plated componentsreplaced by Aluzinc ® .This bulb holder was previously chromeplated. The component above was postgalvanised, now both are Aluzinc converts.High strength inALUZINC ®Eliminating the cost ofstainless steel.Choosing a guaranteed high yield pointsubstrate allowed this secondary equipmentmanufacturer to save cost yet offer his clientsa life longer than the vehicle itself - in Aluzinc.Resisting theelements withALUZINC ®Painting eliminated.No need to paint a component that is likelyto malfunction where the elements havethe chance to affect it’s operation, that’sthe Aluzinc option.MAKE IT - FINISH IT - IN ALUZINC ®10

aluzinc 17/9/08 10:22 Page 11Outside with ALUZINC ®“Galv” is no longer good enough.With a life up to twenty times that of “galv” these type of hose-clamps will lastmuch longer and the harder coating of Aluzinc means that the screw threadswill rust less easily.Roll formed andpunched ALUZINC ®Fence posts perform aboveand below ground.Scandinavian fencing and culvert systemshave to perform both buried and exposedto the elements, needless to say bothperform well and replace stainless steelor painted options.Roof top elementsin ALUZINC ®No need to worry evennear the sea.The excellent corrosion resistance of Aluzincmeans that even major roof top componentsand roofs themselves overlooking the seaare well protected for many years.Cost effectiveALUZINC ®Stadia benefit fromAluzinc ® roofs.Lower in cost than prepainted roofing sheetbut still with a twenty five year warranty.Aluzinc is a cost effective alternativeand greener without the paint.MAKE IT - FINISH IT - IN ALUZINC ® 11

aluzinc 17/9/08 10:22 Page 12Air movement and ALUZINC ®Major air movement manufacturerschoose Aluzinc ® .With it’s clean modern lasting appearance, Aluzinc has become a normin the air movement industry, upgrading outdated galvanised componentsby adding sustainability and lowering whole life product costs.Upgrading withALUZINC ®Eliminate ghastly “galv”.With Aluzinc its easy to upgrade theappearance and appeal of air movementproducts. Often “galv” users “doctor” theirpress release and brochure photos toremove the “galv” look. Aluzinc gives multibenefits as so many manufacturers havediscovered.Quality you cansee and feelAluzinc ® has a specialclean dry feel.It looks good and is manufactured toEuronorm quality specifications andEuronorm quality assurance parameters.It is quite the opposite of “galv” which is acommodity shipped to market from all partsof the globe with little guarantee of quality.Choosing the rightspecification inALUZINC ®Opportunity in choice.This manufacturer has used three differentAluzinc specifications to produce theseair movement items. Deep drawing, Easyfilmand non Easyfilm are well used to hisadvantage.MAKE IT - FINISH IT - IN ALUZINC ®12

aluzinc 17/9/08 10:22 Page 13Embossing with ALUZINC ®Enhance the appearance and strengthof Aluzinc ® .Components are more aesthetically attractive and costsare saved by using thinner sheet.ComponentsaestheticsCreates the best firstimpression.Stucco Aluzinc can be found in cookers,fridges and coffee machines.Simple emboss looks good.ExceptionallystrongDecorative but strong.This emboss is designed to be usedon security kiosks allowing really thinsheets to be used.Mechanical damageresistanceRough handling - sorted.The stucco emboss hides mechanicaldamage and remains attractive.MAKE IT - FINISH IT - IN ALUZINC ®13

aluzinc 17/9/08 10:23 Page 14ALUZINC ®in action.MAKE IT - FINISH IT - IN ALUZINC ®14

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aluzinc 17/9/08 10:23 Page 17DOBEL ALUZINC ®ALUZINC ® / Embossed with the stucco finish and further stiffenedand strengthened with the ZX profile, without the stucco, the ZX profileremains very effective on plain sheet/coil.This profile facilitates the use of thinner sheet thus saving costs.CRIMPROL / significantly stifferA mini sinusoidal emboss which significantly stiffens the sheetand is likely to be used by domestic appliance manufacturers and signmakers (also available in prepainted steel).DOBEL / FloorplateSpecial floorplate emboss for kick plates etc., available in all materials.SWEDISH STEEL’SModern steel processingcentre supplying standard or bespokesheets, blanks, strips, mini and smallor slit coils. Aluzinc and all finishes ofprepainted steel are available.MAKE IT - FINISH IT - IN ALUZINC ® 17

aluzinc 17/9/08 10:23 Page 18ALUZINC ®is the versatilemetallicallycoated steel.Aluzinc’s metallic coating is a true alloy of aluminium and zinc and isadhered to the mild steel substrate by the hot dip galvanising process.Aluzinc components are finished components withreal “fit and forget” characteristics.Aluzinc adds sustainability i.e. a life between 5 & 20 times that of zincgalvanised steel. Aluzinc is often used in place of stainless steel.Aluzinc has an attractive surface of small spangles that stay brightthroughout its life and comes in a variety of steel substrates:STRUCTURAL GRADES /roofing and claddingDEEP DRAWING /gas metersREPETITIVE FORMING /ductingHIGH STRENGTH /silo legsAs with most corrosion resistant metals Aluzinc relies on a dry periodin the climatic cycle to replenish its oxide layer. There may betherefore some applications for which it is less effective, i.e. constantcorrosion cells, contact with more noble metals, strong basicatmospheres. Please check with SSAB Swedish Steel Ltd for advice.MAKE IT - FINISH IT - IN ALUZINC ®18

aluzinc 17/9/08 10:23 Page 19TechnicallyALUZINC ®Data sheet.BASE MATERIALCOATINGCOATING ANALYSISCOATING THICKNESSMild steel sheet to BS EN10326/10327-2004Hot dipped alloy coating (galvanising process)55% Aluminium. 43.4% Zinc. 1.6% Silicon (by weight)150 gm coating = 20 microns (equivalent to 275 gms coating of zinc galvanised)185 gm coating = 25 microns (equivalent to 350 gms coating of zinc galvanised)FINISHQUALITY STANDARDFIRE RATINGAGREMENTCERTIFICATEBright aluminium type, with predictably consistent small spangles. Stays brightthroughout life. Special anti-fingerprint coating available i.e. Aluzinc + Easyfilm ®Manufactured under ISO 9001 Quality Assurance Standard Certificate No.FQA0936907.Distributed under BS EN ISO 9002 Quality Assurance Standard. Certificate No.890916.British Board of Agrement Certificate No. 07/4493 for 20 year outdoor lifeNon-combustible BS476: Part 4; Class 0BBA Agrement certificate number 07/4493.CORROSIONRESISTANCEHEAT RESISTANCEEMISSIVITYUNSUITABLECOMBINATIONSSALT WATERCORROSIONLIFE EXPECTANCYFABRICATION“PAINTABILITY”DIMENSIONSTHICKNESSESWIDTHPACKAGINGDELIVERYEVOLUTIONBetween 6 and 20 times the corrosion resistance of zinc galvanisedin most applications. Aluzinc is particularly good compared to galvanisedin salt laden, acidic and polluted atmospheres.Excellent heat resistance – will not change appearance until beyond 315 0 c.Can be used to much higher temperatures if “greying” is irrelevant.Emissivity figure 0.16 – when new.Basic atmospheres. Contact with more noble metals or their salts.Please consult “Swedish Steel” if in doubt.An Aluzinc sheet has withstood fifteen years of constant salt spray atDungeness Power Station without red rust corrosion at any corner, edge or face.More than 30 years in most environments and beyond 100 yearsin the least corrosive atmospheres.Aluzinc is supplied in a variety of grades but even the mosthumble is a fully lockforming grade. High strength grades as well as deepdrawing grades are available.Aluzinc is very easy to paint. A particularly smooth surface is available.The pre-treatment is easier and more effective than zinc galvanised.Aluzinc + Easyfilm ® is pre-primed ready to paint (most paints).Coils 50 kilos – 10 tonnes. Sheets 1 metre –11 metres. Blanks – All Sizes.Slit coil available.0.4mm thick to 2.0mm thickStandards – 1250mm and 1000mm. Slit widths also available.Sheet and coil substantially packed on refundable pallets.Normal maximum 7 days.Dobel ZX profile version adds strength and aesthetics, fabricates exactly as a flat sheet.Reduces costs by using thinner sheet.MAKE IT - FINISH IT - IN ALUZINC ®19

aluzinc 17/9/08 10:23 Page 20SSAB SwedishSteel LtdNarrowboat Way,Hurst Business Park,Brierley Hill,West Midlands,DY5 1UFPhone: 01384 74660Fax: 01384 77575sales@dobel.co.ukwww.dobel.co.ukInformation correct at time of going to pressdobel.co.ukaluzinc.co.uk