Influence of the natural aluminium oxide layer on ... - ALU-WEB.DE

More documents

Recommendations

Info

EXTRUSION Gerhardi Alutechnik and GIA Clecim – a European partnership Extrusion line from a single source for intelligent pr<strong>of</strong>iles (I) Christoph Deiters, Gerhardi AluTechnik GmbH The German Gerhardi Alutechnik, founded in 1796 and even today owned by <strong>the</strong> founder family, consequently transfers values like reliability, long term thinking and tradition, but also innovation and willingness to invest. The latter has carried <strong>the</strong> company through more than two centuries and was once more proved during <strong>the</strong> last three years: management and owners decided for a second extrusion line with <strong>the</strong> necessary mechanical periphery and a considerable expansion <strong>of</strong> <strong>the</strong> factory. This investment lead to an augmentation <strong>of</strong> capacity from 6, 000 to 16.000 tonnes a year. Today <strong>the</strong>re are 125 employees who develop, produce and market 10,000 to 11,000 tonnes <strong>of</strong> <strong>aluminium</strong> pr<strong>of</strong>iles. These are sold to <strong>the</strong> building industry (‘Geraconstruct’ including ‘Gerasolar’ – shutters pr<strong>of</strong>iles and guide rails, shading technique, room-dividing elements, sanitary equipment, skirting boards, solar industry), <strong>the</strong> automotive industry (‘Geramotive’ – window frames, guide rails, decorative parts, ro<strong>of</strong> rail systems), <strong>the</strong> electronic industry (‘Geratronics’ – pr<strong>of</strong>iles for cooling elements) and industrial technique (‘Geratechnics’ – machine building, lighting industry, furniture). Gerhardi is a state<strong>of</strong>-<strong>the</strong>-art manufacturer <strong>of</strong> semi-finished <strong>aluminium</strong> products and – also due to <strong>the</strong> new 33 MN extrusion line – in a position to meet <strong>the</strong> market’s high requirements as to technical and organizational quality. The Spanish partner, GIA Clecim Press, has become one <strong>of</strong> <strong>the</strong> leaders in <strong>the</strong> metal extrusion market during <strong>the</strong> past years. The company was established in <strong>the</strong> early eighties by Gaspar Fernández in Albacete, Spain. This is nowadays <strong>the</strong> only manufacturing plant with 300 employees exclusively working for <strong>the</strong> field <strong>of</strong> extrusion <strong>of</strong> metals and special alloys. GIA took its position as a complete plant supplier throughout <strong>the</strong> years. The company got <strong>the</strong> vast majority <strong>of</strong> <strong>the</strong> Spanish market as well as presence in many o<strong>the</strong>r countries. In 2006, GIA Clecim Press purchased <strong>the</strong> knowhow and all activities <strong>of</strong> <strong>the</strong> Presses division from Siemens. After this acquisition, GIA Clecim Press became <strong>the</strong> press manufacturer with <strong>the</strong> largest number <strong>of</strong> references in Europe. Why did Gerhardi invest in a new extrusion press? Gerhardi installed <strong>the</strong> first extrusion line in 1945. Up to 2009 <strong>the</strong> company produced with a 2,000-tonne extrusion press <strong>of</strong> 1979. From <strong>the</strong> management’s viewpoint this meant a risk – for <strong>the</strong> customers as well as for <strong>the</strong> enterprise, which bears <strong>the</strong> responsibility for <strong>the</strong> employees and for which <strong>the</strong> subject ‘future’ traditionally was and still is <strong>of</strong> considerable importance according to <strong>the</strong> company’s philosophy ‘Common Future in Pr<strong>of</strong>ile’. As a consequence – after thorough consideration <strong>of</strong> all strategic alternatives – owners and management decided to invest in a second extrusion line in order to be a reliable supplier <strong>of</strong> semi-finished <strong>aluminium</strong> products. As <strong>the</strong> market forecast for semi-finished products in <strong>the</strong> alu-minium sector is positive and even shows considerable growth rates, <strong>the</strong> company acts in a developable and growing market. This could already be observed and had major influence at <strong>the</strong> time <strong>of</strong> <strong>the</strong> investment decision – a very courageous decision: Regarding <strong>the</strong> market potential <strong>of</strong> about 800.000 tpy in Germany, <strong>the</strong> decision makers, however, came to <strong>the</strong> conclusion that <strong>the</strong> accumulated maximum production capacity <strong>of</strong> 16.000 tpy <strong>of</strong> two Gerhardi presses might be a reasonable and realizable target. The investment would be suitable to secure <strong>the</strong> existence <strong>of</strong> <strong>the</strong> company by providing <strong>the</strong> technical prerequisites for an expanded product range and adapting <strong>the</strong>m to <strong>the</strong> company’s high innovation potential. Installation <strong>of</strong> <strong>the</strong> extrusion line New products like pr<strong>of</strong>iles <strong>of</strong> glossy and crash-relevant <strong>aluminium</strong> alloys for automotive applications, resulting from <strong>the</strong> close cooperation especially with Gerhardi’s raw material supplier, required more flexibility <strong>of</strong> <strong>the</strong> production process. What did Gerhardi buy? Gerhardi has invested in a second extrusion line with many technical options. It was important to run <strong>the</strong> press with <strong>the</strong> same billet diameter (8 inch) as <strong>the</strong> existing press. This guarantees that <strong>the</strong> matrices <strong>of</strong> <strong>the</strong> older device can also be used in <strong>the</strong> new press. The dialog with GIA resulted in <strong>the</strong> decision for a press with a power <strong>of</strong> 33 MN in order to be later able to apply a 9 inch or maybe also a 10 inch billet. In order to reach a constant quality, which is especially important for <strong>the</strong> decorative parts and <strong>the</strong> functional parts, Gerhardi bought a combined billet heating: pre-heating with gas and complementary induction heating, which allows an even temperature for <strong>the</strong> pressing process at <strong>the</strong> point <strong>of</strong> matrix. Special attention is given to <strong>the</strong> cooling process. GIA installed a pronounced cooling tunnel with air- / air-water- and water-cooling. These cooling mechanisms allow <strong>the</strong> extrusion <strong>of</strong> higher strength material – also an 36 ALUMINIUM · EAC CONGRESS 2011 Gerhardi
option for <strong>the</strong> future. As Gerhardi wanted to use its building’s full size <strong>of</strong> 120 metres for <strong>the</strong> line, <strong>the</strong> length <strong>of</strong> <strong>the</strong> run-out-system is considerable. The 60-metre pr<strong>of</strong>iles are stacked and <strong>the</strong>n sewed to customized size from 2,000 mm upwards. Press, stacker and saw are followed by a fully automatic assembly line which guarantees that no worker touches <strong>the</strong> pr<strong>of</strong>iles until reaching <strong>the</strong> packing unit. The building concept over two floors prescribes a stringent material flow. Oven storage, packaging and processing <strong>of</strong> <strong>the</strong> pr<strong>of</strong>iles are effected on <strong>the</strong> upper floor. All <strong>the</strong>se requirements were laid down in a specification sheet. The Gerhardi project team travelled a lot, visited various extrusion companies and as many suppliers as possible. The managing director and his team went through all <strong>of</strong> Europe to get to know <strong>the</strong> relevant companies, to talk to <strong>the</strong>m and to see reference lines. Whom did Gerhardi choose? After an intensive analysis <strong>of</strong> all <strong>of</strong>fers as to economic aspects, but also as to <strong>the</strong> product availability and <strong>the</strong> vertical range <strong>of</strong> manufacture, Gerhardi decided to buy an extrusion line made by <strong>the</strong> Spanish company GIA Clecim. The core business for GIA is <strong>the</strong> manufacturing <strong>of</strong> extrusion plants and 95% <strong>of</strong> jobs are turnkey projects. The strategies <strong>of</strong> nonsubcontracting lets GIA get <strong>the</strong> highest quality for such equipment. GIA holds a manufacturing ratio <strong>of</strong> 80%, which means that all equipment is manufactured, assembled and tested in its facilities. For Gerhardi <strong>the</strong> most important criteria in favour <strong>of</strong> GIA were <strong>the</strong> following: • Under an economic point <strong>of</strong> view <strong>the</strong> GIA Clecim <strong>of</strong>fer was persuading in comparison to all <strong>the</strong> o<strong>the</strong>r suppliers • Gerhardi got a good impression <strong>of</strong> <strong>the</strong> technical aspects <strong>of</strong> a GIA press – especially <strong>of</strong> <strong>the</strong> solid machine construction, <strong>the</strong> extremely effective and good hydraulic system, <strong>the</strong> interaction in a completely coordinated system • All from a single source – GIA is <strong>the</strong> only producer <strong>of</strong> complete extrusion systems from <strong>the</strong> billet store over <strong>the</strong> billet heating to <strong>the</strong> press, <strong>the</strong> saw and <strong>the</strong> assembling device • GIA has an enormous in-house production depth. All mechanical parts are manufactured by <strong>the</strong> company itself and even <strong>the</strong> hydraulic system is developed in Albacete and produced by GIA • GIA is a family enterprise like Gerhardi and <strong>the</strong> customer negotiates with <strong>the</strong> owner himself • GIA very much wanted to install a reference extrusion line in Germany so that Gerhardi could take it for granted that <strong>the</strong> Spanish partner would make considerable efforts in this project. How was <strong>the</strong> installation process effected? 33 MN GIA extrusion press for Gerhardi After signing <strong>the</strong> contract both parties formed project teams who communicated directly with each o<strong>the</strong>r. GIA employed a German speaking coordinator for <strong>the</strong> German market, so that <strong>the</strong> communication could take place in German. Innumerable plans were exchanged. In interaction between architects, construction companies and o<strong>the</strong>r project partners <strong>the</strong> prerequisites for <strong>the</strong> installation <strong>of</strong> <strong>the</strong> extrusion line were created. Various journeys from Germany to Spain and vice versa were necessary to realize <strong>the</strong> planned targets. After <strong>the</strong> preparing activities <strong>the</strong> actual installation was effected by a competent team <strong>of</strong> technical assemblers and s<strong>of</strong>tware engineers. Highlights <strong>of</strong> this phase were certainly <strong>the</strong> socalled marriage, <strong>the</strong> merging <strong>of</strong> <strong>the</strong> first part <strong>of</strong> <strong>the</strong> press with <strong>the</strong> building, and <strong>the</strong> first warm billet. Summary EXTRUSION The installation <strong>of</strong> a technologically sophisticated extrusion line is always a great challenge – especially if it is a European line like in <strong>the</strong> case <strong>of</strong> Gerhardi, where <strong>the</strong> devices came primarily from Spain, but also from <strong>the</strong> Ne<strong>the</strong>rlands, from Italy and Germany. Gerhardi – after a careful choice <strong>of</strong> <strong>the</strong> suppliers – was very satisfied that all partners were eager to constructively accompany <strong>the</strong> investment. All companies involved learnt a lot in <strong>the</strong> project – like <strong>the</strong> adequate estimation <strong>of</strong> a permanent dialogue, <strong>of</strong> <strong>the</strong> quality <strong>of</strong> exchanged information, <strong>the</strong> presence and otivation <strong>of</strong> <strong>the</strong> own team within <strong>the</strong> planning and installation process and <strong>the</strong> anticipatory understanding for <strong>the</strong> partner’s different mentality. Gerhardi is aware <strong>of</strong> <strong>the</strong> special challenge <strong>of</strong> a European extrusion line, but is at <strong>the</strong> same time convinced to have placed with <strong>the</strong> GIA Clecim press <strong>the</strong> right investment following its philosophy ‘Common future in Pr<strong>of</strong>ile’. ‘Common’ not only with customers and employees, but also, as it was laid down in <strong>the</strong> corporate presentation many years ago, also with <strong>the</strong> suppliers. Especially with <strong>the</strong> Spanish partners Gerhardi developed a business relationship, which also lead to common private activities. Visits <strong>of</strong> Mr Gaspar Roldan or his fa<strong>the</strong>r Gaspar Fernandez were remarkable events as well as visits <strong>of</strong> <strong>the</strong> Gerhardi owners in Spain. Gerhardi and GIA – this is not only a partnership resulting from <strong>the</strong> purchase <strong>of</strong> an extrusion press for intelligent Gerhardi <strong>aluminium</strong> pr<strong>of</strong>iles, but also a European friendship. � ALUMINIUM · EAC CONGRESS 2011 37
Page 1 and 2: Ebner Special Edition European Alum
Page 3: Christian Wellner Executive Directo
Page 6 and 7: ROLLING INDUSTRY Foil slitting tech
Page 8 and 9: ROLLING INDUSTRY Optifoil Heavyslit
Page 10 and 11: ROLLING INDUSTRY Focus on rolling m
Page 12 and 13: ROLLING INDUSTRY the</stron
Page 14: ROLLING INDUSTRY Gas-fired radiant
Page 17 and 18: Danieli Fröhling 6-high Diamond Mi
Page 19 and 20: Longer campaigns with improved mono
Page 21 and 22: Standard 1 Standard 2 New material
Page 23 and 24: Fig. 1: Selected AGC input variable
Page 25 and 26: �� The flexibility o
Page 27 and 28: Fig. 2: Optimized raw material calc
Page 29 and 30: necessary in the s
Page 31 and 32: Influence
Page 33 and 34: Principle of takin
Page 35: Counter platen with fixed tie rods
Page 39 and 40: Photos: GIA In autumn 2009 Gerhardi
Page 41 and 42: Fig. 3: Experimental setup for extr
Page 43 and 44: initiation at the
Page 45 and 46: The medium-sized, family-run compan
Page 47 and 48: ��
Page 49 and 50: Surface modification and de-coating
Page 51 and 52: following pH values were prepared:
Page 53 and 54: AlMgSi(Cu) alloys”; Mat. Corr., 2
Page 55 and 56: Fig. 2: Al-base metal-alloys and Al
Page 57 and 58: APPLICATION-ORIENTED TECHNOLOGIES <
Page 59 and 60: level significantly, see Fig. 4. A
Page 61 and 62: q H2O = ε(46.52 - 94.9p H2Os)(p2 .
Page 63 and 64: Abbildungen: promeos Resource effic
Page 65 and 66: New: Hot air heating system for ind
Page 67 and 68: Fig. 2: Equilibrium phases for <str
Page 69 and 70: Fig. 7: Net-remelting losses <stron
Page 71 and 72: ant heat transfer between t
Page 73 and 74: Fig. 1: Tool concept for th
Page 75 and 76: EFFICIENT Yes, I/we would like to s

Influence of the natural aluminium oxide layer on ... - ALU-WEB.DE

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?