Monograph_EN

Page 1

A New Way of Designing and Manufacturing Aluminium Components

Your needs Design

When products are complex and involve several suppliers, their ultimate quality

depends

on

the

reliability of the people you are dealing with. Sophisticated

Extrusion

compo-

nents call for knowledge, on your part, of all the technologies and methods adopted and applied at the various stages of the manufacturing process. It is you who must guar-

Machining

antee the quality of the overall process, managing the costs and resolving any issues with control during intermediate stages. In short, with so many different people in the

Surface treatments

picture and such a variety of technical language to HZZPTPSH[L Ă„UKPUN H ]PHISL solution to your particular production problems can VM[LU IL KPMĂ„J\S[ HUK expensive.

Your Production

4

The Advantages of the Pandolfo Alluminio Integrated System

minio is able to guarantee:

margins taken by multiple

service capable of guar-

to speak your language and

- Quality of the end product

Z\WWSPLYZ"

anteeing short lead times,

that of your products. A one

given that the entire manu-

- A collaborative relation-

punctuality, and support for

stop source, offering total

facturing process is certi-

ship

genuine

sophisticated and persona-

dependability.

Ă„LK [V 0:6 ! "

interchange of ideas and

lized procurement policies,

With direct in-house con-

- Cost structures unaffect-

WYVMLZZPVUHS L_WLYPLUJL"

thanks to a logistics service

trol of the entire manufac-

ed by the variable amount of

- Design and production of

that is integrated across all

turing process entrusted to

scrap generated at interme-

components making use of

processes and takes in the

specialist engineering staff

KPH[L Z[HNLZ VM [OL WYVJLZZ"

the most advanced technolo-

entire value chain, utilizing

possessing long industrial

- Increased competitiveness

gies.

the most advanced tools for

experience, Pandolfo Allu-

achieved by eliminating the

( YLSPHISL HUK Ă…L_PISL

optimizing production.

A single contact, able

enabling

a

5

The Pandolfo Alluminio System

Design Customers who come to Pandolfo

Alluminio

need

with design, testing, assem-

VUS` Z[H[L [OL ZWLJPÄJH[PVUZ

bly and supply - all geared

and

to the type of use planned by

performance

component

they

the

of

types

of

the

require: processing

the customer.

6M WHY[PJ\SHY PTWVY[HUJL

steps and their sequence,

HYL Z\YMHJL ÄUPZOLZ ^OPJO

problems

with

include anodizing and pow-

with

der coating.

raw

connected

materials,

and

extrusion, machining, surface

All components can un-

treatments and so forth, will

dergo a wide range of var-

all be taken care of by the

ied and complex machining

Pandolfo Alluminio system.

operations.

Pandolfo Alluminio en-

Pandolfo Alluminio custom-

gineers work together with

LYZ ILULÄ[ MYVT [OL ZRPSSZ

the customer on the design

of the company’s engineering

VM [OL ÄUPZOLK JVTWVULU[

staff, and from the availabil-

optimizing the entire manu-

ity of laboratories equipped

facturing cycle.

with

Whilst extrusion repre-

6

ments, as well as assistance

instruments

of

the

latest generation.

sents the main technology

Elaborate testing proce-

used by Pandolfo Alluminio

dures are designed to en-

in the manufacture of alu-

sure that the end product

minium components, the Inte-

meets with success and re-

grated System also takes in

sponds exactly to customer

machining and surface treat-

ZWLJPÄJH[PVUZ

Machining

Pandolfo Technology

Powder coating

Anodizing

Extrusion Dies

Extrusion

7

Pandolfo Alluminio headquarters at Sarmeola di Rubano (Padua):

Pandolfo Alluminio facility at Lentiai (Belluno):

- General and administrative management

- Extrusion plant

Company facilities

no):

Pandolfo Alluminio facility at Feltre (Belluno): - Sales management - Pre and after sales services - Anodizing and powder coating plant - Machining department

Certified raw materials

The origin and the composition of all raw materials HYL JLY[PÄLK Pandolfo offers

a

Alluminio

wide

range

of

alloys, from which customers can ILZ[

select Z\P[LK

applications.

the [V

formulas ZWLJPÄJ

Extrusion Dies

Dies represent key components of the extrusion process, and are created employing the very latest systems

and

complemented

equipment, by

the

almost artistic skills of design engineers with long L_WLYPLUJL PU [OL Ă„LSK Many different tests to international

standards

can be conducted in the company laboratories, on both sample and subsequent production batches.

Extrusion

The single most important step of the manufacturing process, this involves shaping aluminium billets into a variety of cross-sectional WYVÄSLZ Pandolfo Alluminio operates four extrusion presses YH[LK HUK [VUULZ NP]PUN HU V]Lrall annual output capacity VM TVYL [OHU [VUULZ All extrusion lines are equipped with automatic monitoring and control systems. An advanced and completely automated handling system for transferring proÄSLZ MYVT [OL WYLZZ [V [OL packaging station guarantees a shorter throughput and

optimized

production

ring stage and avoid possi-

In effect, this is one of

ÅV^Z ^OPSL HSZV LUHISPUN

ble surface damage caused

the most modern facilities

management

monitor

by manual handling, as well

in Europe, able to turn out

the progress of the order,

as allowing complete tra-

JVTWSL_ WYVÄSLZ VM HSS

guard against possible hu-

ceability of the product to

shapes and sizes.

man error during the cu-

every stage of the process.

to

Surface Treatments

Surface treatments are applied to aluminium proÄ SLZ H[ [OL -LS[YL WSHU[ All steps of the anodizing process, and the combined electrocolouring process, are computer controlled. The plant has an installed JHWHJP[` VM HTWLYLZ LX\H[PUN [V HU V\[W\[ VM million m . Pandolfo Alluminio is a 8<(3(56+ SPJLUZLL

Components are treated with thermosetting powders by a modern coating system that is vertically structured and fully automated. A high level of automation and constant checks guarantee strict compliance with international standards.

6\[W\[ JHWHJP[` PZ TPS

lion m per year. Pandolfo Alluminio is a SPJLUZLL VM [OL 8<(30*6(;

label, and has also acquired :,(:0+, JSHZZ JLY[PĂ„ JH[PVU

Machining

A well-established tradition in the manufacture of aluminium components made from extruded stock has led to the development of a production centre equipped with machine tools, bending machines and CNC machining centres, all able to perform a wide range of machining VWLYH[PVUZ IV[O LMÄJPLU[S`

and effectively.

different facilities, Pan-

Through full integra-

dolfo Alluminio is in a posi-

tion of the manufacturing

tion to supply components

cycle shared between its

“ready for assembly”.

The Pandolfo Alluminio Quality System Quality has always been a matter of routine for Pandolfo Alluminio, with regard both to company organization and to the end product. Attention to detail, quality of raw materials, technologically advanced systems, thorough-going checks and tests: all these have been key factors in forging the company’s excellent relationship with its customers. The

German

institute

;l= OHZ JLY[PĂ„ LK [OL JVU

sistency of the company’s

operations - is geared to pro-

concern of the Pandolfo

quality system on the ba-

viding customer satisfaction.

Alluminio Integrated System.

sis of stringent tests and

Whether large industrial

The Feltre plant, which

inspections prescribed by

groups or SMEs, businesses

specializes

0:6 !

VM L]LY` RPUK ^PSS Ă„ UK [OH[

treatments and machining

The entire organization

Pandolfo Alluminio has all

operations, is licensee for

of Pandolfo Alluminio - both

the answers they are look-

8<(30*6(; WV^KLY JVH[PUN

PU OV\ZL HUK PU [OL Ă„ LSK

ing for.

HUK 8<(3(56+ HUVKPaPUN

from small everyday tasks

Catering for the needs

to large-scale and complex

of customers is the primary

in

seals of quality.

surface

ProямБles and machining to customer speciямБcation Sector: ,SLJ[YPJHS PUK\Z[Y` /V\ZLOVSK HUK VM├ДJL equipment. 3. Transport. /V\ZLOVSK HUK VM├ДJL equipment. 5. Engineering. 6. Building. 7. Refrigeration industry. ,SLJ[YPJHS PUK\Z[Y` ,UNPULLYPUN /V\ZLOVSK HUK VM├ДJL equipment. ;YHUZWVY[ :WVY[Z LX\PWTLU[ ,UNPULLYPUN ,SLJ[YPJHS PUK\Z[Y` )\PSKPUN 9LMYPNLYH[PVU PUK\Z[Y`

4

5

6 7

3

4

Application: :LUZVY TV\U[PUN WVZ[ for perimeter security control systems. :OV^LY LUJSVZ\YL MYHTL 3. Multifunction system for stowing hand luggage. 4. Coffee machine. 5. Dialysis equipment. 6. Automation systems for gates. 7. Edge moulding for refrigerated display unit. /LH[ ZPUR 4V\U[ MVY HPY VWLYH[LK opening systems. *\Y]LK NSHaPUN \WYPNO[ 4V\SKPUN MVY recreational vehicle. 0U SPUL ZRH[L -P_PUN IYHJRL[ ,U[Y`WOVUL WHULS 4VK\SHY MYHTL MVY ceramic tile faรงade. =LU[PSH[PVU NYPSSL MVY refrigerated counters.

Aluminium components for the transport industry

Lightness is undoubtedly the feature of aluminium most valued in this sector, and explains why it has become so popular so quickly. The need to withstand particularly

severe

me-

chanical stresses has led to the development of special purpose alloys. Pandolfo

Alluminio

is

able to manufacture sections of sizeable proportions.

Aluminium components for the engineering industry

As in other instances, prefabrication is the feature of components made from extruded section members that makes aluminium preferable to other materials. Equally important is the development of alloys which, besides affording excellent mechanical properties, offer all the intrinsic advantages of aluminium in terms of machinability and surface quality.

Aluminium components for the electrical industry

Aluminium

is

suitable

for structural components as well as being a good conductor of electricity and heat. These are advantages that have made the metal increasingly popular for electrical applications, not to mention the high level of prefabrication that can be achieved utilizing machined sections.

Aluminium components for the building industry

,]LY ZPUJL P[ Ă„ YZ[ HW

peared, extruded aluminium has been used extensively in the building sector. It was KVVY HUK ^PUKV^ Ă„ _[\YLZ that predominated initially, but now there are more and more sophisticated applications, which Pandolfo Alluminio has the necessary experience to handle, working with customers on projects that are often notably demanding.

Aluminium components for the refrigeration industry

Materials used in this sector must be adaptable [`WPJHSS` [V KPMĂ„ J\S[ LU]P ronmental conditions (condensation,

hygiene,

etc.),

but increasingly nowadays, the accent is no less on appearance - as one would expect for any item of furniture anywhere.

Aluminium components for household and office equipment

The success of aluminium PU [OPZ ZLJ[VY PZ YLÅ LJ[LK in the fact that manufacturers can supply prefabricated components combining NVVK SVVRZ ^P[O ZPNUPÄ JHU[ mechanical and structural advantages. The ideal material for items that need to be both tough and attractive at one and the same time.

33

ALLOYS AND FIELDS OF APPLICATION ALLOYS

CORROSION RESISTANCE

ANODIZABILITY

WELDABILITY

MACHINABILITY

COLD PLASTIC WORKABILITY

HOT SHAPEABILITY

NVVK

VW[PT\T

NVVK

HKLX\H[L

NVVK

NVVK

KVVY ^PUKV^ Ä_[\YLZ ¶ PU[LYPVY HYJOP[LJ[\YL ¶ OLH[ L_JOHUNLYZ LSLJ[YVUPJZ ¶ W\ISPJ [YHUZWVY[ ]LOPJSLZ

NVVK

TL[HS MHIYPJH[PVU ¶ W\ISPJ [YHUZWVY[ ]LOPJSLZ ¶ YVIV[PJZ ¶ PUK\Z[YPHS H\[VTH[PVU ¶ \ZLZ VM HSSV` with higher TLJOHUPJHS ZWLJPÄJH[PVUZ

H

NVVK

NVVK

NVVK

NVVK

HKLX\H[L NVVK

NVVK

NVVK

NVVK

NVVK

NVVK

NVVK

metal fabrication -mechanical engineering -boats -public transport vehicles -steps -robotics -industrial automation -structural applications

NVVK

HKLX\H[L

NVVK

NVVK

HKLX\H[L

HKLX\H[L

OLH]` TLJOHUPJHS LUNPULLYPUN ¶ W\ISPJ [YHUZWVY[ ]LOPJSLZ ¶ Z[Y\J[\YHS HWWSPJH[PVUZ ¶ TL[HS MHIYPJH[PVU ¶ O`KYH\SPJ WUL\TH[PJ LX\PWTLU[ ¶ WYVÄSLZ HUK THJOPUPUN [V J\Z[VTLY ZWLJPÄJH[PVU

CHEMICAL COMPOSITION EN 573-3

Si

Fe

Cu

Mn

Mg

Cr

Zn

Ti

Impurities EACH

total

Al (*)

,5 (>

9,4(05+,9

,5 (>

9,4(05+,9

,5 (> (

9,4(05+,9

,5 (>

9,4(05+,9

Single values indicate maximum permissible. ;OL HS\TPUP\T JVU[LU[ PZ [OL KPMMLYLUJL IL[^LLU HUK [OL Z\T VM [OL WLYJLU[HNLZ VM HSS V[OLY JVUZ[P[\LU[Z ^P[O H ]HS\L VM UV[ SLZZ [OHU rounded up to the second decimal place (before calculation of the sum). 7LYTPZZPISL YHUNL VM 4U *Y $

34

MECHANICAL PROPERTIES – TO EN 755-2 ALLOY

WALL THICKNESS

EN 573-3

DESIGNATION OF PHYSICAL STATE EN 515

YIELD STRENGTH

ELONGATION

HARDNESS

t (mm)

ULTIMATE TENSILE STRENGTH RM (Mpa)

Rp 0,2 (Mpa)

A (%)

HBW (*)

,5 (>

;

˜

;

˜

;

# [ ˜

;

˜

;

# [ ˜

;

˜

;

˜

;

# [ ˜

,5 (>

;

˜

;

˜

;

# [ ˜

;

˜

;

# [ ˜

;

˜

;

˜

;

# [ ˜

,5 (> (

; VWLU WYVÄSL

˜

; VWLU WYVÄSL

˜

# [ ˜

# [ ˜

; JSVZLK WYVÄSL

˜

; JSVZLK WYVÄSL

˜

# [ ˜

,5 (>

;

˜

; VWLU WYVÄSL

˜

; VWLU WYVÄSL

˜

# [ ˜

; JSVZLK WYVÄSL

˜

; JSVZLK WYVÄSL

˜

# [ ˜

=HS\LZ PUKPJH[LK HYL TPUPT\T ]HS\LZ" ^OLYL [^V ]HS\LZ HYL PUKPJH[LK [OL N\HYHU[LLK TPUPT\T KLWLUKZ VU [OL NLVTL[Y` HUK KPTLUZPVUZ VM [OL L_[Y\KLK WYVÄSL =HS\LZ HYL YLMLYYLK [V WYVÄSLZ" IHYZ HUK [\ILZ TH` OH]L KPMMLYLU[ N\HYHU[LLK TPUPT\T ]HS\LZ ;OLZL HYL [`WPJHS ]HS\LZ [OH[ JHU ]HY` ZPNUPÄJHU[S` KLWLUKPUN VU [OL NLVTL[Y` HUK KPTLUZPVUZ VM [OL WYVÄSL

35

130 120 110 100

Open Profiles

90 In the extrusion of open

80

WYVÄSLZ [OL TH_PT\T KPTLUsional limit is determined

70

by the capacity of the alu-

60

minium, when in the plastic Z[H[L [V ÄSS [OL L_[YLTP[PLZ

50

of the die and the section to be extruded.

40

The central graph shows

30 20

10

20

30

40

50

60

70

80

10 90

100

110

120

130

must also be considered:

140

aspects

150

other

160

profile,

170

maximum dimension of the

10

the

180

determining

220

When

320

that can be produced.

250

the limits of the sections

- Thickness

10

- Geometry - Weight per linear metre

20

- Alloy.

30 40 50 60 70 80 90 100

2° support Die holder assembly

110

1° support Baking ring Flat Die

36

120

Die holder

130

30 0 0

220

00

Tubular Profiles 180

0

Tubular

0

extruded

sections using

are

porthole

and spider dies.

0

Aluminium in the plastic

0

state separates around the spokes, merges again in the

100

0

mandrel area and is then fashioned into a tube.

0

The maximum dimension of

60

0

the tubular part depends on the capacity of the alumini-

0

\T [V ÄSS [OL WLYPTL[LY VM

30 170

160

150

140

130

120

110

90

80

70

60

50

40

30

20

10

100

the mandrel (grey area of

0

the central diagram).

/LYL HNHPU [OL TH_PT\T

dimension depends on the

0

thickness, the geometry, the weight per linear metre and

0

the alloy.

0 0 0 0 0 0 0 00 0 0

Die holder assembly

2° support 1° support Porthole die Die holder

30

37

Anodizing

Thicknesses of anodized layer – to EN 12373-1 Thickness classes

Use

5

Interior, with infrequent handling

0U[LYPVY

,_[LYPVY

,_[LYPVY ^P[O L_WVZ\YL [V HNNYLZZP]L \YIHU VY THYPUL H[TVZWOLYL

,_[LYPVY ^P[O L_WVZ\YL [V WHY[PJ\SHYS` HNNYLZZP]L H[TVZWOLYL

Type

Designation

Description

,5

PUK

,

(WWLHYHUJL VM H TH[LYPHS HUVKPaLK HZ Z\WWSPLK without having undergone any kind of pretreatment

HYZ

,

(WWLHYHUJL VM HU HUVKPaLK TH[LYPHS [OH[ OHZ \UKLYNVUL WYL[YLH[TLU[ I` THU\HS VY TLJOHUPJHS ZJYH[JO IY\ZOPUN TLJOHUPJHS ZH[PU ÄUPZO

arc

E6

Appearance of a material that has undergone a relatively aggressive JOLTPJHS WYL[YLH[TLU[ JOLTPJHS ZH[PU ÄUPZO

Type

Description

- Pandolfo Alluminio is

J V

5H[\YHS

OVSKLY VM 8<(3(56+

J

3PNO[ IYVUaL

Thicknesses

Finishes

Colouring

SPJLUZL U‡

- Sealing: hot, in deionized water. 6\[W\[ JHWHJP[`! [ `LHY

Thickness classes

J

4LKP\T SPNO[ IYVUaL

J

4LKP\T IYVUaL

J

+HYR IYVUaL

J

+HYR IYV^U IYVUaL

J

)SHJR

PU[LYPVYZ VUS`

* * * C 33 C 335 C 34 C 35

5H[\YHS 3PNO[ IYVUaL 4LKP\T SPNO[ IYVUaL Medium bronze Dark bronze Dark brown bronze Black

Thicknesses on exposed surfaces 60 microns minimum

Type of powder: Thermosetting polyester and epoxy-polyester Category

Powder coating Thicknesses

Finishes

Description

.36:: 4H[[L ÄUPZO

.36:: :LTP NSVZZ ÄUPZO

.36:: .SVZZ ÄUPZO

Colouring Type

Description of standard colours

RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL RAL

TRAFFIC WHITE PANDOLFO WHITE CREAM WHITE PEARL WHITE BEIGE DAHLIA YELLOW BRIGHT RED RUBY RED WINE RED WALNUT BROWN CHOCOLATE BROWN GREY GREEN MINT GREEN MOSS GREEN SKY BLUE GENTIAN BLUE COBALT BLUE LIGHT GREY METALLIC WHITE ALUMINIUM METALLIC GREY ALUMINIUM SILVER GREY BASALT GREY ANTHRACITE GREY DARK BLACK

9016 9010 9001 1013 1001 1033 3000 3003 3005 8011 8017 6011 6029 6005 5015 5010 5013 7035 9006 9007 7001 7012 7016 9005

6[OLY 9(3 JVSV\YZ WVZZPISL +LNYLHZPUN HUK KLV_PKPaPUN pretreatments :\YMHJL JOLTPJHS conversion treatment - Output capacity: 8,000 tons/year Pandolfo Alluminio is OVSKLY VM 8<(30*6(; license n° 720

;OL JVSV\YZ PUKPJH[LK PU [OL [HISL T\Z[ HS^H`Z IL considered approximate. :OHKLZ UV[ PUJS\KLK PU [OL VMÄJPHS 9(3 JH[HSVN\L JHU

MARBLED WHITE MARBLED GREY MARBLED GREEN MARBLED BORDEAUX MARBLED BROWN ELECTRO BLACK

IL WYVK\JLK VUS` PM HJJLW[LK I` [OL JVTWHU`»Z ,UNPULLYPUN Management.

39

Laboratory tests

Pandolfo

Alluminio

Physical tests on metals

is

)YPULSS OHYKULZZ [LZ[

,5 0:6

;LUZPSL [LZ[

<50 ,5 0:6

<50 ,5

9V\NOULZZ

,5

able to conduct the tests listed in the table, as prescribed

by

international

Chemical tests

standards. Chemical analyses

UNI 3343-75

Dimensional and shape tests on extruded items Round bars

EN 755-3

Square section bars

EN 755-4

Rectangular section bars /L_HNVUHS IHYZ

,5

Seamless tubes

EN 755-7

;\ILZ L_[Y\KLK MYVT IYPKNL KPLZ

,5

7YVĂ„SLZ

,5

,5

7YLJPZPVU WYVĂ„SLZ

EN 755-5

Dimensional and shape tests on parts that have been machined +PTLUZPVUZ

<50 ,5

.LVTL[Y`

<50 ,5

Inspection of anodized layer ;OPJRULZZ TLHZ\YLTLU[Z

0UK\JLK J\YYLU[ TL[OVK

0:6

-HZ[LUPUN

:WV[ [LZ[

,50

>LPNO[ SVZZ

0:6

(KTP[[HUJL TLHZ\YLTLU[

0:6

4L[OVK \ZPUN ZHUKWHWLY

):

(IYHZPVU YLZPZ[HUJL

Inspection of powder coated material 7YL[YLH[TLU[

+05

)YPNO[ULZZ

0:6

;OPJRULZZLZ

0:6

/HYKULZZ

,5 0:6

+Y` HKOLZPVU

,5 0:6

>L[ HKOLZPVU

4HJO\ [LZ[ IVPSPUN ^H[LY moisture chamber

)LUKPUN

0:6

0TWHJ[

(:;4 +

+YH^PUN

(JL[PJ (JPK :HS[ :WYH` [LZ[ ((::

,5 0:6 0:6

SEMI-MANUFACTURED ALUMINIUM ITEMS MADE FROM PRIMARY ALLOYS /LHKX\HY[LYZ HUK (KTPUPZ[YH[P]L 6MÄJLZ =PH KLSSH 7YV]]PKLUaH 9\IHUV 7HKV]H 0[HS` Tel Fax www.pandolfoalluminio.com info@pandolfoalluminio.com :HSLZ 6MÄJLZ =PH *HTW 3VUJ -LS[YL )3 0[HS` :HSLZ 6MÄJL 0[HS` Tel Fax sales@pandolfoalluminio.com :HSLZ 6MÄJL ,_WVY[ Tel Fax export@pandolfoalluminio.com

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