Pressure die casting in aluminum alloy offers means for very rapid production of engineering and other related component even or intricate design. The technique has obvious advantages when a component is required in large quantities. However, for aeronautic space, defence and automotive applications, mechanical properties and durability are of primary importance It is, therefore, essential that the best features of design should be employed and optimum casting technique with minimum cost be adopted. Pressure die cast products are used in the form of components of various electrical electronic, mechanical instruments and appliances used in domestic as well as industrial field.

Types of Aluminum Alloys for Die Casting Applications

In this eBook, we shall focus on 7 different types of aluminum alloys that are die cast in most industrial setup.

These alloys include the following:

The K-alloy; this aluminum allow is known to possess the following key properties: resistance to corrosion improved cooling and zero post die casting operations.

Alloy 413; superior die casting properties and it possess good fluidity and guarantee better pressure tightness.

Alloy 383; it possesses the following key properties: dimension stability, ease of casting and good mechanical properties. It has superior corrosion resistance too.

Alloy B390; it is known for its superior wear resistance and high hardness. They are mainly used to die cast the internal combustion engine pistons.

The A360; it is mainly used to cast aluminum parts where pressure tightness and fluidity is a priority. It maintains corrosion resistance and strength even at elevated temperature.

Alloy A413; its properties are similar to that of the alloy A360. This alloy is mainly used to die cast hydraulic cylinder components.

Alloy A380; it has good thermal and mechanical properties. Their performance property is similar to most alloys listed above.

Pressure Die Casting

Pressure die casting is a quick, reliable and cost-effective manufacturing process for production of high volume, metal components that are net-shaped have tight tolerances. Basically, the pressure die casting process consists of injecting under high pressure a molten metal alloy into a steel mold (or tool). This gets solidified rapidly (from milliseconds to a few seconds) to form a net shaped component. It is then automatically extracted.

Advantages of Pressure Die Casting:

• Lower costs compared to other processes.
• Economical - typically production of any number of components from thousands to millions before requiring replacement is possible.
• Castings with close dimensional control and good surface finish
• Castings with thin walls, and therefore are lighter in weight.

It is intended to prepare a Feasibility Report to install 900Tons/Year Pressure Die Casting (Aluminium) production facility as a Green Field Project.

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Nowadays, this distinction is not completely exhausting. By properly selecting high quality scrap, a purity level close to primary alloys can be achieved in secondary alloys too.

Iron (Fe) plays an important role in distinguishing between primary and secondary Al alloys. This element cannot be easily removed from the molten metal and it forms generally brittle intermetallic compounds that influence the final mechanical properties of the components.

Primary Al alloys present low Fe content and so they are used for applications where the best exploitation of some specific properties is required (mechanical strength, ductility, corrosion resistance, workability, weldability, electrical conductivity); secondary alloys show good castability, which, combined with the natural low volume density of Al alloys, makes them suitable in high-pressure die casting.

It is intended to prepare a Feasibility Report to install 7200Tons/Year Aluminium Ingot production facility as a Green Field Project.

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Nowadays, this distinction is not completely exhausting. By properly selecting high quality scrap, a purity level close to primary alloys can be achieved in secondary alloys too.

Iron (Fe) plays an important role in distinguishing between primary and secondary Al alloys. This element cannot be easily removed from the molten metal and it forms generally brittle intermetallic compounds that influence the final mechanical properties of the components.

Primary Al alloys present low Fe content and so they are used for applications where the best exploitation of some specific properties is required (mechanical strength, ductility, corrosion resistance, workability, weldability, electrical conductivity); secondary alloys show good castability, which, combined with the natural low volume density of Al alloys, makes them suitable in high-pressure die casting.

Industry and Recycling Trend

The production of secondary aluminium in Europe and United States of America. The contribution of individual European countries is also analyzed. While the production is almost steady in the USA, a continuous growth is evident in Europe, with a production of more than 3 million metric tons in 2014. About half of the total production is concentrated in Germany and Italy. In the considered period, Italy doubled its production from about 500 to 1000 thousand metric tons, becoming the main European producer. Austria, Spain, and Hungary show similar trends with a strong increment in recent years, while France and the Netherlands show an opposite trend. Norway in 2014 recorded a quadruple production increase compared to 1998, but the progress decreases over the next few years until 2014.

Secondary aluminum production from 1998 to 2014 in Europe and some European countries. The production in the USA is also reported. Data elaborated from.

Aluminium properties

Physically, chemically and mechanically, aluminum is a metal similar to steel, brass, copper, zinc, lead or titanium. It can be melted, cast, formed and machined in a similar way to these metals and conducts electric currents. In fact, often the same equipment and fabrication methods are used as for steel.

Light Weight

Aluminum is a very light metal with a specific weight of 2.7 g/cm3, about a third of that of steel. This cuts the costs of manufacturing with aluminum. Again, its use in vehicles reduces dead-weight and energy consumption while increasing load capacity. This also reduces noise and improves comfort levels.

Its strength can be adapted to the application required by modifying the composition of its alloys. Aluminum-magnesium-manganese alloys are an optimum mix of formability with strength, while aluminum-magnesium-silicon alloys are ideal for automobile body sheets, which show good age-hardening when subjected to the bake-on painting process.

Corrosion Resistance

Aluminum naturally generates a protective thin oxide coating which keeps the metal from making further contact with the environment. It is particularly useful for applications where it is exposed to corroding agents, as in kitchen cabinets and in vehicles. In general, aluminum alloys are less corrosion-resistant than pure aluminum, except for marine magnesium-aluminum alloys. Different types of surface treatment such as anodising, painting or lacquering can further improve this property.

Electrical and Thermal Conductivity

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Aluminum is an excellent heat and electricity conductor and in relation to its weight is almost twice as good a conductor as copper. This has made aluminum the first choice for major power transmission lines. It is also a superb heat sink for many applications that require heat to be drained away rapidly, such as in computer motherboards and LED lights.

Reflectivity

Aluminum is a good reflector of visible light as well as heat, and that together with its low weight, makes it an ideal material for reflectors in, for example, light fittings or rescue blankets. Cool roofs made of coated aluminum are invaluable in reducing internal solar heat within a house, by reflecting up to 95% of sunlight.

Ductility

Aluminum is ductile and has a low melting point and density. It can be processed in several ways in a molten condition. Its ductility allows aluminum products to be formed close to the end of the product’s design. Whether sheets, foil, geometrical configurations, tubes, rods or wires, aluminum is up to them all.

Strength at Low Temperatures

In contrast to steel, which rapidly becomes brittle at low temperatures, aluminum shows increased tensile strength as temperatures drop.

Impermeable and Odorless

Aluminum foil is only 0.007 mm in thickness, but is still durable and completely impermeable, keeping any food wrapped in it free of external tastes or smells. It keeps out ultraviolet rays as well.

Moreover, the metal itself is non-toxic and odorless, which makes it ideal for packaging sensitive products such as food or pharmaceuticals. The fact that recycled aluminum can be used reduces the carbon footprint for this stage of food and beverage manufacturers as well.

Non-magnetic

Aluminum is non-magnetic, making it useful for electrical shielding as in computer disks, dish antennas, bus bars or magnet housings.

Non-toxic

Aluminum is non-toxic and is used to make woks, pressure cookers and many other cooking utensils without fear. It is easily cleaned and does not contaminate the food at any stage.

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The aluminum extrusion (also known by "aluminum frames") forming process is a bulk plastic deformation process. First, a billet of aluminum is preheated to a specified temperature that is still comfortably below the material melting point in order to facilitate the plastic flow of the material. The heated billet is then forced through a tooling die that is designed to shape and form the billet into the corresponding profile cross section.

Aluminum is a very commonly specified material for use in extrusions and shape profiles because it possesses mechanical characteristics that make it ideally suited for the shaping and forming metal billet sections.

The high malleability of aluminum means that the metal can be readily shaped into a variety of sections without expending significant energy on the tooling or forming process, and the melting point of aluminum is also generally on the order of half that of ordinary steel. Both of these facts mean that the aluminum extrusion process has a relatively low energy footprint translating into low tooling and manufacturing costs. Finally, aluminum also possesses a high strength to weight ratio, making it an excellent choice for industrial applications.

Aluminum profiles are most commonly used across industrial automation applications such as automated motion applications on process lines and industries throughout manufacturing. They are strong and yet light enough that they yet can be easily man-handled and built into various configurations as necessitated by the automation structure.

Extrusion can be cold or hot, depending on the alloy and the method used. In hot extrusion, the billet is preheated to facilitate plastic deformation.

Factors Affecting Extrusion

Shape is a determining factor in the part's cost and ease with which it can be extruded. In extrusion a wide variety of shapes can be extruded, but there are limiting factors to be considered. These include size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, factor, and scrap ratio. If a part is beyond the limits of these factors, it cannot be extruded successfully.

The size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, and scrap ratio are interrelated in the extrusion process as are extrusion speed, temperature of the billet, extrusion pressure and the alloy being extruded.

In general, extrusion speed varies directly with metal temperature and pressure developed within the container. Temperature and pressure are limited by the alloy used and the shape being extruded. For example, lower extrusion temperatures will usually produce shapes with better quality surfaces and more accurate dimensions. Lower temperatures require higher pressures. Sometimes, because of pressure limitations, a point is reached where it is impossible to extrude a shape through a given press.

The preferred billet temperature is that which provides acceptable surface and tolerance conditions and, at the same time, allows the shortest possible cycle time. The ideal is billet extrusion at the lowest temperature which the process will permit. An exception to this is the so-called press-quench alloys, most of which are in the 6000 series. With these alloys, solution heat-treat temperatures within a range of 498-525° C must be attained at the die exit to develop optimum mechanical properties.

At excessively high billet temperatures and extrusion speeds, metal flow becomes more fluid. The metal, seeking the path of least resistance, tends to fill the larger voids in the die face, and resists entry into constricted areas. Under those conditions, shape dimensions tend to fall below allowable tolerances, particularly those of thin projections or ribs.

An alloy's higher mechanical properties mean a lower extrusion rate. Greater friction between the billet and the liner wall results in a longer time required to start the billet extruding. The extrusion ratio of a shape is a clear indication of the amount of mechanical working that will occur as the shape is extruded.

Extrusion Ratio = area of billet/area of shape.

When the extrusion ratio of a section is low, portions of the shape involving the largest mass of metal will have little mechanical work performed on it.

Advantages of the extrusion process:

There are several advantages of the modern extrusion process

• A variety of shapes are possible, especially with hot extrusion.

• Grain structure and strength properties are enhanced in cold and warm extrusion.

• Fairly close tolerances are possible, especially in cold extrusion.

• Little or no wasted material is created. However, a limitation is that the cross section of the extruded part must be uniform throughout its length.

Types of Extruded Profiles

An extruded profile is defined as a product that is long in relation to its cross section other than extruded rod, wire, bar, tube, or pipe. Many custom or complex cross-sectional designs are possible with aluminum extrusion and, as such, three broad categories of profiles have been established:

? Solid profiles: Extruded cross sections that do not incorporate enclosed or partially enclosed voids (Some examples of solid profiles are I-beams or C-channels; refer to Table 4 and related information to discern solid from semi hollow profiles.)

? Hollow profiles: Extruded cross sections that contain one or more completely enclosed voids in one or more portions of its overall shape geometry

? Semi hollow profiles: Extruded cross sections that contain one or more partially enclosed voids in one or more portions of its overall shape geometry

The global sales of aluminum extrusion is expected to garner a market value of US$ 89 Billion in 2022 and is expected to register a CAGR of 7% by accumulating a market value of US$ 175 Billion through the assessment period 2022-2032.

It is intended to prepare a Feasibility Report to install 5 TPD Aluminium Extrusion production facilities as a Green Field Project near Angul, Odisha

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Thickness of aluminum sheet is less than 6mm, also called as leaf or foil. Aluminum is one of the most widely used materials for making sheets due to its cost effectiveness, ductility, and robustness. Aluminum can be easily moulded into various shapes, grades or in number of forms which has led to increased usage of aluminum sheets in different industrial application. Aluminum sheets are popularly used for industrial applications including aerospace (panel of planes), transportation-(auto panel body), packaging (can bodies) and construction (buildings).

Aluminum sheets exhibit excellent anti-corrosion property and hence are widely being used for marine applications. Aluminum sheets are excellent option for industrial as well as structural application due to its high strength and flexible nature. The global aluminum sheet market is anticipated to grow at a moderate CAGR over the forecast period.

Aluminium is the world’s most abundant metal and is the third most common element, comprising 8% of the earth’s crust. The versatility of aluminium makes it the most widely used metal after steel. Although aluminium compounds have been used for thousands of years, aluminium metal was first produced around 170 years ago. In the 100 years since the first industrial quantities of aluminium were produced, worldwide demand for aluminium has grown to around 29 million tons per year.

About 22 million tons is new aluminium and 7 million tons is recycled aluminium scrap. The use of recycled aluminium is economically and environmentally compelling. It takes 14,000 kWh to produce 1 ton of new aluminium. Conversely it takes only 5% of this to remelt and recycle one ton of aluminium. There is no difference in quality between virgin and recycled aluminium alloys. Pure aluminium is soft, ductile, and corrosion resistant and has a high electrical conductivity. It is widely used for foil and conductor cables, but alloying with other elements is necessary to provide the higher strengths needed for other applications.

Aluminium is one of the lightest engineering metals, having strength to weight ratio superior to steel. By utilizing various combinations of its advantageous properties such as strength, lightness, corrosion resistance, recyclability and formability, aluminium is being employed in an ever-increasing number of applications. This array of products ranges from structural materials through to thin packaging foils.

Market-O-Nomics:

• The Aluminum Plate Market is expected to expand and grow at a CAGR of 5.5%
• These plates and are formed by passing aluminum between rolls under pressure to make it longer and thinner in the direction in which it is moved.
• These plates and sheet coils are non-corrosive, heat resistant, and have high thermal conductivity for which they are extensively used in the automotive, construction, aerospace, and in the power generation industry.
• Properties such as non-corrosive, lightweight, high thermal conductivity have increased the demand of aluminum plates and in the automotive sector, replacing steel and other metals as the sector registers a shift in its preference toward lightweight vehicles.
• Aluminum plates are also used in the food and beverage industry for packaging and preserving. An increase in the consumption of ready-to-eat food due to fast lifestyles is expected to fuel the demand registered in the aluminum plates market.
• The global aluminum plate market can be segmented applications that include automotive and aerospace.
• The global aluminum sheet market is anticipated to be dominated by Asia Pacific region a factor that is attributed to the large base of automotive production and consumption in the region.

Aluminum flat products are produced from flat rolling processing method which turns an aluminum ingot known as slab into thinner product or a plate. Flat aluminum products are widely used in manufacturing of cans, foil, automobile bodies and equipment & machinery which may drive aluminum flat products market demand.

Production of these rolled products is a cost-effective process as the metals are shaped into custom cross-section profiles, which require low labor demands, allowing higher volume production for most products with higher efficiency.

Aluminum flat products are used broadly in various applications including household utensils, packages, closures, building interiors & exteriors, roofs and home electric appliances. Flat aluminum products such as aluminum cans have higher recycling rates than other packaging material. They are lightweight, stackable, and strong, allowing brands to package & transport more beverages using lesser materials.

In past few years, the aluminum industry recycled 56.2 billion cans with a recycling rate of 63.6%. The rising awareness about plastic pollution and its adverse effects on the environment have prompted many government organizations to take initiatives, such as plastic recycling, and impose regulations to curb plastic waste generation. However, as plastic recycling is not completely effective; industries are opting for alternative packaging solutions such as aluminum foil.

Foil stock are also used in pharmaceutical packaging as they possess insulating properties. It acts as a barrier against light, oxygen and moisture which protects the drugs from contamination and deterioration. Usage of foil stock for pharmaceutical packaging also improves longer shelf life of products offering higher security to patients may boost the aluminum flat products market.

Furthermore, the ability to safeguard food and pharmaceuticals from impurity and the natural lightness of aluminum makes it a raw material of choice over other foil options. With disposable packaging trends, where plastic based packaging is posing threat to environment, aluminum foil products can help meet fundamental sustainability goals in the aluminum flat products market.

Aluminum flat products are ideally suited to design electrical vehicles to meet demanding performance requirements. Light weighting through aluminium lowers both the manufacture and the operational expenses of electric vehicles as a lighter car needs less batteries and power to travel the same distance. The automobile manufacturers have switched from steel to aluminum flat products for battery enclosures which may drive the market growth.

It is intended to prepare a Feasibility Report to install 200 TPD Aluminium Plate (Thickness 1mm to 3mm) production facilities as a Brown Field Project.

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Aluminum collapsible tubes are one of the most common packaging solutions in cosmetic, health care, pharmaceutical, food and adhesive industries. They are ideal for packing low viscosity products, such as lotion, cream, ointment and adhesive.

The tube collapses as the contents are squeezed out, effectively preventing suck back of air or contaminants and thus maximizes shelf life of product.

Aluminium collapsible tubes, covered under IS: 3107-1979 (First revision), are suitable for a wide range of liquids, semi-liquids, pastes & formulations containing soluble constituents. All collapsible aluminium tubes with short screwed nozzle are well specified in this standard. The aluminium collapsible tubes with other types of nozzles designs eg. Eye ointment tube, are covered under IS: 7852-1975.

Aluminium collapsible tubes are manufactured from Aluminium grade 19500 as per IS: 737 - 1974. The wrought aluminium & alloys for general engineering purposes belong to this specification. The collapsibility & permeability w.e.f. moisture and easy workability are the main characteristics of the aluminium slugs used for manufacturing collapsible tubes.

Aluminium of 99.70% purity is cast, rolled to predetermined thickness & blanked to provide cylindrical shapes of a defined diameter. These metal pieces are generally referred to in the industry as slugs. Slugs are heat treated to bring them to desired metallurgical state for fabricating into a collapsible tube. Mechanical fabrication an aluminium tube is accomplished in five stages of production, carried out automatically on a mass-production flow line.

The lubricated slugs are converted into tube shapes, by a process of impact extrusion in a specially designed press, with a shoulder & nozzle. The tubes are transferred, next, to an automatic machining lathe for trimming to correct lengths & thread rolling on the nozzle portion.

The severe impact-extrusion forces, involved in the transformation of slug to tube, cause a work-hardening in the tube. To provide flexibility or collapsibility, in the containers, they are annealed at temperature slightly below the melting point of the metal.

It is intended to prepare a Feasibility Report to install a Aluminium Slug production facility with a capacity of 1800TPA as a Green Field Project.

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Specifically, aluminum provides an absolute barrier to protect foods, whether on the shelf, in the cooler or in the freezer. It can go from freezer to oven to broiler to microwave oven and result in quality food products whether at home or in central food processing operations. It is lightweight, so that it is easy and economical to transport. It is formable so that it is available in a wide variety of shapes and sizes. It can be printed, coated or embossed. And, it is recyclable which results in a 95% energy savings over that required to produce primary metal.

The growth of the aluminum foil container is due to its many advantages. The natural qualities of aluminum, its impermeability and barrier properties, provide real benefits for consumers. There simply is not a more versatile material.

Aluminum foil containers offer some of the most versatile packaging solutions available today, like aluminum foil cups/plates, aluminum foil dishes, aluminum foil food containers, aluminum foil trays, aluminum food packaging containers with lids, disposable aluminum foil pans, disposable food containers with lids, foil containers with lids for food, foil food containers with lids, foil takeaway containers, food foil packaging. They combine the features needed to process, conserve and deliver to the consumer perfectly preserved and quickly accessed food products.

Aluminum foil containers are formed by combining mechanical and air pressure to force light gauge aluminum foil into a shaped die cavity. Esthetically appealing aluminum foil containers are ideal for table-ready service after the container has functioned first as a package and a heating utensil. Foil containers also come in a variety of colors and special purpose coatings

Aluminum foil containers are used to prepare, freeze, store, transport, cook and serve a variety of foods. Containers made from aluminum foil are the only containers that can be used in all types of ovens: microwave, conventional, convection and broiler. Moreover, its recyclability makes aluminum one of the most environment friendly materials on earth, a key advantage for planet conscious consumers and local governments. Additionally, recycled aluminum saves more than 95% of the energy necessary to produce new primary aluminum

Foil Containers Features

The aluminum container owes a large part of its acknowledged advantages to the attributes of the foil material:

Barrier: Container foil provides a total barrier against light and gas and protects food from deterioration.

Formability: Container foil has is highly formable and can also be “dead folded,” which is beneficial when deep drawing and shaping containers.

Heating properties: Aluminum is an excellent conductor of heat, and at the same time is heat-resistant, allowing quick and controlled heating of the container’s food content. Aluminum is also one of the only container serving options that is tri-oven able, offering cooking versatility in conventional, microwave and broiler oven types.

Decorative potential: Container foil lends itself to strong shelf appeal and striking package design. The material is both bright and reflective and can be color-lacquered or printed.

Food contact ability: Aluminum container foil meets international mandatory standards on contact with foodstuffs.

Sustainability: Foil helps meet source reduction and sustainability goals through the development of lightweight and down-gauged packaging. Aluminum containers provide perfect preservation and prevent from food waste. Aluminum containers can be recycled over and over again without any loss of quality.

It is intended to prepare a Feasibility Report to install 2400 Ton/Year Aluminium Foil Container Production facility as a Green Filed Project.

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PROPERTIES

The major advantages of using aluminium are tied directly to its’ remarkable properties. Some of these properties are outlined in the following sections.

(1) STRENGTH TO WEIGHT RATIO

Aluminium has a density around one third that of steel and is used advantageously in applications where high strength and low weight are required. This includes vehicles where low mass results in greater load capacity and reduced fuel consumption.

(2) CORROSION RESISTANCE

When the surface of aluminium metal is exposed to air, a protective oxide coating forms almost instantaneously. This oxide layer is corrosion resistant and can be further enhanced with surface treatments such as anodising.

(3) ELECTRICAL AND THERMAL CONDUCTIVITY

Aluminium is an excellent conductor of both heat and electricity. The great advantage of aluminium is that by weight, the conductivity of aluminium is around twice that of copper. This means that aluminium is now the most commonly used material in large power transmission lines. The best alternatives to copper are aluminium alloys in the 1000 or 6000 series. These can be used for all electrical conduction applications including domestic wiring. Weight considerations mean that a large proportion of overhead, high voltage power lines now use aluminium rather than copper. They do however, have a low strength and need to be reinforced with a galvanised or aluminium coated high tensile steel wire in each strand.

(4) LIGHT AND HEAT REFLECTIVITY

Aluminium is a good reflector of both visible light and heat making it an ideal material for light fittings, thermal rescue blankets and architectural insulation.

(5) TOXICITY

Aluminium is not only non-toxic but also does not release any odours or taint products with which it is in contact. This makes aluminium suitable for use in packaging for sensitive products such as food or pharmaceuticals where aluminium foil is used

(6) RECYCLING

The recyclability of aluminium is unparalleled. When recycled there is no degradation in properties when recycled aluminium is compared to virgin aluminium. Furthermore, recycling of aluminium only requires around 5 percent of the input energy required to produce virgin aluminium metal.

The combination of two remarkable properties of aluminium makes the need to recycle the metal obvious. These first of these factors is that there is no difference between virgin and recycled aluminium. The second factor is that recycled aluminium only uses 5% of the energy required to produce virgin material. Currently around 60% of aluminium metal is recycled at the end of its lifecycle but this percentage can still be vastly improved.

Aluminium is a chemical element in the boron group with symbol Al and atomic number 13. It is a silvery white, soft, ductile metal. Aluminium is the third most abundant element and the most abundant metal in the Earth's crust. It makes up about 8% by weight of the Earth's solid surface.

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An aluminium composite panel (ACP) consists of two foil-coated aluminium sheets (typically around 0.5mm in thickness) bonded to a core (around 2 to 5mm thick). Depending on the panel, this core may be aluminium, mineral, or a thermoplastic polymer (usually polyethylene).

TYPES OF ACPS

1. FR

The FR (Fire Retardant) type panel, on the other hand, contains an interior fire retardant core made of thermoplastic resins with mineral charge.

Its reaction to fire classification B-s1, d0 (according to UNE EN 13501-1:2007), makes it a coating material that fulfils most of the architectural applications

2. A2

In the case of the A2 panel, this is a non-combustible panel composed of a mineral core developed to meet the highest regulatory requirements of fire classification

Its reaction to fire classification A2-s1, d0 (according to UNE EN 13501-1:2007), makes it the ideal cladding solution for high-rise buildings and high occupancy.

Aluminium Composite Panels consist of two thin sheets of aluminium continuously bonded to a polyethylene core. This polyethylene core of the aluminium composite panel is faced with two thin sheets of aluminium. The aluminium is bonded onto the core during the manufacturing process and it is virtually impossible to separate the layers of material once they have beenbonded

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PROPERTIES

The major advantages of using aluminium are tied directly to its’ remarkable properties. Some of these properties are outlined in the following sections.

(1) STRENGTH TO WEIGHT RATIO

Aluminium has a density around one third that of steel and is used advantageously in applications where high strength and low weight are required. This includes vehicles where low mass results in greater load capacity and reduced fuel consumption.

(2) CORROSION RESISTANCE

When the surface of aluminium metal is exposed to air, a protective oxide coating forms almost instantaneously. This oxide layer is corrosion resistant and can be further enhanced with surface treatments such as anodising.

(3) ELECTRICAL AND THERMAL CONDUCTIVITY

Aluminium is an excellent conductor of both heat and electricity. The great advantage of aluminium is that by weight, the conductivity of aluminium is around twice that of copper. This means that aluminium is now the most commonly used material in large power transmission lines. The best alternatives to copper are aluminium alloys in the 1000 or 6000 series. These can be used for all electrical conduction applications including domestic wiring. Weight considerations mean that a large proportion of overhead, high voltage power lines now use aluminium rather than copper. They do however, have a low strength and need to be reinforced with a galvanised or aluminium coated high tensile steel wire in each strand.

(4) LIGHT AND HEAT REFLECTIVITY

Aluminium is a good reflector of both visible light and heat making it an ideal material for light fittings, thermal rescue blankets and architectural insulation.

(5) TOXICITY

Aluminium is not only non-toxic but also does not release any odours or taint products with which it is in contact. This makes aluminium suitable for use in packaging for sensitive products such as food or pharmaceuticals where aluminium foil is used

(6) RECYCLING

The recyclability of aluminium is unparalleled. When recycled there is no degradation in properties when recycled aluminium is compared to virgin aluminium. Furthermore, recycling of aluminium only requires around 5 percent of the input energy required to produce virgin aluminium metal.

The combination of two remarkable properties of aluminium makes the need to recycle the metal obvious. These first of these factors is that there is no difference between virgin and recycled aluminium. The second factor is that recycled aluminium only uses 5% of the energy required to produce virgin material. Currently around 60% of aluminium metal is recycled at the end of its lifecycle but this percentage can still be vastly improved.

Aluminium is a chemical element in the boron group with symbol Al and atomic number 13. It is a silvery white, soft, ductile metal. Aluminium is the third most abundant element and the most abundant metal in the Earth's crust. It makes up about 8% by weight of the Earth's solid surface.

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