Aluminium extrusion compounds and assemblies - Otto Fuchs KG

We bring form and function to high performance materialsTechnical InformationAluminium extrusioncompoundsand assembliesOTTO FUCHS KGShaping the future of metal forming

2 OTTO FUCHSThe Aluminium profi le technologyis the key to forward-looking lightweightdesign. Our sophisticatedextrusion designs offer solutionsfor technical problems in the dailyroutine: e.g. in modern façadeand solar-constructions, in themechanical engineering as wellas in the aerospace and automotiveindustries. Our lightweightconstructions achieve the customerrequirements wherever massis an issue.More capacity, greater payload, lessconsumption, less toxic – these areare the musts in both logistics andtransportation. The future belongs tothe most effi cient commercial vehiclesand we develop innovative conceptsto reduce weight and costs.Our constructions are optimized withregard to economical and ecologicalaspects.Give us a challenge!

OTTO FUCHS 3Contents4 The OTTO FUCHS cold joining process5 Outstanding properties -Extrusion joint6-7 Outstanding properties -Extrusion compounds8 Your advantages at a glance9 Conclusion10-11 Examples of use

4 OTTO FUCHSThe OTTO FUCHS cold joining processDefi ned properties - long durability guaranteedThe use of single extrusions in modernlightweight designs is limited by thefeasible maximum size of the availableextrusions. In addition increasing thesize of extrusions leads to increasingthe minimum wall thickness. Thus largeload bearing constructions, made fromextrusions, become heavier than is requiredby the specification for static loads.The solution: The use of a few small,lightweight extrusions, joined togetherto form an integral structure.The cold joining technique, developedand patented by OTTO FUCHS, offersthe possibility of a strong and durableconnection of extrusions. Instead ofheavy large-sized extrusions, lightweightextrusion assemblies can beproduced. Compared to large extrusionsthe necessary tooling investmentis considerably lower for smallextrusions, which makes it easy tooptimize a design concept to anyparticular application.The OTTO FUCHS cold joining techniquehas proved its capability inthousands of components in differentapplications. These extrusion compoundsshow their unique static anddynamic load bearing capacity dayby day.The OTTO FUCHS - cold joining process (OFCJ)The OFCJ is a capable and economicjoining process. It requires that the individualprofiles are appropriately designedfor their purpose, by incorporating anintegral tongue and groove system.The actual joining process consists ofthe profi les to be integrally connectedwith each other, clamping of the parts- especially the connection zone - andactual rolling of the individual profiles.The integral couples of tongue andgrooves are thus squeezed together.For this reason our cold joining processis an economical alternative to the weldingtechniques. No distortion is produced becauseno heat is introduced into the componentduring the joining phase, as it is forwelded joints. So on one hand no additionalalignment is necessary and on theother hand the process prevents the material’sproperties from being influenced ina negative manner. In addition, the eliminationof welding causes a visually cleansurface without any disturbance/distortionby the welded joint zone.groovetonguejoining toolThe OFCJ is particularly environmentfriendly:no use of fi ller metal, and alsono inert gas resulting in no emissionslike smoke residue, UV or IV. The essentialadvantage is the economicaspect of this technique. The coldjoining operation can be performedmuch faster than a welding operation.The freedom of design, given by extrusion-moldingtechnology, is maintainedto almost its complete extent whendesigning individual profi les. In this wayfor example, screw head grooves foraccepting sliding nuts can be integratedinto individual profi les; as can sealinggrooves for fi tting rubber seals, or screwchannels for connecting further constructionparts. A great variety of modularpanels can be manufactured from afew profi les, because individual profi lescan be inserted at the preferred location.The edge profi les of panels can alsobe equipped with tongue and groovesystems, which enable individual,extrusion panels to be assembled tocover larger areas.

OTTO FUCHS 5Properties of compoundsProperties of the extrusion platesTechnological preferences.The OTTO FUCHS cold joining processis characterized by technological outstandingproperties.The main characteristic is a high staticand dynamic load bearing capacity,which does not alter even under repeatedloading. No distortion is producedbecause no heat is introduced to thecomponent during joining. The resultis: elaborate alignment work is not requiredand has no infl uence on thematerial’s properties. A further economicadvantage for the customer is theuse of thin walled single profi les resultingin high material utilization. The visuallyappealing joining zone is anaesthetic advantage of our Aluminumcompounds.Our strong, durable and rigid connectionis an attractive alternative to thecommon clips or snap connections -of course based on an economicaland environmentally friendly process.Material competence.The OTTO FUCHS material AS 05.71that is used preferentially, allows itselfto be processed well by extrusion technology,even for demanding profi les inconstruction. It also offers the coldworkability required for cold joiningapplications.material propertiesMaterial Yield strength Tensile strength Elongation to fractureEN AW 6060/6063* > 160 N/mm 2 > 215 N/mm 2 > 12%(AS 05.71)* different materials on enquiry!example of use: loading ramp

6 OTTO FUCHSProperties of compoundsProperties of the extrusion platesCorrosion resistance.The material used also has a very goodresistance to corrosion and could beused in various areas of applicationwithout further additional surface treatments.No corrosive reaction of thesamples - particularly in the rolled connectionarea- was ascertainable after10 hours in the Kesternich device atSF W 2.05 according to DIN 50018and an additional, salt spray test accordingto SS DIN 50021.Strength.Because the basic strength of the materialused is not achieved in the rolledconnection it is essential to ensure thatthe design must take into account thehighest bending stresses orientated asparallel as possible to the rolled seam.The following strength -values can beapplied for the cold joint:Transverse strength of the rolled connectionLongitudinal strength of the rolled connection> 200 N/mm**> 100 N/mm**typical strength values** These values do not represent the characteristic values of materials, but the results of technologicaltests on the rolled connection which are related on the metal deck‘s thickness; theyare heavily dependent on the sample‘s geometry. The attainable strengths can currently beconsiderably higher. Please speak to us about this feature.25020015010050Woehler diagram01,00E+03 1,00E+04 1,00E+05 1,00E+06 1,00E+07maschined platform element

OTTO FUCHS 7FEM-Analyse einer Profilplatten-KonstruktionLoad-bearing capacity.The panel’s structural properties aredetermined to one part by the extrusion-moldedprofi les used for them.The demands for rigidity should beclearly defi ned and the panel’s optimumprofi le should match the requirements.Our extrusion-molding technologyoffers all possibilities for designto meet loading stresses in this respect.Particular attention must begiven to the fact that with increasingpanel thickness the moment of inertiawill rise steeply whereas the weightjust increases in a linear manner.OTTO FUCHS offers unlimited supportwhen adapting the profi le’s crosssectionto suit the customer’s specifi crequirements, e.g. FEM.Dependency of the geometric moment ofimertia and weight on the panel‘s thickness[cm 4 , kg/m 2 ]4035302520151050moment of imertiaweightplate thickness [mm]Range of possibilities.Connecting identical kinds of hollowprofi les that have rectangular crosssections,thus gives the possibility ofmanufacturing extrusion panels havingdimensions that are only limited by thecapability of fabrication equipment.TypewhHParameterExtrusion height H:> 12 - 150Internal height h:Internal width w:> 9> 48Range of possible dimensionspossible compound dimensions:Width W W max = 3.600 mmLength L L max = 6.300 mmWL

8 OTTO FUCHSYour advantages at a glanceTechnical advantagesEconomical advantages• high load bearing capacity• a clearance free, unsolvableconnection• shear strength• no infl uence on material propertieshappens in welded joints due to theapplication of welding heat• aesthetically appealing joint patch• low minimum wall thickness,resulting in low weight per metreof the extrusion as compared tolarger extrusions• lower construction weight = lower costs• application of lower strength alloys ascompared to welded components• the high degree of design freedomcomes along with low tooling costs• short manufacturing times• costs effective high speed joiningtechnique• high availability, low minimum volumesper fabrication lot• favourable ratio of stiffness to weight• paintable due to the absence of relativemovement of adjacent profi les• variant designs by possibility ofcombining different extrusions• (virtually) waterproof

OTTO FUCHS 9ConclusionParticular light and rigid panels can bemanufactured by combining the conventional,extrusion-molding technology withthe OTTO FUCHS cold joining process.Significantly improved rigidity and weightratios are achieved compared with componentsmade from larger welded profi les.The lower tooling costs for individual profiles,that are joined together, facilitate aneconomic and technical optimization ofdesign regarding the respective demands.The elimination of the welding processavoids an influence on the material’sproperties and the distortion of the wholeassembly. This technique enables veryeven panels to be manufactured, withoutany elaborate and expensive alignmentwork.The OTTO FUCHS cold joining processallows the manufacturing timeto be shortened and thus reducesmanufacturing costs, compared withwelded constructions.We would be glad to assist with thedesign of profi les and extrusion compositesto suit specifi c problems.Give us a challenge!Lightweight construction in perfection

10 OTTO FUCHSSelective examples of useOTTO FUCHS -your development and system partnerSelf-supporting freight floors,front and side walls for trucks.The customer specifi c concept incorporatesa self-supporting design of analuminium freight fl oor. The applicationof the OTTO FUCHS cold joiningtechnique resulted in a pronouncedweight saving. The front wall alsoconsists of extrusion profi les, whichare joined together using this technique,which results in better economicperformance.By producing these large-sized, preassembledcomponents OTTO FUCHSsubstitutes the costly and manualmanufacturing process previouslyapplied.Costumer advantages andvalues:• Increasing payload• Faster production andassembly• Easier disposition:one assembled componentinstead of single parts• Increased vehicle value byuse of aluminium materialTaillift platformsThe cold joint extrusion compounds,developed and produced by OTTOFUCHS, substituted the welded platformsusually applied. The eliminationof the welding process allowed theuse of an aluminium grade of loweralloy content and strength, which,in turn, improves the processabilityby extruding and reduces costs.Costumer advantages andvalues:• cost reduction (./. 30% ascompared to welding)• short manufacturing time• aesthetic appearance• high fl exibility for productvariants

OTTO FUCHS 11Costumer advantage and values:Bridge designs, made from Steel, woodor concrete, can be substituted by aconcept, based on durable aluminiumextrusion compounds. High costs,caused by the construction of thebridge on the building ground can besaved as well as maintenance cost.The large-sized bridge componentsare preassembled at OTTO FUCHSand incorporated in the fl oor construction.Costumer advantages andvalues:• short assembly time by industrialpreassembly of fl oorcomponents• low costs on the building siteby use of preassembled bridgesections• high durability and low maintenancecost• aesthetic appearanceShading elements for constructionindustryOTTO FUCHS also offers innovativesolutions for modern building conceptswith demanding architecture.Shading elements, initially made fromlarge sized extrusions, are replacedby an extrusion compound from asymmetrical, small and light weightextrusion profi les.The application of a smaller extrusionoffers not only the advantage of lowerweight, allowing a lighter subassembly,but also a higher surface quality, whichis of particular interest in architecturalapplication.Costumer advantages andvalues:• lower tooling cost• pronounced weight advantage• better surface quality andappearance• optional two-tone appearanceof shading element• smaller minimum productionbatchPlatform for ladder scaffoldWooden scaffolding, which is subjectedto ageing and fouling, means asevere safety risk to the operators.An aluminium platform, made byOTTO FUCHS from a shear resistantaluminium compound, allows the eliminationof a welded frame, which inturn resulted in a considerable reductionof production cost. So a safe anddurable aluminium design replacesthe usual wooden construction withoutreducing the economical efficiency.Costumer advantages andvalues:• safety and reliability underhigh-duty application inconstruction industry• weight advantage• resistant to ageing• durability, low maintenance• aesthetic appearance

OTTO FUCHS KGDerschlager Straße 26D-58540 MeinerzhagenGermanyPhone +49 2354 73-0Fax +49 2354 73-201info@otto-fuchs.comwww.otto-fuchs.comwww.fuchsfelge.de