ALUMINIJ-spec

7/25/2019 ALUMINIJ-spec

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Defence Aluminium


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Defence Aluminium

... Solutions from Aleris 3

... Plate Products 4

... Extruded Products 11

... Component Manufacturing 13

Customer Engineering Support

Research and Development 14

Quality Assurance

Approvals Our Brand is Quality 15

Pictures used by courtesy of

General Dynamics European Land Systems - Ger-

many GmbH, Krauss - Maffei Wegmann GmbH &

Co. KG, Textron Marine and Land Systems, BAE

Systems, Hyundai Rotem Company, Doosan DST

Co., Ltd. and CEFA (France).

Contents

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Aleris with its European headquarter in

Switzerland is among the worlds head-

ing suppliers of high-quality aluminium

rolled and extruded products, aluminium

recycling manufacturing top-quality cast,

wrought and magnesium alloys, as well

as custom-made components for the

defence industry.

As a result of more than five decades

of experience and knowledge, gained

by being the principal supplier to many

industries, and continuous investment

in state-of-the-art production facilities,

research and development, quality as-

surance, as well as ongoing education

and training of employees, Aleris prod-

ucts are continuously improved.

This continuous improvement has enabled

Aleris, via defence specialized plants in

Koblenz, Bonn (both in Germany) and

Duffel (Belgium), to supply the interna-

tional defence industry with innovative

aluminium materials and components

of the highest quality, which fulfil, not

only the highest industry standards but

also all conceivable individual customer

specifications with respect to their di-

mensions, properties and quality char-

acteristics.

Aleris know-how has been applied in de-

veloping niche products of various alloys

like thick and extremely wide defence

aluminium plates or sections in custom-

ized sizes and large extruded products,

as well as custom-made components

which fully satisfy the requirements of

the worldwide defence industry.

A comprehensive quality management

system has been established for all speci-

fied material properties, continually con-

trolled and documented during the entire

fabrication processes, which guarantees

that the most stringent requirements of

both customers and governmental in-

stitutions worldwide are complied with.

It ensures highly consistent quality and

helps to continuously improve the prod-

uct quality.

If you need further data or more ur-

gent assistance, please contact us

using the information provided at the

back of this brochure or simply visit

our website at www.aleris.com.

Defence Solutions from Aleris

Defence Aluminium 3


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Defence Aluminium Plate Products

Aleris in Europe with its two entities Al-

eris Aluminum Koblenz GmbH in Ger-

many and Aleris Aluminum Duffel BVBA

in Belgium operates two world-class

rolling mills with unique manufacturing

capabilities for flat rolled semi-finished

products for e.g. the automotive, aero-

space and defence industry.

Traditionally, the aluminium alloys used

for armoured vehicles and other military

related applications are high strength,

heat-treatable 2xxx and 7xxx series al-

loys but also low-density and cost ef-

ficient 5xxx series alloys with excellent

ballistic properties, good weldability and

outstanding corrosion resistance.

As part of Aleris strategic plan to de-

velop new aluminium plate materials and

solutions for armoured vehicles with the

highest property performance in extreme

dimensions in particular with respect

to thickness and width various devel-opment projects, investment programs

as well as other activities have been

carried out, enabling Aleris (especially

the Koblenz plant) to become one of the

most important suppliers of aluminium

armour plate products into the worlds

defence industry.

Aleris aluminium plates offer an opti-

mum solution for any kind of structural

application with specific ballistic per-

formance, if required. They allow the

design of light-weight, reliable and cost

efficient components for light armoured

civilian and tactical vehicles as well as

for heavy constructions like military

bridges. They improve strategic and

tactical mobility of defence components

e.g. by transport aircraft into combat or

disaster relief which gives aluminium a

comparative advantage over steel.

Aluminium armour plates with ballistic

requirements are being tested at certi-

fied testing laboratories such as BWB

(Germany), TNO (The Netherlands) or

APG (USA) with consideration of na-

tional and international regulations and

standards.

Aleris supplies defence aluminium plate

products based on the following alloys

and tempers according to the various

relevant material specifications:

Alloys and specifications

With ballistic requirements

Alloy* Temper Specification

AA 5083 H131 MIL-DTL-46027

EN AW 5083 TL 2350-0004

AA 5059 H131 MIL-DTL-46027

EN AW 5059 TL 2350-0004

Alustar

AA 5059 H136 MIL-DTL-46027

Alustar

AA 2519 T87 MIL-DTL-46192

AA 7017 T6 TL 2350-0004

EN AW 7020 T6 TL 2350-0004

AA 7039 T6 MIL-DTL-46063

* Other alloys on request

Without ballistic requirements

Alloy* Temper Specification

AA 5456 H116 ASTM

AA 2024 O ASTM

AA 6061 T6 AMS-QQ-A

EN AW 6061 EN 485-2

EN AW 7020 T6 EN 485-2

EN AW 7022 T6 EN 485-2


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In the following tables Aleris aluminium

armour plates with ballistic requirements

are characterized in detail and compared

to minimum values specified in TL and

MIL standards.

Additionally, typical mechanical proper-

ties after fusions welding and friction stir

welding (FSW) demonstrate the advan-

tage of Aleris theAlustaralloy in a cost

efficient manufacturing process.

Basic material properties

Physical properties

Alloy* Density E-Modulus

Coeff. of thermal expansion

Thermal conductivity Electrical conductivity

20-100C 68-212F 20C 68F 20C 68F

g/cm3 lbs/in3 MPa 103ksi m/m K in/in F W/(m * K) btu/(ft h F) m/( mm2) %IACS

5083 2.66 0.096 69,200 10.0 24.5 13.6 131 75.7 17 29.3

5059 2.64 0.095 70,400 10.2 23.0 12.8 130 75.1 16 27.6

Alustar

2519 2.82 0.102 71,000 10.3 22.0 12.2 140 80.9 19 32.8

7017 2.77 0.100 70,500 10.2 23.3 12.9 130 75.1 21 36,3

7020 2.77 0.100 71,000 10.3 23.1 12.8 137 79.2 20 34,5

7039 2.73 0.099 69,600 10.1 23.4 13.0 125 72.2 19 32,8

* According to AA or EN AW

Chemical composition

Alloy* Chemical elements Other Other

Si Fe Cu Mn Mg Cr Zn Ti Zr V Individual Total

5083 Min. weight (%) 0.00 0.00 0.00 0.40 4.0 0.05 0.00 0.00 - - 0.00 0.00

Max. weight (%) 0.40 0.40 0.10 1.0 4.9 0.25 0.25 0.15 - - 0.05 0.15

5059 Min. weight (%) 0.00 0.00 0.00 0.6 5.0 0.00 0.4 0.00 0.05 - 0.00 0.00

Alustar Max. weight (%) 0.45 0.5 0.25 1.2 6.0 0.25 0.9 0.2 0.25 - 0.05 0.15

2519 Min. weight (%) 0.00 0.00 5.3 0.10 0.05 - 0.00 0.02 0.10 0.05 0.00 0.00

Max. weight (%) 0.25 0.30 6.4 0.50 0.40 - 0.10 0.10 0.25 0.15 0.05 0.15

7017** Min. weight (%) 0.00 0.00 0.10 0.10 1.7 0.00 4.0 0.00 0.10 - 0.00 0.00

Max. weight (%) 0.30 0.40 0.20 0.70 3.3 0.25 6.0 0.15 0.25 - 0.05 0.15

7020** Min. weight (%) 0.00 0.00 0.00 0.05 1.0 0.10 4.0 0.08 - 0.00 0.00

Max. weight (%) 0.35 0.40 0.20 0.50 1.4 0.35 5.0 0.20 - 0.05 0.15

7039 Min. weight (%) 0.00 0.00 0.00 0.10 2.3 0.15 3.5 0.00 - - 0.00 0.00

Max. weight (%) 0.30 0.40 0.10 0.40 3.3 0.25 4.5 0.10 - - 0.05 0.15


** According to TL 2350-0004

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Minimum mechanical properties

Alloy Temper Specification* Test Plate thickness Tensile strength Rm

Yield strength Rp0.2

Elongation A

direction mm in MPa ksi MPa ksi %AA 5083 H131 MIL-DTL-46027 L 6.35 - 12.67 0.250 - 0.499 310 45.0 241 35.0 8

(table VI) 12.7 - 50.8 0.500 - 2.000 310 45.0 255 37.0 8

50.83 - 76.2 2.001 - 3.000 303 44.0 241 35.0 9

EN AW 5083 H131 TL 2350-0004 LT 6.35 - 12.67 0.250 - 0.499 311 45.0 242 35.0 8

12.7 - 50.8 0.500 - 2.000 311 45.0 256 37.0 8

50.83 - 76.2 2.001 - 3.000 304 44.0 242 35.0 9

AA 5059 H131 MIL-DTL-46027 L 6.35 - 12.67 0.250 - 0.499 393 57.0 303 44.0 8

Alustar (table VI) 12.7 - 50.8 0.500 - 2.000 393 57.0 296 43.0 7

50.83 - 76.2 2.001 - 3.000 344 50.0 289 42.0 8

EN AW 5059 H131 TL 2350-0004 LT 6 - 60 0.236 - 2.362 370 54.0 300 44.0 8

Alustar

AA 5059 H136 MIL-DTL-46027 L 6.35 - 12.67 0.250 - 0.499 365 53.0 296 43.0 10

Alustar (table VI) 12.7 - 50.8 0.500 - 2.000 358 52.0 289 42.0 10

50.83 - 76.2 2.001 - 3.000 344 50.0 289 42.0 10

AA 2519 T87 MIL-A-46192 L 12.7 - 38.1 0.500 - 1.500 455 66.0 407 59.0 10

(table II) 38.1 - 50.8 1.501 - 2.000 455 66.0 407 59.0 9

50.8 - 76.2 2.001 - 3.000 462 67.0 414 60.0 8

76.2 - 101.6 3.001 - 4.000 469 68.0 421 61.0 7

AA 7017 T6 TL 2350-0004 LT 6 - 50 0.236 - 1.969 430 62.4 360 52.2 8

> 50 - 76 > 1.969 - 2.992 410 59.5 340 49.3 8

> 76 > 2.992 410 59.5 340 49.3 6

EN AW 7020 T6 TL 2350-0004 LT < 25 < 0.984 350 50.8 280 40.6 10

> 25 - 60 > 0.984 - 2.362 340 49.3 275 40.0 8

AA 7039 T6 MIL-DTL-46063 L < 38.1 < 1.5 414 60.0 352 51.0 9

(table II) > 38.1 > 1.5 393 57.0 331 48.0 8

* Mechanical properties according to table VI of MIL-DTL-46027 for standard dimensions up to 60 x 140 (width x length)

For wider plates with dimensions 60 < width < 100 mechanical properties are guaranteed according to MIL-DTL-46027 table II

Other dimensions on request

Mechanical performance

Minimum and typical mechanical pro-

perties are measured in L-direction

as specified in MIL standards, while

plates produced according to TL stan-

dards are tested in LT direction. Pro-

perties after welding are always mea-

sured across the weld seam, typically

in the LT direction.

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Typical mechanical properties (based on actual production values)

Alloy* Temper Test Plate thickness Tensile strength Rm


Elongation A

direction mm in MPa ksi MPa ksi %5083 H131 L 6.35 - 12.67 0.250 - 0.499 345 50.0 285 41.3 10

12.7 - 50.8 0.500 - 2.000 330 48.0 275 40.0 10

50.83 - 76.2 2.001 - 3.000 320 46.4 265 38.4 11

5059 H131 L 6.35 - 12.67 0.250 - 0.499 405 58.7 360 52.2 9

Alustar 12.7 - 50.8 0.500 - 2.000 395 57.3 350 50.8 9

50.83 - 76.2 2.001 - 3.000 360 52.2 310 45.0 10

5059 H131 LT 25.8 1.016 411 59.6 319 46.3 11

Alustar

5059 H136 L 6.35 - 12.67 0.250 - 0.499 375 54.4 310 45.0 12

Alustar 12.7 - 50.8 0.500 - 2.000 380 55.0 320 46.4 11

50.83 - 76.2 2.001 - 3.000 355 51.5 295 42.8 12

2519 T87 L 12.7 0.500 484 70.2 455 66.0 12

25.4 1.000 488 70.8 464 67.3 12

38.1 1.500 484 70.2 458 66.4 12

7017 T6 LT > 6 < 50 0.16 - 1.97 445 64.5 385 55.8 11

7020 T6 LT > 4 < 25 0.16 - 0.98 360 52.2 300 43.5 13

> 25 < 60 1 - 2.36 355 51.5 295 42.8 11

7039 T6 L < 38.1 < 1.5 435 63.0 375 54.4 11

> 38.1 > 1.5 425 61.6 355 51.5 10

Typical values after fusion welding

Alloy* Temper Typical Typical plate Tensile strength Rm


filler wire thickness

alloy* mm in MPa ksi MPa ksi

5083 H131 5183 20 - 30 0.78 - 1.18 275 40.0 125 18.2

5059 H131 5183 20 - 30 0.78 - 1.18 300 43.5 160 23.2Alustar 5556

5059 H136 5183 20 - 30 0.78 - 1.18 300 43.5 160 23.2

Alustar 5556

2519 T87 2319 101.1 4 280 40.6 204 29.6

7017 T6 5183 25 - 30 1 - 1.18 260 37.7 205 29.7

5356/5556

7020 T6 5183 25 - 30 1 - 1.18 275 40.0 205 29.7

5356/5556

7039 T6 5183 25 - 30 1 - 1.18 310 45.0 175 25.4

5356/5556

for comparison:

6061 T6 4043 < 30 < 1.18 185 26.8 115 16.7

5183


All values are measured across the weld seam and rolli ng direction (LT-direction)

after friction stir welding (FSW)

Tensile strength Rm


MPa ksi MPa ksi

285 41.3 162 23.5

340 49.3 180 26.1

340 49.3 180 26.1

** ** ** **

** ** ** **

325 47.1 240 34.8

** ** ** **

252 36.5 162 23.5

** To be determined

Defence Aluminium 7


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Milne de Marre graph for armour plate materials (according to MIL)

Ballistic performance

The following Milne de Marre graphs have

been generated to offer a design guide

to engineers and designers of armoured

vehicles, as well as to demonstrate the

ballistic performance and weight effi-

ciency of most commonly used Aleris

armour plate alloys.

They allow a simple estimation of the

weight of an aluminium plate under con-

sideration of the ballistic performance ac-

cording to the appropriate MIL standard

and the individual alloy density.

Projectile .30AP M2 0

950 3,117

900 2,953

850 2,789

800 2,625

750 2,461

700 2,297

650 2,133

Projectile 20 mm FSP

950 3,117

850 2,789

750 2,461

650 2,133

550 1,804

450 1,476

350 1,148

V50

limit velocity

[m/s] [ft/s]

V50

limit velocity

[m/s] [ft/s]

Areal density [kg/m 2(lb/ft2)] Areal density [kg/m2(lb/ft2)]

70 80 90 100 110 120 130 140

(14.3) (16.4) (18.4) (20.5) (22.5) (24.6) (26.6) (28.7)

70 80 90 100 110

(14.3) (16.4) (18.4) (20.5) (22.5)

AA 2519 AA 2519AA 5059Alustar AA 5059AlustarAA 7039 AA 7039

How to use the graph:

Requirement V50

: 800 m/s 2,625 ft/s

Arial density AA 5059Alustar: 115 kg/m2 23.6 lb/ft2

Assumed plate dimension: t x 2,000 x 3,000 mm t x 78.7 x 118.1 in

Assumed plate weight: 690 kg 1,521 lb

Example:

V50

= 800 m/s (2,625 ft/s)

Result:

Arial density = 115 kg/m2(23.6 lb/ft2)

Defence Aluminium8


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Natural sea water test

Alloy* Temper Thickness

Test time

MIG welded Remarks

mm in month

with filler alloy5059 H136 12.7 0.5 14 5183 insignificant attack on the water line, no visible attack on the weld seam

Alustar insignificant attack in the Heat Affected Zone (HAZ), pitting on the surface

2519 T87 13 0.51 3 2319 corrosion on the rolled surface, insignificant attack on the weld seam and in the HAZ


AA 5059 H136

front side (final weld pass)

AA 2519 T87

front side (final weld pass)

AA 5059 H136

back side (root pass)

AA 2519 T87

back side (root pass)

Corrosion performance

The AlerisAlustaralloy was originally

developed for the challenging corrosion

requirements of the international ship-

building industry. Alustarhas been

further developed to make it applicable

to the defence industry, where corrosion

performance is an essential operational

requirement.

For example, not only for amphibious

vehicles but also for other armoured

vehicles in corrosive environments due

to chemical / biological exposure or the

extreme environment conditions seen

through operational deployment through-

out the life time of such vehicles.

Todays economic expectations are lead-

ing to extended life cycles for current and

future military platforms requiring new

materials like Alustarwith outstand-

ing corrosion resistance and excellent

ballistic protection.

Welded samples of AA 5059 and AA 2519 after natural sea water corrosion test

Defence Aluminium 9


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Advantages

General dimensionalcapabilities for armour plate*

mm inThickness up to 254 10

Width up to 3,300 130

Length up to 24,000 945

* Subject to alloy, temper and

thickness x width combination

Larger dimensions on request

Specific manufacturing capabilities

Alloy* Temper Specified Specified Produced Produced width

thickness (MIL) thickness (TL) thickness

mm in mm in mm in mm in

5083 H131 76.2 3 76.2 3 76.2 3 2,540 100

5059 H131 76.2 3 60 2.36 76.2 3 2,921 115

Alustar

5059 H136 76.2 3 - - 152.4** 6** 3,048 120

Alustar

2519 T87 101.6 4 - - 101.6 4 2,032 80

7017 T6 - - 76 ~ 3 76.2 3 2,000 ~ 79

7020 T6 - - 60 2.36 60 2.36 2,870 ~ 113

7039 T6 101.6 4 - - 101.6 4 2,108 83


** Without ballistic requirements; other dimensions on request

not suitable excellent

Characteristics of aluminium armour alloys

Alloy* Temper Corrosion Weldability Ballistic requirements Spalling Mine Blast

resistance according to MIL standards

.30 AP M2 0 20 mm FSP

5083 H131

5059Alustar H131

5059Alustar H136

2519 T87

7017 T6

7020 T6

7039 T6


Based on Aleris unique manufacturing

technologies, such as the worlds most

powerful 160 (4,064 mm) wide hot roll-

ing mill and the 8,000 tons stretcher,

high performance plate products with

extraordinary dimensions can be pro-

duced, leaving nothing to be desired.

All dimensional requirements in terms

of thickness covered by the relevant TL

and MIL specifications can be fulfilled

as a minimum. Moreover, armour plates

in extreme widths can be provided to

reduce the number of weld seams in a

cost efficient manufacturing process

a key manufacturing cost and design

integrity advantage.

ThroughAlustarAleris offers the broadest

range and maximizes design flexibility.

Conclusion

Aleris offers a large variety of armour

plate materials for ballistic protection.

The product portfolio comprises high

strength, heat-treatable 2xxx and 7xxx

series alloys but also 5xxx series alloys,

such asAlustarwith low density, excel-

lent weldability and corrosion resistance.

At the same time the ballistic protection

is comparable to the best performing

high strength alloys used in the indus-

try today.

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Defence Aluminium Extruded Products

High strength alloys are heat-treated in

one of the most modern horizontal so-

lution-heat-treatment furnaces, built by

Ebner with an annual capacity of about

4,900 tons. Based on a highly sophis-

ticated quenching system, as well as a

800 tons-stretcher for straightening and

stress relieving Aleris new equipment

allows the production of complex shapes

with nearly no distortion. It increases

Aleris production capacity to a larger

range of sizes and shapes and brings

Aleris process capability to a higher

level for the entire product range.

Aleris in Europe operates a number of

extrusion plants, two of which are dedi-

cated to the manufacturing of high per-

formance extruded rod, bars and shapes

for the defence industry.

The extrusion plants Aleris Aluminum

Bonn GmbH (Germany) and Aleris Alumi-

num Duffel BVBA (Belgium) are equipped

with sophisticated production equipment

utilizing all the necessary machinery for

the production of approved defence ex-

truded products.

In order to produce small, medium size,

wide and heavy extrusions, either as

open or hollow sections out of 5xxx, 6xxx

and 7xxx series alloys, various extrusion

presses are operating in direct or indirect

mode up to 90 MN.

Defence extrusion alloys*

2618A 6005A 7003 7022

5049 6060 7010 7049

5059Alustar 6061 7020 7075

5083 6082 7021 7175


All alloys are subject to profile size and geometry Other alloys on request

Weight of compact solids

Alloy mm in mm in mm in mm in mm in

du 40 1.57 60 2.36 89 3.50 225 8.86 560 22.05

2xxx / 5xxx / 7xxx Min. weight (kg/m; lbs/ft) 1.0 0.67 1.5 1.01 2.4 1.61 11.8 7.93 26.6 17.87

Max. weight (kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2

6xxx Min. weight (kg/m; lbs/ft) 0.6 0.40 1.0 0.67 1.5 1.01 7.6 5.11 10.0 6.72

Max. weight (kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2

Weight of wide compact solids

Alloy mm in mm in mm in mm in mm in

W x H 120 x 70 4.72 x 2.76 150 x 30 5.91 x 1.18 194 x 30 7.64 x 1.18 700 x 120 27.56 x 4.72 700 x 180 27.56 x 7.09

730 x 120 28.74 x 4.72

750 x 60 29.53 x 2.36

2xxx / 5xxx Min. weight

7xxx (kg/m; lbs/ft) 5.9 3.96 3.8 2.55 5.9 3.96 26.6 17.87 - -

Max. weight

(kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2 350.0 235.2

6xxx Min. weight

(kg/m; lbs/ft) 3.8 2.55 2.5 1.68 3.8 2.55 10.0 6.72 10.0 6.72

Max. weight

(kg/m; lbs/ft) 102.5 68.9 102.5 68.9 102.5 68.9 350.0 235.2 350.0 235.2

du

H

W

Alloys and capabilities

Defence Aluminium 11


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Minimum wall thickness of open extrusions

Alloy* mm in mm in mm in mm in mm in mm in

du < 100 < 3.94 < 200 < 7.87 < 300 < 11.81 < 400 < 15.75 < 500 < 19.69 < 540 < 21.26

5083 / 5049 5.0 0.20 5.5 0.22 6.0 0.24 7.0 0.28 7.0 0.28 8.0 0.31

6060 / 6005A 1.0 - 1.5 0.04 - 0.06 2.0 0.08 3.0 0.12 4.0 0.16 4.5 0.18 5.0 0.20

6082 / 6061 1.8 0.07 2.5 0.10 3.5 0.14 4.5 0.18 5.5 0.22 7.0 0.28

7020 / 7021 / 7003 3.5 0.14 4.0 0.16 4.5 0.18 5.0 0.20 6.0 0.24 7.0 0.28

Minimum wall thickness of extruded hollows

Alloy* mm in mm in mm in mm in mm in

du < 100 < 3.94 < 200 < 7.87 < 300 < 11.81 < 400 < 15.75 < 490 < 19.295083 / 5049** 5.0 0.20 5.5 0.22 6.5 0.26 7.5 0.30 8.0 0.31

6060 / 6005A 1.0 - 1.5 0.04 - 0.06 2.5 0.10 3.5 0.14 4.5 0.18 5.0 0.20

6082 / 6061 2.5 0.10 3.0 0.12 4.0 0.16 5.0 0.20 6.0 0.24

7020 / 7021 / 7003 3.5 0.14 4.0 0.16 4.5 0.18 5.5 0.22 6.5 0.26

** The aluminium extruded hollows can only be manufactured by mandrel (no porthole or bridge dies)

Minimum wall thickness of wide extruded hollows

Alloy* mm in mm in mm in

W x H 500 x 150 19.69 x 5.91 550 x 200 21.65 x 7.87 720 x 30 28.35 x 1.18

700 x 60 27.56 x 2.36

5083 / 5049 - - - - - -

6060 / 6005A 4.5 0.18 3.0 0.12 3.0 0.12

6082 / 6061 5.0 0.20 4.5 0.18 4.0 0.16

7020 / 7021 / 7003 6.0 0.24 5.5 0.22 5.0 0.20

Minimum wall thickness of wide open extrusions

Alloy* mm in mm in mm in

W x H 500 x 150 19.69 x 5.91 550 x 200 21.65 x 7.87 720 x 30 28.35 x 1.18

700 x 60 27.56 x 2.36

5083 / 5049 7.0 0.28 7.0 0.28 7.0 0.28

6060 / 6005A 3.5 0.14 3.0 0.12 2.8 0.11

6082 / 6061 4.5 0.18 4.0 0.16 3.0 0.12

7020 / 7021 / 7003 6.0 0.24 5.5 0.22 4.5 0.18


Individual sections and specific designs on request

du

H

W

du

H

W

Design guidelines

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Aleris Aluminum Bonn GmbH is spe-

cialized in large extrusions and project

business. With Europes most modern

large 90MN extrusion press and extra

long run-out length the plant in Bonn is

well prepared to cope with the demands

coming from general engineering, electri-

cal power supply and distribution, rail-

way, waterway, road transport, and the

aircraft and defence industries.

Aleris key to success is to support the

OEMs with expertise and engineering

know-how in extrusions and components

manufacturing as part of the product

development with professional project

handling.

On-site aluminium welding facilities and

machining equipment are designed to

handle heavy duty profiles and over-

sized modular assemblies. Customers

appreciate a single point of contact be-

fore, during and after the projects and

the ability to receive all goods from a

single partner.

Welding of assemblies

The applied welding processes are: MIG

for automated and MIG / TIG for manual

welding. The equipment for the auto-

mated welding of long panels like floors,

roofs, bulkheads, hulls, ramps, etc. has

a range of 26,000 x 3,600 mm.

Machining and milling

Aleris Bonn has two high performance

cutting CNC Machining Centers designed

for milling of tailor-made aluminium sec-

tions, in particular for:

single main extrusions

for structural parts

welded subassemblies e.g.

floor plates, roofs, bulkheads, hulls.

Machine specifications

Type Axes Working area

Fooke 1 5 30,000 x 4,200 x 1,500 mm (~ 1,180 x 166 x 59 in)

Fooke 2 5 25,000 x 4,000 x 1,250 mm

(~ 984 x 157 x 49 in)

Defence Aluminium Component Manufacturing



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Customer Engineering Support

It is one of our strategic goals not only

to supply material to our customers but

also to provide them with comprehen-

sive engineering support. Our team of

Product Engineers and Process Spe-

cialists will take any challenge to de-

velop together with our customers new

technologies and processes to improve

their products. They are the technologi-

cal link between customer demand and

our production capabilities.

The customer engineering team gives

support by technical consulting, product

and material training, problem solving in

their special field of application as well

as service on the basis of experience

gained in different global industries.

Aleris metallurgical knowledge enables

the transfer of customers requirements,

specific applications and newly defined

properties into metallurgical fabrication

practices for both standard and newproducts.

Research and Development Our New

Product and Technology Pipeline

Research and development is a collec-

tive exercise and is based on a close

cooperation between R&D teams in our

customers, our plants and external par-

ties, e.g. a strategic cooperation with a

partner laboratory located in IJmuiden

(The Netherlands), which acts as a central

research facility for fundamental work,

with excellent facilities and highly quali-

fied, motivated researchers.

The R&D activities focus on the devel-

opment of innovative technologies to

improve both processes and products

to exceed todays and to shape tomor-

rows requirements.

Areas of research:

alloy and technology development

casting technology

hot and cold rolling technology

optimization of heat treatment

processes

numerical and physical modelling

of processes and product

performance

NDT-technology

corrosion and surface technology

forming technology

welding technology

(e.g. LBW, FSW)

other joining techniques

(brazing, adhesive bonding,

mechanical joining)

high speed machining

product design support and

numerical simulation in close

cooperation with OEMs.

Customer Engineering SupportResearch and Development

Defence Aluminium14


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Quality AssuranceApprovals Our Brand is Quality

The quality concept is an essential ele-

ment of the company policy. Its objec-

tives are a continuous improvement in the

quality of Aleris products and services

to fulfil all customer requirements. The

quality principles are formulated by the

company management, implemented

and known on all levels and by all em-

ployees within the corporation.

To ensure these quality principles, a

documented quality system has been

implemented. The first quality manual

was established in 1979 based on the

requirements set by the aerospace in-

dustry. Since then the quality system

has been continuously up-dated and

expanded in scope.

Process control ensures that production

takes place under controlled conditions.

Quality inspections are regularly carried

out in various production facilities.

In-house laboratories with state-of-the-

art equipment control proper compo-

sition of alloys and their mechanical

performance.

Aleris Aluminum Koblenz GmbH

Defence related

BWB according to TL 2350-0004

Non defence related

DIN EN ISO 9001

ISO/TS 16949

Environment

DIN EN ISO 14001

Ballistic testing

Bundeswehr, Wehrtechnische

Dienststelle fr Waffen und

Munition, Germany

TNO Prins Maurits Laboratory,

The Netherlands

U.S. Army Aberdeen Test

Center (APG), USA

Certified external testing laboratories

conduct ballistic testing of armour plates

according to national and international

standards and specifications.

The quality philosophy means zero

defects. The quality system takes into

account the customers continuously

rising requirements and specific qual-

ity standards as well as legislative and

regulatory measures which may have

an additional effect.

Aleris Aluminum Bonn GmbH

Defence related

DIN 2303 Q2

Non defence related

DIN EN ISO 9001

ISO/TS 16949 DGR 97/23/EG

DIN EN 15085 CL 1

DIN V 4113-3

Environment

DIN EN ISO 14001

Aleris Aluminum Duffel BVBA

Non defence related

EN ISO 9001

ISO/TS 16949

Environment

EN ISO 14001



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www.aleris.com

Defence Department

Aleris Aluminum Koblenz GmbH

Carl-Spaeter-Strae 10

56070 Koblenz Germany

T +49 (0) 261 891 7479

Aleris

European Headquarter

Aleris Switzerland GmbH

Balz Zimmermann-Strae 7

8058 Zurich Airport Switzerland

T +41 44 828 1400

Care has been taken to ensure that this information is

accurate, but Aleris, including its subsidiaries, does not

accept responsibility or liability for errors or information

which is found to be misleading.

ALUMINIJ-spec

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