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Chris Moyle
14th February 2019
Aluminium casting for extrusion
Casting table
Aluminium casting for extrusion
Billets ready for extrusion
Aluminium extrusion
The press mouth – max. size Hydro
Aluminium extrusion
Solid profiles
Straight internal webs
Triangulated internal webs
Aluminium extrusion
Hollow profiles
Aluminium extrusion
Solid profile die assembly
Aluminium extrusion
Porthole (hollow profile) die assembly
From Concept to Reality
From Concept to Reality
From Concept to Reality
FABRICATION AND VALUE ADDING
• CNC Machining
• Friction Stir Welding
• Bending
• Rolling
• Punching
• Drilling
• Hydro Forming
• Painting
• Anodizing
Example case #1 – Converting Plate design to Extrusion for weight reduction
Helicopter deck
Example case #1 – Converting Plate design to Extrusion for weight reduction
Required Specifications
• Type of Helicopter
• Maximum take off load
• Maximum crash force
• Wheels or skids
• If wheels what is the diameter and tire pressure
• What type of tie downs will be used
Example case #1 – Converting Plate design to Extrusion for weight reduction
DON’T THINK IN STEEL WHEN DESIGNING IN ALUMINIUM !!!
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Example case #2 – Converting steel design to aluminium for weight reduction
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Example case #2 – Converting steel design to aluminium for weight reduction
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• Approx 500 Ton extruded solutions per vessel
• Large machined profiles
• FSW Panels
• Balcony solutions
• Formed Pipes for Exhaust Funnels
• Estimated weight saving of 1225 Ton per vessel
Example case #2 – Converting steel design to aluminium for weight reduction
• Helideck profile
S = 70 kN/mm2 * 2268.2 * 10^4 mm4 =
1588 * 10^6 kNmm2 15.8 kg/m
• Steel plate
S = 200 kN/mm2 * Iz = 1588*10^6
Iz = 7940000 mm4 = 466 * h^3 / 12.
217 kg/m
• Uneven Steel I-section
Iz = 7923000 mm4 37.3 kg/m
http://www.marinteknikk.no/
Living Quarters
30%Stair Towers
50%
Climate Shields
50%
Decking
50%47 KTon
topside
Aluminium
ABO
Logistics & Construction cost
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1. Lift larger aluminium sections
2. Lift fewer sections
= Cost reductions
OVERVIEW
Mega Yachts
Customers Globally
• Scope of Supply
o FSW Panels (Decks & BHD’s)
o Structural profiles
o Components
o Passerelles
o Standard profiles
Cruise Vessels
Predominantly European Customers
• Scope of Supply
o FSW Panels (Decks & BHD’s)
o Machined structural profiles
o Balcony Components
o Funnel components
o Outfitting
o Engine room flooring
Defense Vessels
Customers Globally
• Scope of Supply
o FSW Panels (Decks, BHD’s & Shell plates)
o Machined structural profiles
o Helo deck solutions
o Standard profiles
o Ramps
Ferry’s
Customer Globally
• Scope of Supply
o FSW Panels (Decks, BHD’s & Shell plates)
o Machined structural profiles
o Balcony Components
o Outfitting
o Engine room flooring
o Ramps
OVERVIEW
Offshore Vessels
Customers Globally
• Scope of Supply
o FSW Panels (Decks, BHD’s)
o Helicopter Decks
o Large Structural Profiles
o Standard Profiles
Offshore Structures
Customers Globally
• Scope of Supply
o FSW Panels for Living Quarters
o Helicopter Decks
o Stair Tower Structures
o Boarding Gangways
o Weather Shields
OVERVIEW
Boat Masts & Sailing Components
Customers Globally
• Scope of Supply
o Masts
o Booms
o Large Structural Profiles
o Standard profiles
Marine Components
Customers Globally
• Scope of Supply
o Freezer Plates
o Ramps & Hatches
o Gangways
o Engine Components
o Reefer Gratings
OVERVIEW
Some Customer References
• Straighter products due to less heat input from FSW compared to MIG
• Longer products due to use of smaller extrusions that are joined
• Finished product incl. Fabrication on CNC machine (precise)
• Excellent weld quality – no need for NDE weld checks
• Possibility to integrate functionalities into the profiles
Advantages
BIG FSW beams
BIG FSW beams
Main product groups
I-beam: 2 T-s I-beam: 2 T-s and Plate Box-beam: 2 U-channels
Purple = 6082 profiles Green = 5083 plate
Current process
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Today design. New design extrusion or standard.
• Large % scrap during production – water quench
• Billet weight limits extrusion length.
Box-beams – longer, lighter, straighter
BIG FSW beams
Profile 1 Profile 2 Profile 3
BIG FSW beams
I-beams – straighter, fabricated – from extrusion and plate
BIG FSW beams
I-beams 800x350x10x15 – straighter, fabricated – from extrusion and plate
Panels & walls – from extrusion and plate
BIG FSW panelsExtrusions
Plate
CLASS SOCIETIES
105
