How to reduce the defects of precision aluminum pipes

As a factor in the cause of waste, even a small defect on the precision aluminum pipe will destroy the entire length of sawing precision aluminum pipe. Due to the high added value of precision aluminum pipe, aluminum extrusion manufacturers should make every effort to reduce the precision aluminum pipe defects.

Non-Extruded Cycle Time - Assuming that the precision aluminum pipe extruder produces 30 aluminum rods per hour, each non-extruded cycle saves 10 seconds, and then an additional 2 hours of extrusion time can be added per day which means a 2 hour production makes 8% of the output more, and which is equivalent to a 8% conversion costs reduction on each kilogram profiles. Extrusion speed –compared to extrusion manufacturers’ own mold, if the precision aluminum pipe mold purchasing from others can achieve a faster extrusion speed, a moderate number of orders can make up for the additional costs incurred the purchase of molds. For example, assuming a normal cost is 2,860.00 yuan / hour, and the additional cost in purchase of high-tech mold is 10,000.00 yuan, as long as the extrusion speed increases by 50%, the basic production efficiency can achieve 800 kg / hour so that a less than 10-tonf orders can make up for the additional cost of the mold.

A porous mold is able to make an increase of 200% (2-hole mold) or even 300% (3-hole mold) at the extrusion, making higher economic benefits. One of the biggest benefits of modern precision aluminum pipe tractors is that when the precision aluminum pipe reaches the correct extrusion length, the tractor can stop automatically the extrusion of the extruder. This is similar to the non-extrusion cycle, but since the extruded precision aluminum pipe is just the desired length, there is no waste caused by additional extrusion time. Thus at the same time of saving more costs, the process of transport and recycling of extruded waste can be removed. After the precision aluminum pipe is extruded from the extruder, the most important goal is to reduce the amount of waste, to increase production and delivery rate so as to send more products to customers. Any waste that is produced after squeezing costs very high, so waste generation should be reduced as much as possible in subsequent processes. To minimize defects, it is necessary to achieve a saw at the parking mark (parking marks refers to in the process of non-extrusion cycle, the traces left on of the modular aluminum profile).

Only two techniques can realize the sawing at the parking mark - that is, the flying sawing and the dual-length systems. Flying sawing technology refers to the cutting process during the sawing. The flying saw cutting technology can be achieved in cutting at the parking mark after extruded out. Dual-length system is to wait until after squeezing the second profile, in the non-extrusion cycle, the first and the second sections can be cut off. Both technologies have their own advantages. The dual-length system can provide two air-cooling cycles for the extrusion, which is very benefit to the building alloys. However, the cost of the saw cutting system is low (equipment costs and plant space costs) and allows a one-bar multi-cutting mode operation without stopping the extruder. So, the later one is a better choice for the defects reduction.

Two Heat-isolation Pipes are Occupying Market

When we talk about heat-isolation pipes, there are 2 heat-isolation pipes that we can’t ignore -- the rock wool pipe and the Silicate aluminium extrusion.

The rock wool pipe

With the increasing needs for the pipeline of many industries and some important areas, the pipeline industry advanced much now. So, to a certain extent, in order to meet the needs of the market better, it is necessary to go on a road of diversification of pipe production. So now, there are many products with excellent performance on the market, and the rock wool pipe is one of them. Rock wool pipe is economic and durable, inexpensive as well.

Then, what are the important advantages of the rock wool pipe?

First of all, its row material is strictly selected, and it takes the melting processing technology to make it better physical properties..

At the same time, it also meets well with the current market demands which have a high requirement on the insulation material. Through a unique processing technology, it is effective not only in the insulation and insulation, but also in the sound absorption.

Silicate aluminum pipe -- Silicate aluminum needled blanket

Silicate aluminum needled blanket is made of high quality coke gems which solidify with other additives fusion after melting through high temperature of more than 2000 degrees Celsius. It has a number of special properties, such as good elongation, strong vibration resistance, light weight, excellent heat insulation, and strong stability. Silicate aluminum needled blanket is white, and size standardized, and is able to resistant to fire and heat, without adding any other bonding agent. In the neutral and oxidative condition for long-term, silicate aluminum needled blanket can still maintain the outstanding tensile strength, durability and fiber structure. The temperature of heat resistance is 950-1400 ℃. It also has advantages of chemical stability, thermal stability, sound and noise reduction, high tensile strength, low thermal conductivity and low heat capacity.

Silicate aluminum needled blanket should take the 20 or 25mm thick ceramic fiber needle blanket and fold it to process into the specified size, and only the folding wrinkle surface is a high temperature heating surface. The module should be temporarily tightened to the specified size so as to maintain the amount of compression, its size and shape of the ceramic module before installation. The permanent metal anchors in the MA and MB modules shall be confined within the area in one third of thickness of the module's low temperature end and should be embedded in a sufficient blanket to ensure that the module is structurally stable under various using conditions.

Then, what are differences between the 2 pipes?

The rock wool pipe belongs to a medium-heat isolation material, usually lower than 600℃; the silicate aluminum belongs to a high-heat isolation material, usually in between 400℃-1000℃.

(High temperature adhesive is the auxiliary product of all insulation materials, such as silicate aluminum fiber products, rock wool pipe, mineral wool material, and microporous calcium silicate insulation. It is not only used in self-bonding and connection with the steel pipe and metal flat for refractory and insulation materials but also used in the masonry for refractory bricks, foam bricks. )  

Aluminum cable industry becomes the trend

Aluminum cable has been in China has experienced nearly eight years of promotion. Begin with zero bases, now aluminum cable technology and products have been gradually known and accepted by the market. Because of the vigorous promotion by the national Ministry of Industry, Ministry of Construction and other major management departments, the aluminum cable industry favors the main power users, such as the national grid, industrial and mining enterprises, commercial real estate, residential real estate, etc, and keeps pace with the copper industry.

Aluminum cable, as a new material, becomes an unstoppable popularity. It is the need to build a resource-saving society, is the need to save the cost of construction, and is the need for technological progress. In terms of the recent trend of the market, some large demand for cable has been shifted to choose the aluminum cable.

The popularity of Aluminum cable technology and products in China suggests that the industry's production technology, product quality and comprehensive ability have been basically mature, and the brand level has a clear guide. Those high-end users, who focus on comprehensive ability, have the courage to accept new things, and also care about the cost, have begun to pay close attention to high-quality aluminum cable brand.

The common characteristics of high-end users are to pursuit the quality and perfect applications, to fully affirm and favor that the aluminum cable and the aluminum terminal consistent with cable performance have mature connection solution, and to succeed the standardized application experience.

Stepping up the rational stage, the market of is fair. In terms of the current market trends, those high-end users who really understand the value and advantages of aluminum cable will have the first choice of the real professional high-end brands with fully complete technical products solutions. Because of the relatively poor technical ability, the mid-end users have the consciousness of the quality pursuit, but they are lack of knowledge for the real application of aluminum cable, and vulnerable to misleading from the so-called professional company. They are usually hesitant in the brand selection, and it is difficult to really get selected and used high end aluminum cable products. Low-end users basically have no real technical capacity, and poor quality awareness, so for brand selection, they only focus on low prices, so that fall into the trap of shoddy products, causing the proliferation of shoddy products on the market.

Enterprises based on comprehensive strength, product quality and other factors have formed their own brand-level pattern. Due to the different awareness of each level users, the pattern of market users in aluminum cable industry and the have gradually come into being.

The integrating of market management mechanism and the knowledge popularization of aluminum cable technology and product, I believe that the mid end users will be high-end users in line to choose the real qualified aluminum cable products, and the low-end users will certainly change the current positioning for aluminum cable demand, to more rationally choose aluminum cable brand. To be sure, the applications of cost-effective and safe-guard aluminum cable products will be inevitable choice of more and more users.

From the early promotion of the blank, difficult to cultivate, to the mid-chaos to now, the aluminum cable market has gradually moved toward mature. Although there is still unavoidable competence between copper and aluminum, the user has gradually matured with their own rational choice. Aluminum cable industry firmly believe that through the joint efforts of all Chinese aluminum profile manufacturer, with continuous improvement of the aluminum cable manufacturing technology and application conditions, the aluminum cable industry will have his day, as well as his other companions, aluminum channel, aluminum slot profile, modular aluminum profile, and etc.

Application of Aluminum profile in Mobile Phone Design (2) -- The paint flaking event of iPHONE6s

Some iPhone6S mobile phone may occur to flake paint when have been used for a time. Its surface presents random peeling spots, and the whole appearance looks rusty as if it was covered with insects, creepy and horrible. The iPhone’s value is totally decreased.

The main reason:

the previous iPhone6’s​ phone shell have also been produced with the 6 series aluminum profile whose alloy elements are magnesium and silicon and the content accounts for little, so that the anodic oxidation yield is high with a strong adhesion of oxide film to protect the aluminum profile from corrosion. Thus, the previous iPhone6 did not get rusty. But the biggest disadvantage of the 6 series aluminum is the low strength so that it is prone to bending. So the Apple Company had to choose the 7 series aluminum for aviation with a higher strength.

The 7 series of aviation aluminum used in IPhone6S has the highest strength in the aluminum at the normal temperature indoors, but also is easiest to corrosion. This series aluminum, addition to aluminum, is also composed with zinc, magnesium and copper. It is these alloy elements composed that the strength is enhanced 2-3 times the ordinary low carbon steel. The bending problem of iPhone6 ​​is solved. But the corrosion problem occurred instead.

In order to improve the corrosion resistance, the phone's aluminum shell surface will be artificial anodized, so as to improve the surface hardness and the appearance looks more beautiful as well. The quality and adhesion of the anodic oxide film directly affect the appearance quality and corrosion resistance of the phone. Due to the high quantity alloy composition of 7 series aluminum, these elements in the conventional casting process of aluminum rods is difficult to avoid uneven distribution, resulting in segregation, also known as macroscopic segregation. Partial segregation will be partially improved during subsequent homogenization and extrusion of aluminum, but can not be completely eliminated. The presence of segregation means that the distribution of material in various parts is not uniform. And the uneven composition will cause the different quality and adhesion of anodic oxide film then, resulting in defects after oxidation, such as uneven color appearance, the unstable using performance, part of oxide film peeling. Once losing protection from the oxide film, coupled with hand sweat, humid air and high temperature corrosion will be accelerated. Therefore, the paint flaking event happens on the iPhone6S.

The segregation problem of 7 series aluminum occurs along the process from casting to producing. It has been a headache problem, continually affecting the anodic oxidation. The complete solution to the problem should try to produce high end machining aluminum parts with high homogeneity and zero-segregation.