Process Optimization Workshop. Rosemont, Illinois October 25-26, 2016

Transcription

1 Process Optimization Workshop Rosemont, Illinois October 25-26, 2016

2 Process Optimization Workshop Considerations for Profile Tolerancing Rosemont, Illinois October 25-26, 2016

3 Process Optimization Workshop Considerations for Profile Tolerancing Rosemont, Illinois October 25-26, 2016

4 Process Optimization Workshop Considerations for Profile Tolerancing Rosemont, Illinois October 25-26, 2016

5 Process Optimization Workshop Considerations for Profile Tolerancing Lb./Hr. Rosemont, Illinois October 25-26, 2016

6 Process Optimization Workshop Considerations for Profile Tolerancing 10 Press 5000 lb/hr 7 Press 2500 lb/hr Rosemont, Illinois October 25-26, 2016

7 Process Optimization Workshop Considerations for Profile Tolerancing What Effects Extrusion Tolerances?

8 WHAT EFFECTS EXTRUSION TOLERANCES? EVERYTHING!!

9 What Effects Extrusion Tolerances? Reduction Ratio Profile Symmetry Dimensioning Convention Press Size (Press Selection) Alloy-Temper End Application Process Capability Requirements

10 What Effects Extrusion Tolerances? Reduction Ratio RR= Ac/(Ap x number of cavities) RR= Reduction Ratio Ac= Container area Ap= Profile area If Ac = π(9.375 in/2) 2 = in 2 and Ap =.295 in 2 x 4 (profiles per die) = 1.18 in Most Productive Most Common Least Productive OVER 90 - Problem Profiles (hard to push, high die breakage) 20 and under Profile Integrity (Coring, incomplete die welds) RR = 69.03/1.18 = 59:1

11 What Effects Extrusion Tolerances? Profile Symmetry

12 What Effects Extrusion Tolerances? Profile Symmetry

13 What Effects Extrusion Tolerances? Dimensioning Convention

14 What Effects Extrusion Tolerances? Press Size (Press Selection)

15 What Effects Extrusion Tolerances? Alloy-Temper Minimum Die Exit Temperature, Temperature Entering Quench, and Cooling Rate in the Quench Zone Alloy Min Die Exit F [ C] Min Temp Entering Quench F [ C] Min Cooling Rate, F/min [ C/min] [510] 825 [440] 300 [165] 6005A 950 [510] 825 [440] 360 [200] 6061, 6262, 6041, 930 [500] 850 [455] 600 [335] , [510] 900 [480] 600 [335] 6060, 6063, 6101, 930 [500] 825 [440] 150 [85] 6360, 6463, , [520] 910 [490] 900 [500] 7004, to 1000 max/ 725 [385] 120 [65] C [400 to 540] max 7029, 7046, 7116, 7129, to 1000 max/ [480 to 540 max] 750 [400] 600 [335]

16 What Effects Extrusion Tolerances? End Application

17 What Effects Extrusion Tolerances? Process Capability Requirements

18 Considerations for Profile Tolerancing pre Aluminum Standards and Data (1955) ANSI H35.2 (2013)

19 Considerations for Profile Tolerancing pre Aluminum Standards and Data (1955) ANSI H35.2 (2013)

20 Process Optimization Workshop Standards and Specifications: Gary Jones ILSCO Extrusions Inc October 25-26, 2016

21 The Value of Technical Standards

22 Should Your Company Use Technical Standards to Drive Business Value? Standards are the infrastructure of efficient commerce. Standards support Lean Manufacturing 5S Toyota System ISO/TS-16949:2002 Standards are the way we get the organization (regardless of size) on the same page.

23 Key components of a successful global standards management strategy A successful strategy has a very clear policy Measurable goals Internet based Automatic updates and confirmation of update implementation Compliance audits are part of each site performance assessment Lessons learned and best practice sharing feed standard development and revision Standard development must reflect a 360 view of the issue Basically, we know what standards we re supporting and which ones we re not and why, and how that position supports the goals of the organization

24 Key components of a successful global standards management strategy Technical standards provide value to the organization when they: Provide a common operating language Describe the most efficient method to produce a product that conforms to requirements Facilitate a rapid time to market for new manufacturing sites.

25 Outline What are the various types of standards and specifications Standards writing organizations: Who they are and what are the challenges Types of Standards Specification Review Specification Comparison: Not all Specifications are Created Equal Conclusion: The Who, What, Where, When and How of Spec Review

26 Standards Organizations AA ASTM (ASME*) EN ISO EAA/GAG - definitions SAE AMS Aerospace Material Specifications QQ-A ARP Aerospace Recommended Practice AS Aerospace Standard AIR Aerospace Information Report AMEC Aerospace Materials Engineering Committee Marine class societies (ABS) Nadcap audits/certifications *ASME adopts ASTM specifications (e.g. ASTM B221 -> ASME SB221) with few revisions; unlike ASTM specifications, ASME specifications require the chemical analysis of the material to be included on the certificate.

27 Specification Review Challenges Among different specifications: Requirements will vary Format for finding information will vary Controlling reference standards will vary

28 Types of Standards Standard The term "standard" serves as an adjective in the title of documents, such as test methods or specifications, to connote specified consensus and approval. Guide an organized collection of information or series of options that does not recommend a specific course of action. Discussion A guide increases the awareness of information and approaches in a given subject area. Practice a set of instructions for performing one or more specific operations that does not produce a test result. Specification an explicit set of requirements to be satisfied by a material, product, system or service Test Method a definitive procedure that produces a test result. Terminology document composed of terms, definitions of terms, descriptions of terms, nomenclature, and explanations of abbreviations, acronyms, and symbols. REF: ASTM Regulations Green Book

29 Al Extrusion ASTM Specs Standard B308/B308M B491/B491M B221 B221M B429/B429M B236 B236M B317/B317M B241/B241M B345/B345M B210 B210M B234 B234M B211 B211M B316/B316M B483/B483M Title Aluminum-Alloy 6061-T6 Standard Structural Profiles Aluminum and Aluminum-Alloy Extruded Round Tubes for General-Purpose Applications Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes (Metric) Aluminum-Alloy Extruded Structural Pipe and Tube Aluminum Bars for Electrical Purposes (Bus Bars) Aluminum Bars for Electrical Purposes (Bus Bars) (Metric) Aluminum-Alloy Extruded Bar, Rod, Tube, Pipe, Structural Profiles, and Profiles for Electrical Purposes (Bus Conductor) Aluminum and Aluminum-Alloy Seamless Pipe and Seamless Extruded Tube Aluminum and Aluminum-Alloy Seamless Pipe and Seamless Extruded Tube for Gas and Oil Transmission and Distribution Piping Systems Aluminum and Aluminum-Alloy Drawn Seamless Tubes Aluminum and Aluminum-Alloy Drawn Seamless Tubes (Metric) Aluminum and Aluminum-Alloy Drawn Seamless Tubes for Condensers and Heat Exchangers Aluminum and Aluminum-Alloy Drawn Seamless Tubes for Condensers and Heat Exchangers (Metric) Aluminum and Aluminum-Alloy Rolled or Cold Finished Bar, Rod, and Wire Aluminum and Aluminum-Alloy Rolled or Cold Finished Bar, Rod, and Wire (Metric) Aluminum and Aluminum-Alloy Rivet and Cold-Heading Wire and Rods Aluminum and Aluminum-Alloy Drawn Tube and Pipe for General Purpose Applications

30 Information in Specifications Scope and Methods of Product Manufacture (to make sure that you are producing and certifying your product to the correct specification Ordering Information (includes more than alloy-temper and quantity) Reference Standards (must comply with all referenced standards order to comply with the specification) Testing and Lot Release Technical Requirements (chemical composition, mechanical property limits, corrosion, etc.) Replacement / Retesting Allowances Heat Treatment and Other Process Requirements Dimensional Tolerance Marking, Packaging, and Certification

31 Not a Specification

32 Spec Review: Applicability B Scope* 1.1 This specification covers aluminum and aluminum alloy extruded bars, rods, wire, profiles, and tubes in the aluminum alloys (Note 1) and tempers shown in Table Materials and Manufacture 5.1 The products covered by this specification shall be produced by the hot extrusion method or by similar methods at the option of the producer, provided that the resulting products comply with the requirements in this specification. B241/241M 1. Scope* 1.1 This specification covers aluminum and aluminum alloy seamless pipe in the alloys (Note 1) and tempers shown in Table 1 [Table 2] and seamless extruded round tube in the alloys and tempers shown in Table 3 [Table 4] intended for pressure applications. The standard sizes for seamless pipe are listed in Table 16.7 of ANSI H35.2 and H35.2M. Nonstandard alloys, tempers, and sizes of pipe are produced as seamless extruded tube. 5. Materials and Manufacture 5.1 The pipe and tube shall be produced from hollow extrusion ingot (cast in hollow form, or drilled, or pierced from solid ingot) and shall be extruded by use of the die and mandrel method. Pipe and tube may be subsequently cold drawn at the option of the producer.

33 Spec Review: References SUBSET OF CONTROLLING REFERENCE STANDARDS IN ASTM B221 B557 Test Methods for Tension Testing Wrought and Cast Aluminum- and Magnesium-Alloy Products B594 Practice for Ultrasonic Inspection of Aluminum-Alloy Wrought Products B660 Practices for Packaging/Packing of Aluminum and Magnesium Products B666/B666M Practice for Identification Marking of Aluminum and Magnesium Products B807/B807M Practice for Extrusion Press Solution Heat Treatment for Aluminum Alloys B918 Practice for Heat Treatment of Wrought Aluminum Alloys B945 Practice for Aluminum Alloy Extrusions Press Cooled from an Elevated Temperature Shaping Process for Production of T1, T2, T5 and T10 Type Tempers E29 Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications E34 Test Methods for Chemical Analysis of Aluminum and Aluminum-Base Alloys E716 Practices for Sampling and Sample Preparation of Aluminum and Aluminum Alloys for Determination of Chemical Composition by Spectrochemical Analysis E1004 Test Method for Determining Electrical Conductivity Using the Electromagnetic (Eddy-Current) Method E1251 Test Method for Analysis of Aluminum and Aluminum Alloys by Spark Atomic Emission Spectrometry G34 Test Method for Exfoliation Corrosion Susceptibility in 2XXX and 7XXX Series Aluminum Alloys (EXCO Test) G47 Test Method for Determining Susceptibility to Stress- Corrosion Cracking of 2XXX and 7XXX Aluminum Alloy Products H35.2 Dimensional Tolerances for Aluminum Mill Products AMS 2772 Heat Treatment of Aluminum Alloy Raw Materials

34 Spec Review: Ordering Information 4.2 Additionally, orders for material to this specification shall include the following information when required by the purchaser: Whether solution treatment at the press is unacceptable (9.3), Whether heat treatment in accordance with Practice B918 is required (9.4), Whether ultrasonic inspection is required (Section 17, Table 3), Whether inspection or witness of inspection and tests by the purchaser s representative is required prior to material shipment (Section 18), Whether certification is required (Section 22), Whether marking for identification is required in accordance with Practice B666/B666M, Section 20, Whether Practice B660 applies and, if so, the levels of preservation, packaging, and packing required (21.3), and Requirements for tensile property and dimensional tolerance for sizes not specifically covered (8.1.3 and ) Whether Titanium and Zirconium algorithm is allowed as shown in Table 1, Footnote G, when ordering 2014 or Whether Titanium and Zirconium algorithm is allowed as shown in Table 1, Footnote N, when ordering Ref: ASTM 221

35 Spec Review: Heat Treatment 9. Heat Treatment 9.1 For the production of T1 and T5-type tempers, producer or supplier heat treatment shall be in accordance with ASTM Practice B For the production of T3, T4, T6, T7 and T8-type tempers, except as noted in 9.3 or 9.4, shall be in accordance with AMS Unless otherwise specified (4.2.1), alloys 6005A, 6041, 6060, 6061, 6063, 6064, 6066, 6162, 6082, 6262, 6351, 6360, 6463, and 6560 may be solution heat treated and quenched at the extrusion press in accordance with Practice B807/B807M for the production of T4 and T6-type tempers. 9.4 When specified (4.2.2), heat treatment of the production of T3, T4, T6, T7, and T8-type tempers shall be in accordance with Practice B918. Ref: ASTM 221

36 Spec Review: Testing/Lot Release Need to Know: Lot release test requirements Number of tests Test location and specimen orientation Test specimen geometry How to run the test Allowance for replacement and/or retesting Surveillance testing requirements Lab capability testing requirements

37 Spec Review: Marking 20. Identification Marking of Product 20.1 When specified in the contract or purchase order, all material shall be marked in accordance with Practice B666/B666M. NOTE 7 Ordering per B666/B666M will require the supplier to mark the lot number on each extruded section The requirements specified in 20.1 are minimum; marking systems that involve added information, larger characters, and greater frequencies are acceptable under this specification and shall be agreed upon between the producer and purchaser. Ref: ASTM 221

38 Spec Review: Marking Ref: ASTM B When required by the material specification, the word seamless on certain tube or pipe. Ref: ASTM B When specified in the contract or purchase order all tubes in straight lengths shall be marked in accordance with Practice B666/B666M and the marking legend shall include the word seamless.

39 Spec Review: Press Quenching B945 B807/B807M Requirement Billet/Log Max Temperatures Yes Yes Controls to preclude overheating Yes Yes Calibrated temperature control and recording devices Temperature Measuring System Accuracy (any temperature sensing system) ± 1 % System Accuracy Tests (non-contact) No ± 2 F / Weekly check Temperature Measuring System Accuracy (contact systems) No ± 2 F (weekly) ± 2 F (dual sensors - quarterly) Test Instrument/Sensor for SAT calibrated to NIST traceable source No greater of: ± 2 F or 0.4% of true temperature (quarterly) Die exit temperature No Yes Temperature entering the quench No Yes Cooling rate No Yes Quality Assurance and Process Surveillance Tests Yes Yes Equipment Re-qualification Yes Yes Process Re-qualification No Yes Extrusion process control record-keeping ID specific press Yes Yes Frequency and results of measurement calibration equipment Yes Yes Dates and description of equipment repairs Yes Yes Instances of disqualification and corrective action Yes Written operating practice and data collection for press solution heat treat process No Yes

40 Not All Specifications Are Created Equal 6061-T6511 ASTM B221 QQ-A-200/8 AMS 4173 Press Quenching Allowed, unless otherwise specified Allowed, unless otherwise specified Allowed, unless otherwise specified Required Controls ASTM B807/B807M ASTM B807/B807M Aging Requirements Special Requirements ASTM B918/B918M Cancelled MIL-H-6088 is replaced by AMS2772 (requires pyrometry in accordance with AMS 2750) Additional sampling and testing: "may" include hardness tests followed by tensile test on the two softest extrusions in the inspection lot. AMS2772 (requires pyrometry in accordance with AMS 2750) Additional sampling and testing: "shall" include hardness tests followed by tensile test on the two softest extrusions in the inspection lot. Report must identify heat treatment as "Class 2"

41 Conclusion The Who, What, Where, When and How of Spec Review Who: What: Where: When: How: Are the who s in the system trained? What process is allowed? What tests are required? What limits must be met? What is to be included on the certificate? Where do samples come from relative to the product (i.e. the location of the test specimen, the orientation)? When is testing done? When are replacement or retests allowed? How is process to be controlled? How is tolerance measured? How is surveillance requirements carried out?

42 Thanks for Listening Gary Jones has been part of the extrusion industry for 35 years, holding positions in Quality Engineering, Quality Assurance, Sales, Marketing, and Operations Management. He is a co-author of several ET papers and Best Paper award winner in 1984 and Giving back to the industry, Gary serves on several Technical Committees at the Aluminum Extruders Council and The Aluminum Association. Gary graduated from Penn State University with degrees in Metallurgical Engineering 84 and Business 03. Gary is currently Commercial Operations Manager for ILSCO Extrusions Inc.