Profiles that perform

7/30/2019 Profiles that perform

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All you want to do with a profle.A d m re.Many people associate aluminium profles with bars, rods and tubes.But did you know that we also manu acture customized profles ortrains, wind turbine nacelles and automotive components?

Aluminium is suitable or many industrial applications. It is light,strong, durable, corrosion resistant, 100% recyclable and highlyductile allowing profles to be ormed into practically any shape.

emarkable 3D structures can be made out o a single profle, orexample car roo rails. We can extrude complex hollow profles,traditionally only obtainable using more expensive casting processes.

Customers can eliminate production steps by changing toaluminium profles as their pre erred construction material. A steelstructure requiring the assembly o 510 individual parts can bereplaced by a single aluminium profle. Complex designs thatintegrate several design eatures can be made more easily, yet withcomparable per ormance.

We live with aluminium every day and know its capabilities. Wewould like to share our experiences with you. ur application engi-neers work exclusively on guiding customers to design shortcutsthat can lower their material, design and manu acturing costs.

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What is ull service?I s up y u.o some, ull service is being able to order customized heat sinks,profles or solar mounting systems or ship deck panels. o others,its relying on secure, regular just-in-time shipments o large quanti-ties o standard profles delivered straight into their warehouses.

Some wish to manage orders to Sapa production plants onthree continents via a single point o contact with us at Sapa.thers depend on our local support and ability to adapt swi tly totheir changing business conditions.

And there are those that co-operate with us throughout theli e cycle o their products. From initial design concept to recyclingo the aluminium scrap a ter the products end o li e thus ullyexploiting the economical and ecological advantage o 100 percentrecyclable aluminium.

What is ull service to you?

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What can we dof r y u?he scope o use o aluminium profles is limited only by the

imagination. erhaps its no surprise then that more and morearchitects, engineers and industrial designers are now turning theirattention to aluminium.

No matter what you wish to manu acture, there is every reasonto take a closer look at aluminium. he versatility o aluminium asa material, and o profles as design elements, allows or ingeniousdesigns and signifcant cost savings. In many cases, the paybacktime o switching to aluminium is short due to its many production-related benefts.

In the next ew pages, you will fnd examples o customercases where we contributed with profles, application insights anddesign support and a variety o value-added services. We hopethese stories can inspire new ideas.

We at Sapa will help you to realize them.

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APPlIcAtIon AnSI n S PPo t

We guide you to thesmartest designs or newor existing productsbased on best practiceand the properties oaluminium.

P nc In he astest and mosteconomical method orhole cutting, cutting outblanks and cutting olengths.

P Int/lASn AvIn hese are techniqueso ered by Sapa tomake customer-specifcinscriptions onaluminium details.

ASS l We can take care oassembly processes,where the profles arepart o a larger entity.

n In ur bending methods including stretch bending,roller bending and pressbending o er highshaping accuracy.

xt SIon ressing a heated billetthrough a die with greatorce o ers endlessdesign possibilities.

cnc P oc SSInWith several CNC-controlled multi-taskmachines, Sapa is wellequipped in the area ohigh-speed machining.

c ttInur cross-cuttingsaws make cutting soburr- ree it meets mostrequirements withouturther processing othe cut.

F IctIon StIw l In (FSw) FSW provides a new,homogeneous structurewith greater strengthand less heat de orma-

tion than conventionalwelding.

S FAct At nt Anodising and powdercoating are commonmethods or changing theproperties or appearanceo aluminium sur aces.

w l In Most aluminium proflealloys are suitable orwelding, using mainlyMI and I techno-logy.

lo IStIcS We are per ectly capa-ble o co-ordinating thewhole logistics chainto guarantee superbdelivery precision.

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What we did or Volvo

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Sealed i h a ri gSapa supplies an rings made o aluminium profles or truckengines. he an rings channel and optimize the air ow rom thean to the radiator unit.

Volvo needed to upgrade the quality o its an rings. Improvedsti ness, joining and shape regularity were required in order to

reduce movement and swinging.Sapa invested in a new production line including a press or

punching to create more reliable shapes, while robot weldingensures uni orm thickness o the welded zone. his resulted inreduced weight, increased stability and improved tolerances.

he Volvo an rings are a per ect example o how we can helpimprove, develop and produce new products in co-operation withour customers.

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What we did or Brammo


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Aluminiume -bikeAs a concept o the uture, Brammo Enertia captures the essenceo aluminium. A ully electric powercycle, it reduces emissions and,made mostly o 100 percent recyclable aluminium, it also reduces

the extraction o raw materials.Sapa has been supplying the rame assemblies or the eco-bikessince 2009. A ter trying out early carbon fbre prototypes, Brammoturned to aluminium and Sapa or their one-o -a-kind bikes.

hey realized that aluminium is strong, attractive, lightweight,ormable, and with its green properties, the metal o choice.

Brammo chose Sapa or its ull-service capabilities and local.S. presence. he Sapa team then worked closely with the Bram-mo team as they designed the rame.

A number o Sapas capabilities went into building the rame,including machining processes, bending and welding. A ter welding,a fnal heat treatment and artifcial ageing process then restored thefnished assembly to ull 6 properties, a ter which it was anodised.

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What we did or Walther


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Aimi g f r a ura ySapa helped erman ri e manu acturer Walther develop aluminiumparts or its new lympic-quality air ri e, L 400.

sing extruded aluminium or the stock o ers desirable weightbenefts. And unlike synthetic stocks, aluminium provides thesti ness necessary or maximum shooting accuracy. An aesthe-tically pleasing brushed aluminium sur ace also contributes to theexcellent design.

he project required all o Sapas expertise. ooling and millingwere challenging as ri e components involve a lot o detail andmust ft together per ectly.

Sapas journey began at the metallurgy stage seeking the rightalloy composition ollowed by design, profling, CNC machining,anodising and printing. For some shooters, the journey may well

end up on the lympic podium.

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What we did or Sport- rans er

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An elevatedp si iA good re eree is invisible. At least according to certain sports ansand commentators. Whatever the case may be, re erees do need aclear view to do a good job.

In beach volleyball, re erees are o ered an excellent viewthanks to aluminium re eree stands, designed and manu acturedby Sapa in oland on behal o Sport- rans er a leading olishsports equipment provider.

Sapa came up with a versatile concept with special eatures.he re eree stand is oldable to allow easy assembly without toolsand it has an adjustable plat orm with three fxed height levels.

Standard profles eliminated the need or investing in new dies.Since the stand is almost always covered by banner ads, sur ace

quality was not a major issue so a 15-micron o anodising layer wassu fcient sur ace treatment.

he re eree stand remains a standard product inSport- rans ers annual product catalogue to this day.


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What we did orower- ne

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A su shi e storySolar energy panels depend on inverters to convert DC to AC orcommercial use. Italy-based ower- ne is a world-leading providero solar inverters and Sapa provides the heat sinks necessary or

their cooling.Excellent heat dissipation makes aluminium ideal or use in heatsinks. Moreover, extruded aluminium outper orms cast aluminiumdue to its higher thermal conductivity, and copper due to its lowerweight.

eat sinks are optimized or maximum thermal per ormance,and all the machinery used is customized or ower- ne. Sapais a total solution supplier, rom extrusion to delivery directly intoower- nes production line, including gasketing o the heat sinks.

ower- ne awarded Sapa the task o supplying the heat sinksto their 30 kW three-phase model Aurora rio confrming Sapasposition as their number-one provider.

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FSW

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What we did orLite Industries

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I he re hesImagine kneeling in a trench to do maintenance work. Its theclaustrophobic reality or many ground workers today. renchshields rom Australian Lite Industries make li e easier or theseexposed workers.

Mini excavators are mainly used in deep excavation work.

Although versatile and easy to manoeuvre, they have limited li tingcapabilities. renches are there ore being made narrow, which putsground workers at risk.

Lite Industries trench shields reduce the risk o collapsingtrench walls or alling objects by rein orcing the walls. Sapasstructural grade aluminium solution o ers several benefts.

hey are as strong as steel but one-third the weight, thussimpli ying transport and assembly. hey are corrosion- ree,una ected by contaminated soils and less maintenance-intensivethan steel or timber systems.

Besides the product itsel , Sapa provided the technical supportnecessary to fne-tune the product.

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i d b i g giantWith a rotor diameter o 120 metres, WinWinD 3 ranks among thegiants in megawatt wind turbines. he impressive rotors make theturbine productive even at low speeds.

WinWinD 3 is the latest addition o wind turbine generatorsrom Finnish WinWinD. Sapa delivers the lightweight, aluminium-based nacelle cover, which makes installation easier and more coste fcient.

he sel -supporting nacelle cover replaces conventional partso a nacelle cover and the steel support rame (I-beams). It isa sti structure in terms o bending and torsion, which also o ersnatural sur ace protection without painting.

he nacelle cover is made o extruded panels joined together byFriction Stir Welding (FSW). Sapa per ormed static and dynamic f-nite element analysis (FEA) to optimize the design o the aluminiumextrusions.

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What we did or WinWinD 3

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Nacelle cover or WinWinD 3

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Shaping the world since 1963In 50 years, Sapa has grown to become the worlds leading providero aluminium profles, with production in more than 30 countries onthree continents. So no matter where your profles are produced,we are able to provide ull local support.

We ocus entirely on the design and manu acturing o proflesand their applications and on providing frst class service to ourcustomers. As profle specialists, we are able to create solutionsthat add signifcant value to our customers. We call it profles thatper orm.

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Ab u Sapa Pr es

Sapa is the worlds leading producer o extrudedaluminium profles. We help customers exploit theull beneft o aluminium profles.

Aluminium weighs only one third o steel. It iseasy to shape into advanced designs, it has a smoothsur ace fnish and it is 100 percent recyclable.

As experts on the material, we are able toprovide pro essional technology and engineering

support, allowing customers to optimize theirdesigns based on the properties o aluminium.

Strongly ocused on sustainability management,we strive to continuously improve our economic,environmental and social per ormance.

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