9.-11. June 2014 - AIMCAL Web Coating & Handling ... · 9.-11. June 2014 - AIMCAL Web Coating &...
Transcript of 9.-11. June 2014 - AIMCAL Web Coating & Handling ... · 9.-11. June 2014 - AIMCAL Web Coating &...
9.-11. June 2014 - AIMCAL Web Coating & Handling Conference 2014 Europe
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Hydro Paper on Foil
Marcus Eue
Structure
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• Value Chain
• How to produce aluminium foil
• Material and production given aspects to be considered and controlled
01 Value Chain
Hydro Aluminium’s value chain
Bauxite/ alumina
Primary metal
Automotive
Casthouse products
Fabrication & Systems
Rolling Extru- sion
02 How to produce aluminium-foil
• first detection in LeBaux 1821.
• equator belt as main source.
• near to the earth-surface -> approx. 30m
• day mining.
Bauxite.. Bauxit
Aluminium..
• is the 3rd frequent element in the earth crust
• high internal reaction energy -> only as combined material in nature
• mostly combined with oxygene Al2O3 - Bauxite
Aluminium
8% misc.
17%
Silicon
28%
Oxygene
47%
Bauxite-mining production of Alumina primary aluminium (Aluminiumoxide)
+ -
Bauxit Alumina
Steps of aluminium production Produktionsschritte für Primäraluminium
4,5 t Bauxite => 2 to Alumina = > 1 to Aluminium Al2O3, Fe2O3, SiO2, TiO2, CaO Al2O3=Aluminiumoxid ca. USD 2000 / t 50% 10% 5% 2,5% 1%
Alumina
Melt (ca. 960°C)
liquid Aluminium
+
-
4 - 5 [V] 150 - 180 [KA]
From Alumina to Aluminium -> Electrolysis
Produktionsschritte zur Herstellung von Primäraluminium
Production Process – Casting (Direct Chill DC) & Hot Rolling
vs. ContinousCasting (CC)
Casting of slabs
Sawing and scalping
Production of aluminium-foil Slab dimension up to 9m x 2,20m x 0,60m
Slitting
Hot rolling
Cold rolling
Production of aluminium-foil
Cold Rolling
Doubling
Foil Rolling
Intermediate Annealing
Production of Aluminium Foil
Coil length after this steps (~0,006 mm gauge)
=> ~ 340.000 m
Separating and Slitting
Final Annealing
Shipping
Production of Aluminium Foil
Wide Foil Mill
Separating and Slitting
Annealing and Slitted Materials
Shipping
Annealing
03 Material and production given aspects to be considered and controlled
Thin foil for flexible packaging
10µm 600:1 600:1 10µm
human hair ~ 55 µm
Aluminium foil 6,3 µm
break-down tandem DC-cast pre-annealing hot rolling cold rolling annealing
process chain and typical microstructures in Aluminium sheet production
Core
Foilannealing - Finalannealing
Oxygen
Rolling oil
Goal: • unwinding properties to be secured • recristallisation – mechanical properties • degreasing • wettability as requested
Relative pressure
low
high
Distribution of winding-pressure inside a reel (schematic)
Core
9 µm (0.00035‘‘) foil behaviour at different tensions: 8 MPa 22 MPa
1 MPa = 145 PSI
Elastic deformation / Plastic deformation
Stress-Strain Curve (schematic)
0
20
40
60
80
100
0 0,5 1 1,5 2 2,5 3 3,5
Elongation [%]
Tens
ion
[MP
a]
0,2
30
Elastic;reversible Plastic; non-Reversible
1 MPa = 145 PSI
0102030405060708090
0 0,5 1 1,5 2 2,5 3 3,5
Tens
ion
[MP
a]
Elongation [%]
Stress-Strain Curve (schematic)
0,2
30
Example for specific web tension 6.3 µm (0.00025‘‘) or 9.0 µm (0.00035‘‘)
• 1,616 mm x 6.3 µm (63.6 ‘‘ x 0.00025 ‘‘)
• Tension 140 N
• Specific tension:
= 140 N / 1616mm x 6.3µm
(31.5 lbf / 63.6 in x 0.00025 in) = 140 N / 10,2 mm²
(31.5 lbf / 0.0159 in²) = 13,7 N / mm²
(1979 lbf/in²)
• 1,468 mm * 9.0 µm
• Tension 180 N
• Specific tension:
= 180 N / 1468 mm x 9µm = 180 N / 13,2 mm² = 13,6 N / mm²
1 MPa = 1 N/mm² = 145 PSI
Tension setting specific tension of 15 MPa [N/mm²]
Gauge
Width 6,3 µm (0,00025‘‘) 9,0 µm (0,00035‘‘)
800 mm (31.5 ‘‘) 7.6 daN 10.0 daN
1300 mm (51.2 ‘‘) 12,3 daN 17,6 daN
1400 mm (55.1‘‘) 13,2 daN 18,9 daN
1500 mm (59 ‘‘) 14,2 daN
20,3 daN
1600 mm (63 ‘‘) 15,1 daN 21,6 daN
1 MPa = 145 PSI
„Perfect“ unwinder (1)*
Peel Off Roller, Ø >200 mm
Dancer Roller
10 ... 20 mm
* Remark: based on TCS Foil experience, but consider Hydro is not machine producer
„Perfect“ unwinder (2)*
• centric fixing of the core
• soft chucks (expansion to center the reel)
• foil is supported by the moving peel-off-roller to keep the distance constant at all diameters
• rollers are driven
• roller diameter > 200mm (~ 8“)
• closed light/easy turning bearings
• Material: aluminium or CFK (carbon fibre) for thin foil (< 12-15µm)
PU 80-85 shore for thick foil (>15µm)
• notched rollers to minimize air flow (spirals or straight)
* Remark: based on TCS Foil experience, but consider Hydro is not machine producer
„Perfect“ unwinder (3)*
• all rollers parallel and dynamic balanced (Q=2.5)
• free foil length below 500 mm (~20 ‘‘)
• acceleration and breaking torques have to be considered (-> weight of rollers)
• Wrap-around angle -> influence on bending of rollers (e.g. 180° = 2 x tension); recommended is 90 – 120°
• pneumatic controlled dancer roller to keep web tension constant
• automatic tension control system
• web tension ~12-15 MPa (1,740 – 2,200 PSI) for thin foil
• In front of converting station there is a „S-part“ to stabilize the web (equal wrap-around and torques)
* Remark: based on TCS Foil experience, but consider Hydro is not machine producer
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Hydro Aluminium Rolled Products GmbH
BU P&B Foil Marcus Eue
Aluminiumstrasse 1 41515 Grevenbroich
Germany
Thank you for your attention