Alumec 100 - English

Advanced specialised alloy for
today’s moulding technologies
Alumec 100: Strength and Consistency
Specifically designed for volume precision moulding
applications, Alumec 100 has been developed to
combine high strength, through thickness hardness
and good fracture toughness with outstanding
machinability.
Available up to 305mm plate thickness, Alumec 100
is the highest strength Alumec alloy, for higher volume
injection moulding and blow moulding applications
where superior wear resistance, polishability and
corrosion resistance are required.
Physical Properties
Thermal Conductivity
W/mK
159
Coefficient of Thermal Expansion
10-6/K
24.3
Modulus of Elasticity - tensile
GPa
69.6
Compressive
GPa
Density
10 kg/m
2.85
Specific Heat
J/kgK
879
Hardness
Rockwell B
85 - 91
3
72.4
3
Mechanical Properties
Typical Strengths
0.2% Proof Stress (MPa)
Tensile Strength (MPa)
600
600
534
527
524
509
563
560
485
534
MPa
500
400
300
400
300
200
200
>25.4-50.8
>50.8-101.6 >101.6-152.4 >152.4-203.2 >203.2-254
>25.4-50.8 >50.8-101.6 >101.6-152.4 >152.4-203.2
>254-304.8
Thickness (mm)
180
170
Alumec 99
160
Alumec 79
150
7075 T651
75
Surface
Centre
140
Surface
n
tio
irec
D
g
llin
Ro
130
Brinell Hardness HB
190
85
80
>254-304.8
Fracture Toughness (MPa√m)
Alumec 100
Alumec 89
90
>203.2-254
Thickness (mm)
Through Thickness Hardness
Rockwell Hardness HRB
545
512
502
500
MPa
566
Thickness (mm)
L-T
T-L
S-L
50.8
42
31
29
76.2
33
28
29
101.6
32
27
28
127.0
30
26
28
152.4
27
27
27
250.0
30
24
25
304.8
27
24
26
Machining Characteristics
Turning
Parameters
Rough turning with carbide Fine turning with carbide Turning with high speed steel
Cutting speed (Vc) m/min
604 - 1207
1207 - 2515
251 - 302
Feed (fz) mm/r
0.30 - 1.02
up to 0.30
up to - 0.30
Depth of cut mm
2.0 - 6.1
0.5 - 2.0
0.5 - 3.0
Parameters
Indexable insert
Solid carbide
Brazed carbide1
Cutting speed (Vc) m/min
201 - 402
201 - 299
151 - 251
Feed (fz) mm/r
0.05 - 0.25
Drilling
Carbide drill
1
2
0.10 - 0.30
2
2
0.15 - 0.362
Drill with internal cooling channels and brazed carbide tip
Feed dependent on drill diameter
High speed twist drill1
Drill diameter mm
1
Cutting speed (Vc) m/min
Feed (fz) mm/r
_< 5
50 - 70
0.08 - 0.20
5 - 10
50 - 70
0.20 - 0.30
10 - 15
50 - 70
0.30 - 0.36
15 - 20
50 - 70
0.36 - 0.41
Point angle 118° Helix angle 16-30°
Face Milling
Parameters
Rough milling with carbide
Fine milling with carbide
Milling with high speed steel
Cutting speed (Vc) m/min
604 - 1006
1006 - 3018
251 - 402
Feed (fz) mm/r
0.20 - 0.61
0.10 - 0.20
up to - 0.41
Depth of cut mm
2.0 - 8.1
up to - 2.0
up to - 8.1
Parameters
Solid carbide
Indexing carbide insert
High speed steel
Cutting speed (Vc) m/min
302 - 503
302 - 503
122 - 251
Feed (fz) mm/r
0.03 - 0.20
End Milling
1
1
0.08 - 0.20
1
0.05 - 0.361
Feed depending on radial depth of cut and cutter diameter
Size Availability
Plate Hot Rolled, Heat Treated and Stress Relieved by Stretching or Cold Compression. Available as Alumec 100
Thickness: 6.35mm to 305mm
Forged Block Available as QC-10®
Thickness: 305mm to 810mm
Surface Treatment
Polishing Guidelines
Techniques
Both mechanical and manual techniques may be used.
When seeking a mirror finish the use of power tools should
be avoided.
Media
Carborundum paper should be used for grinding starting with
imperial grades 300 through to 800. When seeking a mirror
finish, continue with 1200 grade paper and if necessary
followed with 6 micron / 3 micron diamond paste.
General
Maintain a clean work environment and ensure that the work
piece is flushed with an appropriate industrial solvent to
prevent accumulation of polishing debris. Renew grinding paper
frequently and change direction of polishing between grades.
When working towards a mirror finish use copious quantities of
lubricant such as a light oil applied via an aerosol.
Hard Anodising
Hard anodising can give hardness equivalent to a tool steel of
65 Rockwell C. Therefore, machining should be carried out prior
to treatment to reduce tool wear. Hard anodising is particularly
useful for slides, wear guides, guide bushes and ejector pins
since it reduces friction. Note: this treatment will cause
dimensional changes in the workpiece.
Hard Chrome Plating
Hardness levels equivalent to 80 Rockwell C are possible using
processes such as zincate, stannate and nical which have been
developed for aluminium alloys. Plated layer thickness is
typically 100 to 200 microns.
Chemical Nickel Plating
(also known as Electroless Nickel Plating)
Hardness levels equivalent to 50 Rockwell C are possible. Plated
layer thickness is typically 30 to 100 microns whilst adhesion
and corrosion resistance are generally superior to a chrome
plated finish.
Repair Welding
Weld Alloy
Criteria
5356
2319
Alcoa QC-10*
33
333
333
Texture Match
33
333
333
Pitting
33
33
33
Adhesion
3
33
333
Durability
3
3
333
Hardness
3
3
33
Thermal Shock
3
3
333
Impact Shock
3
3
333
Coefficient of Thermal Expansion
3
3
33
Colour Match
*Specifically developed to weld Alumec 100 and QC-10®
Comparison of Alumec Products
Strength
Machinability
Polishability
Weldability
Alumec 100
Alumec 99
Alumec 89
Alumec 79
Alumec HT
NOT RECOMMENDABLE
EXCELLENT
Corrosion
Resistance
Heat Resistance
Alumec 100/QC-10®: Case Studies
Automotive
Product Description:
Interior rear tray
Resin:Polypropylene
Textured Surface:
Yes
Mould Style:
Single cavity
Volume:225,000/year
Total Parts to date:
700,000+
Mould in Service:
August 2007
Mould Material
QC-10® Forged
P20
Improvement
Cycle Time, seconds
60
80
25%
Mould Temp., °C
40
55
27%
Pieces per day
1080
900
20%
Consumer Electronic
Product Description: LCD TV back cover
Resin:
High Impact Polystyrene
Part Weight: 1.31kg
Quantity: 200,000 units
Machining Time Mould Part
Alumec 100/QC-10®
P20, min
Improvement
Cavity
45 hours
54 hours
16%
Core
30 hours
54 hours
44%
Mould Material
Alumec 100/QC-10®
P20
Improvement
Cycle Time, seconds
29
58
50%
Production per 11 hour shift
1350 pcs
680 pcs
98.5%
Designed and produced in the UK by Zest www.thinkzest.com
Alcoa GmbH
Heinrichstrasse 24
40239
Düsseldorf
Germany
Alcoa Global Rolled Products
PO Box 383
Kitts Green Road, Kitts Green
Birmingham, B33 9QR
England
Alcoa Forgings and Extrusions
1600 Harvard Avenue
Cleveland
Ohio 44105-3092
USA
T: +49 211 47 111 0
F: +49 211 47 111 90
E:alumec@alcoa.com
W:www.alumecuserguide.com
T: +44 (0) 121 252 8000
F: +44 (0) 121 252 8010
E:alumec@alcoa.com
W:www.alumecuserguide.com
T: +1 (216) 641 3600
W:www.alcoa.com/mold
All information herein is obtained from sources, which Alcoa to the best of its knowledge, believes are reliable. It is given for general
guidance only without guarantee or warranty whatsoever as to its accuracy and completeness, and Alcoa accept no liability whatsoever
arising out of the use of the information herein.