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:[email protected] W:www.alumecuserguide.com T: +44 (0) 121 252 8000 F: +44 (0) 121 252 8010 E:[email protected] 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.