H a r d t o B e at efficiency by design The business benefits of aluminium for commercial vehicles are indisputable: weight savings that allow substantially higher payloads and fuel efficiency, ease of working and repair, durability, superior corrosion resistance and minimal maintenance. To bring these operational advantages to the highly-abrasive work environment of tipper trailers, Alcoa has perfected an ultra-rugged shate material of exceptional surface hardness and abrasion resistance: Endur-Al. Endur-Al is an advanced 5456 alloy in H34 temper that was originally developed to withstand the extreme rigours of maritime applications. Drawing on our vast experience of freight transport applications, exhaustive testing in the lab and in the field proved its performance characteristics to be uniquely suited to tipper trailer sides and floors: • Extreme surface hardness • Outstanding resistance to abrasion • Excellent corrosion resistance • Superior workability Aluminium: The Benefits Harder surface = less wear + longer life Whatever the cargo, Endur-Al’s exceptionally hard surface resists abrasive wear like no other comparable alloy. As well as reducing the need for ongoing repair, this gives Endur-Al tipper trailers a considerably longer working life than is possible with conventional materials. Proven abrasion resistance Endur-Al’s resistance to wear by abrasion was determined to ISO 8251. Testing was performed under a 3.9N load over sliding distances equivalent to 1600 movements of 300mm at a constant speed of 60 mm/s using abrasive paper of SiC grit 320. Wear losses were obtained by weighing the samples before and after testing. Weight loss values were obtained in the rolled and transverse directions, both from the as-rolled surface and after removing 1mm in depth and polishing. The table overleaf shows the averaged weight losses values and the Brinell hardness values (measured according to EN-10003-1). Aluminium: The Benefits Less weight = bigger payloads + lower operating costs Corrosion resistance = longer life + less maintenance Tipper trailer designs optimised for aluminium normally weigh between 20 and 30% less than steel bodies of equivalent strength, stiffness and durability. With the high density loads normally carried, this dramatic reduction in dead weight not only increases payloads by about 1 tonne for the average trailer box, but also improves fuel efficiency when empty. For the operator, this means significantly more revenue for each delivery and/or cost savings that can allow more competitive rates. Using Alcoa’s market-leading experience of optimising the natural corrosion resistance of flat rolled aluminium alloys, Endur-Al was originally formulated to withstand extremely hostile marine and off-shore environments. In tipper trailer applications, these characteristics ensure a significantly longer service life, irrespective of the materials being transported – and with no protective surface coating needed, cleaning is easy and the maintenance requirement is minimal compared to steel. Construction sheets ready for shipment In addition to the environmental benefits of sidestepping the painting process, the attractively bright, clean appearance of unpainted aluminium enhances the operator’s brand image – and as many can confirm, drivers take more care of vehicles that they’re proud to drive. Double T chassis beam made with Endur-Al plate Aluminium welding using automated TIG Fuel savings + local recyclability = smaller carbon footprint The average one tonne reduction in the dead weight of a tipper trailer is estimated to save some 1,300 litres of diesel over 100,000 km. Over the lifespan of the vehicle, the consequent reduction in CO2 emissions is in the region of 42 tonnes. Taking primary production, operational use and eventual recycling into account, every kilo of aluminium in a large trailer saves at least 20kg of CO2. And because aluminium is so easy and inexpensive to recycle, Endur-Al bodied trailers retain consistently high residual value right up to the end of the vehicle lifecycle. Not only does this deliver financial benefits for operators, but they have the reassurance of knowing that the energy required to produce primary aluminium is ‘stored in the metal’ rather than lost. Design versatility Available in thicknesses between 4mm and 8mm, Endur-Al is ideally suited to the construction of all styles and sizes of tipper trailer whether large or small volume, rounded or rectangular. Specially formulated for ease of fabrication as well as durability, it has high yield strength and offers excellent welding and cold bending performance. Market-leading expertise Endur-Al is available exclusively from Alcoa, a world leader in flat rolled aluminium alloys. With state-of-the-art production and finishing facilities throughout Europe, our European Mill Products (EMP) division supplies a tremendous variety of specialised products for aerospace, transport, construction and engineering applications. From EMP, you can choose from a complete portfolio of differently tempered aluminium alloys for virtually every aspect of trailer and tipper production (including chassis, body panels, covers, sides and floors), together with expert technical support for your design team. Chemical composition Si % Fe % Cu % Mn % Mg % Cr % Zn % Ti % Min. - - - 0,5 4,7 0,05 - - Max. 0,25 0,40 0,10 1,0 5,5 0,20 0,25 0,20 Mechanical properties Thickness range 4-8mm Rm (MPa) Rp,02 (MPa) A% HB Hardness 370 - 430 ≥ 270 ≥8 ≥ 110 Typical values at room temperature Thickness range 4-8mm Rm (MPa) Rp,02 (MPa) A% HB Hardness 380 300 13 114 Typical hardness values 5083 O/H111 5083 H32 5083 H34 Endur-Al 0 10 20 30 40 50 60 Hardness Brinell (HB) 70 80 90 100 110 120 Abrasive wear resistance test The abrasive wear test has been performed using an Erichsen 317 apparatus (ISO 8251), where a rim of a rotating wheel coated with abrasive paper slides back and forth on the surface of a specimen. The sliding distance is 480m and the speed is 60mm/s. 5083 0/H111 5083 H32 5083 H34 Endur-Al 0 10 20 30 40 50 60 Weight loss (mg) Bending capability 5456 H34 sheets are capable of cold bending at an angle of 90º around a pin having a radius equal to “t” times the thickness of the plates without cracking: Minimum bending radii Thickness range 180º 90º 4,0 – 6,0 mm --- 3.5t 6,1 – 8,0 mm --- 4.5t Width (mm) Length (mm) Dimensional range Thickness (mm) min max min max min max 4 8 980 2200* 800 15000 * wider than 2200mm sheets may be supplied upon request Physical properties Endur-Al Density 2.66 x 103 kg/m3 Average Coefficient of Thermal Expansion (20–100 ºC) 23.9 x 10-6 per ºC 570–640 ºC Approximate Melting Range Thermal Conductivity 117 W/m ºC (at 25 ºC) Modulus of Elasticity 71 GPa 0.33 Poisson’s ratio www.alcoa.com/emp/endural T: F: W: +41 22 919 60 00 +41 22 919 61 00 www.alcoa.com/emp www.alcoa.com/emp/endural Designed and produced in the UK by Zest www.thinkzest.com Alcoa Europe SA European Mill Products Avenue Giuseppe Motta 31-33 CH-1202 Geneva Switzerland