PRESS LINE
SURFACE COATING
MACHINING
WATER TREATMENT TECHNOLOGY
PRESSING
Pressing the aluminum profile is a deformation process used to obtain a long flat products whose length is significantly greater than the dimensions of cross sections (rods, tubes, tapes, etc.). The principle of molding is simple: due to high load (force the piston presses) Material tree snaps through the tool which gives the desired shape of the profile.
FEAL has installed four modern lines for molding aluminum profiles. The lines vary in strength presses installed. Dimensions of the cross-sectional profile and its required mechanical properties, define the material (alloy), a tool for pressing the line on which the profile will be made.
| Power Presses | 14 MN - Direct Press | 18 MN - Direct Press | 25 MN - Direct Press | 35 MN - Front loading direct Press |
| Manufacturer | Gia | Gia | Presezzi - USMB | Gia |
| Year of manufacture | 2010 | 2003 | 2006 | 2014 |
| The diameter of the recipient/billet Ø (mm) | 156/152 | 184/178 | 210/203 | 254(10“) & 305 (12“) |
| Minimum weight profile ( kg ) | 0,10 | 0,15 | 1,60 | 2,5 |
| Maximum weight of a full profile ( kg ) | 2,5 | 6,50 | 11 | 18 |
| Max width profile ( mm ) | 170 | 220 | 300 | 420 |
| Max. profile perimeter hollow (mm) | 140 | 160 | 200 | 240 |
| Max.press-out length (exit table) (m) | 45 | 45 | 52 | 52 |
| Min./max. saw length (m) | 3 / 8 | 3 / 8 | 1,20 / 8 | 1,5 / 13 |
| Annual capacityt ( t / year ) | 5500 | 7500 | 12 000 | 20 000 |
| Avaible alloys | EN AW-6060 EN AW-6063 | EN AW-6060 EN AW-6063 | EN AW-6060 EN AW-6063 EN AW-6005A EN AW-6082 | EN AW-6060 EN AW-6063 EN AW-6005A EN AW-6082 |
| * other lentgh are specifically negotiated with the customer | ||||
As a raw entry material we use aluminum billets diametara Ф 152 mm, Ф 178 mm, Ф 203 mm Ф 254 mm and Ф 305 mm,cast out of primary aluminium alloy.
Type alloy and method of heat treatment after molding determine the mechanical properties profila. In following table the alloys used in FEAL with their chemical composition and mechanical properties after molding are shown. The quality of the chemical composition of the alloy manufacturer guarantees.
Alloy ENAW 6060 ( AlMgSi 0,5 )
| Chemical composition % | Mechanical properties | ||||||||||||
| Si | Mg | Fe | Mn | Ti | Cu | Ni | Cr | Zn | Ostali | Rm | Rp0.2 | A | |
| Min | 0,42 | 0,43 | 0,17 | N/mm2 | N/mm2 | % | |||||||
| Max | 0,45 | 0,47 | 0,22 | 0,02 | 0,02 | 0,02 | 0,02 | 0,02 | 0,02 | 0,02 | 220 | 150 | 8 |
Alloy ENAW 6063 ( AlMgSi 0,5 )
| Chemical composition % | Mechanical properties | ||||||||||||
| Si | Mg | Fe | Mn | Ti | Cu | Ni | Cr | Zn | Ostali | Rm | Rp0.2 | A | |
| Min | 0,50 | 0,55 | 0,16 | N/mm2 | N/mm2 | % | |||||||
| Max | 0,55 | 0,65 | 0,25 | 0,02 | 0,02 | 0,02 | 0,02 | 0,02 | 0,02 | 0,02 | 250 | 180 | 11 |
Alloy ENAW 6005A ( AlMgSi 0,7 )
| Chemical composition % | Mechanical properties | ||||||||||||
| Si | Mg | Fe | Mn | Ti | Cu | Ni | Cr | Zn | Ostali | Rm | Rp0.2 | A | |
| Min | 0,65 | 0,45 | 0,25 | 0,05 | 0,05 | N/mm2 | N/mm2 | % | |||||
| Max | 0,75 | 0,55 | 0,35 | 0,10 | 0,10 | 0,10 | 0,10 | 0,10 | 0,05 | 270 | 250 | 8 | |
Alloy ENAW 6082 ( AlMgSi 1 )
| Chemical composition % | Mechanical properties | ||||||||||||
| Si | Mg | Fe | Mn | Ti | Cu | Ni | Cr | Zn | Ostali | Rm | Rp0.2 | A | |
| Min | 0,70 | 0,60 | 0,40 | N/mm2 | N/mm2 | % | |||||||
| Max | 1,30 | 1,20 | 0,50 | 1,0 | 0,10 | 0,10 | 0,10 | 0,20 | 0,05 | 310 | 260 | 10 | |
LINE FOR SURFACE TREATMENT
On the surface protection line we protect aluminum profiles, sheets and other parts made of aluminium with anodizing and electrostatic painting
Anodization
In our product range we offer anodization in natural color, in bronze, from bright to completely black and anosidation in gold color. thickness of anodized layer is standard from 18-22 microns, and by special request we also do anodized layer of other thickness.
Electrostatic painting / Powder coating
Electrostatic painting is done in several phases. Before the electrostatic powder coating is done pretratment a profile, creating a conversion layer, which allows good adhesion of powder and resistance and color stability.
After pretreatment and drying of the profile, the procedure applied by electrostatic powder, and then going to roast in the oven for curing products are delivered in color according to customer.
Plant for decoration with sublimation technology
Installing facilities for sublimation, we got unlimited decorations surface profile.
Process decorations profile is in two phases:
- The first phase of the electrostatic powder coating and baking in the oven for curing
- The second phase of the sublimation process, i.e transmission of color with decorative foil to the previously coated profile.
With Line of decorative aluminum profiles we obtained the possibility of protection and decoration of aluminum profiles in imitation of wood, stone, etc. We practically unlimited possibilities of design areas
MACHINING
Machining is done through the final formation of PTM profile and treatment of intermediate and final product according to technical requirements of clients, all while respecting the highest standards of quality.
Production PTM profile
The line connecting the PTM profile of the total installed capacity of 8000 tonnes/year. That line is equipped with modern CNC machines, which enable the connection profile of the largest cross-section 410x360 mm. On this line it is possible to connect the profile of the raw and colored state, which enables the connection of two- coloured profile. Furthermore, it is possible to connect a variety of materials such as combinations of aluminum-PVC-wood.
Production cycle connecting PTM Summary
This procedure can be divided into four phases::
- Notching of the grooves
- Insertion of poliamide drips
- Process of joining profiles
- Quality control of joint profiles
Quality control involves controlling the profile of the combined geometry and profile control mechanical maximum force between the profiles. Recommended value of mechanical force is 400-500 [N/cm]. Standard polyamide strips are stable at high temperatures, allowing for subsequent coating profile.
Machining of aluminum profiles
Thanks to many years of experience and an advanced technology FEAL is able to offer its customers, the service and the most demanding machining aluminum structures, ranging from small pieces to be used as connecting elements locksmith-facade structure, until the very complex aluminum structures of various shapes and lengths up to 15 m.
Services for sawing a profile section to 480 mm, and further processing on automated fiveaxial CNC machines.
We are able on bending arches, flex profile in its raw state, the minimum bending diameter mm R380 with more folding points, and then painted and anodised them. Prepared in this way supplied the arches are regularly shaped and without mechanical damage. The total installed capacity of the line of machining the 6000 t/yr.
Using top quality machines from renowned manufacturers, as well as ongoing review of the technological process of machining a guarantee of successful business.
Saws
Saw Elumatec DG 244
Automatic two-headed saw with high cutting capacity and possibility of automatic positioning of cutting angle from 22.5° to 140°. With The series of automatic saws Elumatec we are able to process the profile dimensions: [345-7000 mm ± 0.2 mm].
CNC saw MIRAGE 600
AMIRAGE 600 is electropneumatic machine for sawing (90°). High capacity and speed of cutting with purpose for sawing of positions length: [5-1500 mm ± 0.1mm].
Machining centers
SBZ 122
SBZ122 is a triaxial CNC machine for processing of aluminium bar profiles lengths up to 4 [m]. machine is fully automated and supports CAD / CAM data exchange.
Technological features:
- processing of ( bar) profiles in five axis/ 5 axis
- kind of processing: milling, drilling, cutting
- automatic changes of tools
- length measuring of processed pieces
- security systems
SBZ 150 – 151
SBZ 150-151 are fiveaxial CNC devices for processing of aluminium bar profiles up to 30 [m]. The machines are fully automated and supported by CAD / CAM data exchange.
Basic features:
- processing of (bar) profiles in 6 axis
- kind of processing: milling, drilling, cutting, threading
- automatic changes of tools
- treated pieces lenght measuring
- security systems
Bending arcs
ARCUS 12 CNC
Machine for bending Al-profile in a plane whose nominal capacity of 12T. We are able to bend arches of minimum bending diameter of Ø 380 [mm] with a maximum of 5 folding points. The ingoing parameters are dimensions of profile sections, tool diameter, radius and bending angle.
Machine automatically corrects arc due to differences in elasticity of particular materials. Next to the above mentioned, we own suitable machine devices and qualified staff so that in every moment we can provide our customers all kind of aspects from projecting to the final processing of the most demanding positions of aluminum systems.
ARCALL CR 248 RIMW
High performance hydraulic 4-axes CNC device for bending of profiles in combination with advanced numerical-control unit CNW333 that enables bending of the most complex positions with one to the max 36 transitional radius on one profile.
WATER TREATMENT TECHNOLOGY
In FEAL we are consired about the methods and processes used in the production, while respecting the environment and safety
Discharge of water purification technology is done on modern automated plant for water treatment technology.
Using modern technology and means of protection and constant control of the requirements ofISO 14001, that is the guarantor of our concern for the environment. In addition to the authorized institutions, the analysis of water is regularly checked in our own laboratory.
