PCP Aluminium

Matmatch MAX5 Ideal Materials for Mould Applications Rev. 1 KO

imago — Thu, 27 Aug 2020 14:04:14 +0000

Moulding parts is a manufacturing process that is ubiquitous in industry. It is typified by requiring moulds made to fit a certain machine type or process type, depending on the parts to be manufactured. Moulds are made by machining various grades of alloys, including aluminium. Among the most important properties when machining moulds are high dimensional stability/accuracy, machinability, corrosion resistance, and light weight. Aluminium, and its alloy AA5083 in particular, is a very common material used for mould applications. It sufficiently meets all of the above-named property requirements and is very versatile in meeting more specific requirements through specific variations of the AA5083 alloy. We will now take a look at how and why AA5083 is well suited for mould applications.

There are numerous mould applications with different mechanisms which place emphases on one or more material properties over others for their successful operation. Some of these properties are non-negotiable across all mould types – for example, excellent dimensional stability and machinability – while others have wider tolerances and allowances. Aluminium alloys perform favourably for these applications and two products (produced from a modified version of the AA5083 alloy) MAX5® and ALCA5® are particularly suitable.

They have undergone precise heat treatment to be relieved of virtually all internal stresses after which they are milled/sawed to high levels of precision. Both MAX5® and ALCA5® have the same alloy constitution of 4 – 4.9% magnesium, 0.4% (max.) iron, 0.4 – 1% manganese, 0.4% silicon (max.), 0.25% zinc (max.), 0.15% titanium (max.), 0.15% zirconium (max.), 0.1% copper (max.), 0.05 – 0.25% chromium.

Why is AA5083 Aluminium Alloy Excellent for Mould Applications?

There are many moulding processes such as blow moulding, plastic injection moulding, panel moulding, compression moulding, thermoforming moulding, and more. Each of these types of moulding requires different critical mould-making properties of the materials they are constructed with to function optimally. AA5083 aluminium in the form of MAX5® and ALCA5® is very suitable for these mould applications for reasons which will be discussed below.

Machinability

Distortions during machining of moulds are unacceptable. For a material to be used for moulding applications, the tight tolerances that are expected for the mould and finished parts require machinability without distortion. This is a key feature of MAX5® and ALCA5® which makes it excellent for applications for plastic moulds. MAX5® and ALCA5® can be easily cut into intricate shapes that involve cams and pins for more complicated mould designs.

Dimensional stability

MAX5® and ALCA5® are made from stress-relieved, primary AA5083 aluminium ingot and have excellent dimensional stability due to their extremely low internal residual stresses and zero recycled content. Unlike other materials that may warp or work-harden during machining or over time due to the effects of internal mechanical stresses, MAX5® and ALCA5® AA5083 remain flat and stable.

Recyclability

MAX5® and ALCA5® have excellent recyclability and re-manufacturability which means that at the end of the lifespan of the material in one application, the aluminium alloy can be repurposed. For example, it can be melted and recast or machined for another application. Machine chips should also be easily scrapped and recycled.

Weldability

The design and building of moulds may require some parts of the mould base plates to be independently created first and then later welded together. Aluminium is typically difficult to weld but welding is not an issue for AA5083. Both MAX5® and ALCA5® offer excellent weldability. Contact PCP Aluminium for further technical welding specifications.

Light weight

Moulding operations may involve processes where the mould itself is part of a production line. In such applications, the weight of the mould would be a consideration. AA5083 aluminium, being 3 times as light as steel, is a good choice based on that fact alone, giving the production line more possibilities in design and handling. An example application is in packaging machinery which use blow moulds or automobile assemblies with robotics and panel moulds.

Surface finish and porosity

MAX5® and ALCA5® are produced to achieve a very high surface finish, with surface roughness as little as 0.4 μm for ALCA5® and 2.4 μm for MAX5®. Coupled with the fact that their alloy structure is practically pore-free, this makes them excellent for moulding processes that require extremely fine surface finishes.

Corrosion and chemical resistance

AA5083 aluminium has excellent corrosion and chemical resistance for mould applications as it doesn’t react with most plastics and other materials that are cast with it. This also allows moulding techniques that involve quenching media to be used. The integrity of the mould is intact after multiple mould operations without wearing off as a result of corrosion, which would have consequently required re-polishing and thus impacted the dimensional tolerances of the mould.

Table 1. Properties of ALCA5® and Max5®

	ALCA5®	MAX5®
Density ρ	2.66 g/cm³ at 20 °C	2.66 g/cm³ at 20 °C
Surface roughness RMS	0.4 μm	25.4 μm (max)
Elastic modulus E	71 GPa at 20 °C	71 GPa at 20 °C
Elongation A	16 % at 20 °C	16 % at 20 °C
Hardness, Brinell HB	70 [-] at 20 °C	70 [-] at 20 °C
Tensile strength Rm	283 MPa at 20 °C	283 MPa at 20 °C
Yield strength YS	124 MPa at 20 °C	124 MPa at 20 °C
Coefficient of thermal expansion α	2.376E-5 1/K at 20 °C	2.376E-5 1/K at 20 °C
Thermal conductivity λ	120 W/(m·K) at 20 °C	120 W/(m·K) at 20 °C
Electrical conductivity σel	1.57E+7 S/m at 20 °C	1.57E+7 S/m at 20 °C
Specific Electrical conductivity	27 % IACS	27 % IACS

How can you take advantage of MAX5® and ALCA5®

The ALCA5® cast precision plate and the MAX5® mould block are registered trademarks of PCP Aluminium which produces them from the best aluminium ingots and raw materials. The MAX5® block can be produced in dimensions of up to 102” in width, 42.5” thickness and 290” in length. These dimensions are larger than required for most mould applications and so the MAX5® can be sawn to the exact required size to minimise wastage. The ALCA5® plate is available in thicknesses between 1/4” to 4” and in widths and lengths, up to 96.5” and 289” respectively.

Visit the PCP Aluminium supplier page for more information on their materials listed on Matmatch and to get in direct contact with them.

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L’article Matmatch MAX5 Ideal Materials for Mould Applications Rev. 1 KO est apparu en premier sur PCP Aluminium.

MAX5® — Aluminum Block for molded and thermoformed parts

imago — Tue, 03 Dec 2019 19:14:41 +0000

From the same prime AA5083 aluminum ingot PCP Aluminum processes into ALCA5® cast tool & jig
plate, PCP Aluminum produces MAX5® aluminum block. MAX5® blocks are heat treated (stress
relieved) per PCP Aluminum’s Quality Procedures, and then squared-off in our state-of-the-art,
automated production facility.

PCP Aluminum’s saws process MAX5®blocks up to 102” wide, 42.5” thick and 290” long. Blocks are then
either further sawn at PCP Aluminum to end-user size specifications, or full-size blocks are sent to our
distributors who also precision saw cut MAX5® blocks for end-users. By working in coordination with
our distributors PCP Aluminum maximizes block yield for our MAX5®end-user customers.

The feedback we’ve received from end-users, mold makers and machine shops is that MAX5® is easier
and faster to machine than other aluminum block alloys. MAX5® always remains stable and flat during
and after machining. MAX5® blocks do not warp or twist after machining. Machined parts reliably and
consistently meet tolerances without re-work or scrap. Hard-coat anodizing and polishing can be done
to MAX5® after cutting cavities or machining.

We love to talk about the very large molds that are being made from MAX5® block, and they are
impressive. But the majority of MAX5® is sawn into smaller blocks, often for plastic molds. This is where
PCP Aluminium’s secondary sawing and squaring operation becomes a real asset for our distributors and
end-users, providing the exact size MAX5® aluminum blocks needed, on time-every time.
Examples of parts or molds made from MAX5® AA5083 aluminum block include:

Blow Molds and Blow Mold automation
Plastic Injection Molds, prototype molds
Automotive fascia and panel molds, seating molds, interior and under-hood part molds
Tire Molds, Rubber compression molds
Thermoforming molds for consumer packaging, clam shell packaging machines, parts
Large plastic tank molds
Off-road vehicle, tractor, snow mobile & ATV body panel molds
Composite lay-up molds and fixtures
Plastic boot molds

MAX5® is the right choice for many aluminum mold and aluminum block applications. With our
inventory and excellent distributors, we will meet your project deadlines with on-time and industry-
leading deliveries.

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It takes big ingot to make big plate – ALAC5® aluminum cast tool & jig plate

imago — Wed, 02 Oct 2019 14:18:38 +0000

How does PCP Aluminium provide our customers with such large plates and blocks of prime AA5083 aluminum? We start with big ingots!

PCP Aluminium is located in the “Aluminum Valley” of Canada, where green, sustainable and inexpensive hydroelectricity is used to produce our prime aluminum ingot. With this abundance of aluminum smelting capacity near PCP Aluminium, we offer some of the largest aluminum mold block and widest aluminum cast tool & jig plate available anywhere in North America or the world.

Pictured above is our Director of Sales and Marketing, Simon Holsgrove, standing in front of the rough ingot PCP Aluminum uses to manufacture ALCA5® aluminum AA5083 cast tool & jig plate. These large ingots allow us to provide ALCA5® plate up to 96.5 inches wide and 290 inches long. Our end-use customers are free to design and manufacture larger and more productive machinery for automation, packaging, molding, robotics and converting; for example.

Once our stress-relieved raw ingots are received, PCP Aluminum’s manufacturing process begins by precision sawing the “crust” off the ingot and squaring the block. Next, using state-of-the-art laser-guided equipment, PCP Aluminum horizontally saws the squared block into plates, which are then 1-pass milled on our 126-inch diameter milling machine. One-pass milling produces the exceptional flatness of ALCA5® plate, without any milling overlap that may affect secondary operations such as anodizing or powder-coating.

After milling the top and bottom surfaces of the plate, every ALCA5® plate is measured on our enormous granite surface plate utilizing CMM technology. Each plate is then protected with a removeable PVC liner. PCP Aluminium’s manufacturing process is automated, in-line and very efficient. Our Production Engineers have carefully designed our ISO-9001:2015 registered, industry-leading manufacturing processes to deliver the defect-free, flat and dimensionally stable aluminum plate and block that our customers want.

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ALL CAST PLATE ARE BORN EQUAL, SOME ARE MORE EQUAL THAN OTHERS

imago — Wed, 04 Sep 2019 17:38:03 +0000

Aluminium cast plate is well known to be the best material in mold making and prototyping. Its main characteristic is its dimensional stability to machining, especially with high speed lubloss CNC machining. This characteristic is due to its «isotropic» nature which means that the material will behave the same way whatever the direction as opposed to rolled material. It is intrinsic (central) to AA5083 alloy when properly heat treated to release the residual stress generated by horizontal DC casting.

When PCP Aluminum was created 13 years ago from, (a sell off of Pecheny), PCP decided to move the installations closer to the Rio Tinto cast house foundries in Quebec Canada. This close proximity and brand-new fabrication equipment, gave PCP the opportunity to develop the best suitable alloy for cast plate applications. All of this while focusing on the main target: dimensional stability as the key property. PCP Aluminium also kept in mind the other properties often requested by end users.

We carefully examined the properties of each available alloy to finalize our choice on AA5083. The AA nomenclature (American Association) ensures the customer that the chemical composition is guaranteed to be the same all the time. From this high grade alloy (AA5083) PCP Aluminium created its high precision ground cast plate named Alca5.

Alca5 is made of prime aluminum with very tight specifications. The specifications targeted are the following: dimensional stability, weldability, corrosion resistance, machinability, flatness (after sawing), gauge control, hard anodization, dry powder painting, surface treatment (chroming, etc), mechanical properties, electrical conductivity, thermal conductivity, and workability.

We discard series such as 2000 series since they were more prone to corrosion and the difficultly involved in its recycling (due to its nickel or beryllium and contamination from copper alloying)_. We also discarded 7000 series not being a food grade in Europe and because weldability and anodization require outstanding skills to achieve good quality level. Some 7000 series do not stand very well to laser cutting as cracking may appear. Especially with tight cutting pattern lines.

Alca5 AA5083 is also known for exceptional performances in extreme environments. It is highly resistant to attack by both seawater and industrial chemical environments. It retains exceptional strength after welding. When welding to itself or another alloy from the same sub-group, the recommended filler metal is 5183. Other suitable fillers are 5356 and 5556. Furthermore, it is a food grade and it is very easy to anodize the parts to a nice decorative aspect.

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AA5083 – CAST BLOCKS FOR MOLD APPLICATIONS WITH HIGH QUALITY PRODUCTS

imago — Tue, 06 Nov 2018 22:43:19 +0000

Our team at PCP Aluminium understands you need premium quality products for the success of your business. That’s why we offer Max5®, an AA5083 aluminium alloy that is the best choice for mold products. Our AA5083 – cast blocks for mold applications are the highest quality in the industry. Max5® surpasses all others by providing better machinability, a good anodizing response, weldability, and excellent strength.

WE TAKE PRIDE IN OUR PRODUCT
At PCP, we always deliver a quality product with our 100% zero defect guarantee. That’s why our quality department uses our proprietary ultrasonic scanner to scan each block for deficiencies, never sending you a compromised product. Our team of experts is highly knowledgeable in the properties of aluminium. We put this knowledge and expertise to use by handling our product with care, from manufacturing to shipping, so that it doesn’t become damaged or compromised along the way. Each member of our team takes personal accountability when handling your product to ensure only the highest quality product is delivered to you.

WE’RE DEDICATED TO DELIVER QUALITY PRICES THAT LOWER YOUR COSTS
To show our dedication to your business, all of our Max5® aluminium cast blocks for mold applications always come with a precision sawed surface. Our casting supplier guarantees internally low levels of porosity. This premium product is easily recyclable after it’s useful life, further cutting your costs.

ALWAYS CHOOSE PCP ALUMINIUM FOR YOUR AA5083 CAST BLOCKS FOR MOLD APPLICATIONS
For excellent dimensional stability, always choose Max5® cast aluminium mold blocks and get them from PCP Aluminium. Whether you’re choosing this product for its weldability, strength, machinability or great anodizing response, it’s always the best choice. If you need this product made to certain specifications to suit your needs, contact us today. You may also visit our website to learn more about the cast block products we offer. We are here to answer any questions you may have about AA5083 cast blocks or any other of our products.

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CHOOSE PCP ALUMINIUM FOR YOUR AA5083 PRECISION CAST ALUMINIUM PLATE

imago — Tue, 06 Nov 2018 22:42:05 +0000

As leaders in the industry, our team at PCP Aluminium understands all of your business needs for quality aluminium products. That is why we supply AA5083 precision cast aluminium plate among our wide variety of top-tier aluminium cast products.

We use the 5083 alloy for precision cast aluminium plate because of its ability to provide you with exceptional dimensional stability. The most common applications for this product are jigs, tools, molds, reference plates, construction equipment and machine parts.

If you need a cast precision plate, you’ll want our unique ALCA5® which possesses outstanding dimensional stability giving it an edge over other products you may encounter elsewhere. Our product always contains the lowest levels of internal stress. This can significantly reduce the possibility of plate deformation both during and after machining.

WE’RE COMMITTED TO MEETING YOUR BUDGET
At PCP Aluminium, we know that you want the best products for the best prices. While we always strive to maintain fair pricing for the industry, we also do what we can to ensure our products increase your cost savings any way we can. With our AA5083 precision cast aluminium plate, you’ll find that buying top of the line materials lends itself to further cost savings. By avoiding further operations such as re-works, finishing, and rough-milling, you’ll save time and money over the long haul.

CUSTOMIZED TO MEET YOUR REQUIREMENTS
While we always offer this product in a range of specifications suitable for typical applications, we have no problem tailoring the product to suit your unique specifications. If you need other thicknesses, widths, or lengths, contact us today to see what we can do for you.

Our team is committed to providing exceptional quality and outstanding lead times to ensure you get the results you need for your business and your projects. If you have applications where machinability, flatness and/or dimensional stability are critical, rely on us and our expertise to deliver the right aluminium solutions.

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ALUMINIUM CAST TOOL AND JIG PLATE FOR YOUR PROJECT

imago — Tue, 06 Nov 2018 22:40:27 +0000

At PCP Aluminium, we understand your need for a quality product when shopping for aluminium cast tool and jig plate. We manufacture these under the name of ALCA 5® and distribute them through our trusted partners.

All of our premium aluminium products have precision machined surfaces for excellent flatness. We deliver products with complete dimensional stability allowing for extensive machinability while reducing the occurrence of distortion both during and after use.

STRENGTH CHARACTERISTICS
All of our products can compete with the highest standards in the industry with a tensile strength of 41,000 PSI, a yield strength of 18,000 PSI, as well as a Brinell hardness of 70 HB. The edge conditions of this product are always precision sawed.

CUSTOM SIZES
Our cast tool and jig plate products can be found under the trade name of ALCA 5 ® Our ALCA 5® products are available in a variety of industry standard sizes. In addition, all of our cast tool and jig plates can be cut-to-size or produced with custom thicknesses, widths, and lengths upon request.

EXCELLENT OPTION FOR MANY APPLICATIONS
Our products have excellent machinability as well as weldability. Our aluminium cast tool and jig plates are suitable for many applications across the industry, including reference plates, construction equipment, machine parts, tools, and jigs. If you need products with sound dimensional stability and excellent strength, choose PCP Aluminium.

Contact us with any questions you may have about our aluminium cast tool and jig plate products. You can also find more information about what we offer by visiting our website. We offer the fastest lead times in North America, less than 7 days. Our team is committed to delivering the highest quality aluminium cast plate products to meet the project requirements of our customers.

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FAQ – DO YOU KNOW WHERE TO BUY ALUMINUM BLOCKS?

imago — Tue, 06 Nov 2018 22:37:10 +0000

At PCP we understand your requirements for quality aluminium blocks. We are an industry leader in cast aluminium plate. When you need to know where to buy aluminium blocks, you can count on our team to deliver a high quality product every time. Dimensional stability is one great benefit offered by aluminium blocks in alloy 5083. The applications that make use of this product include tools, construction equipment, and molds. If you’re looking for where to buy aluminium blocks, PCP Aluminium is your source. We provide these blocks and cast precision plate as well. In fact, if you need cast precision plate with excellent dimensional stability, we still have you covered. These products are characterized by low levels of internal stress that allow for the minimization of plate deformation after and prior to machining operations. Affordable Aluminium Block Products At PCP Aluminium our aim is to deliver the best possible products at the best possible prices. We want to help you to find cost savings in whatever way we can. The quality and stability of our AA5083 precision aluminium blocks will help to this end. These characteristics help to avoid the need for finishing, re-working or rough-milling which can save substantial time and money on your end over the long-term. We Offer Customized Sizes We offer standard aluminium block sizes that are suitable for a variety of applications. We are also able to accommodate customized sizes to match your specific requirements. If you require other lengths, widths or thicknesses than what we have listed, let us know. At PCP Aluminium, you can rely on us to provide you with the products you need for your applications. Since our aluminium block and cast aluminium plate products offer superb flatness, machinability, and dimensional stability, they are uniquely positioned to deliver the results you need for your applications. We always give great attention to detail when producing our products. Along with our advanced production process and techniques, this ensures that you have a final end product in which you can have confidence and which perfectly meets the demands of your project requirements.

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ELECTRICAL GRADE ALUMINUM BUS PLATE – ITS BENEFICIAL QUALITIES

imago — Tue, 06 Nov 2018 22:34:29 +0000

At PCP Aluminium, you can count on us to deliver a high level of service and a quality finished product when it comes to electrical grade aluminium bus plate. We pride ourselves in being able to provide our customers with the fastest lead time in North America as well – an order to delivery that takes about 5 to 7 days on average. We carry high a quality inventory and sell our products through our network of distributors to ensure fast and professional delivery every time. In order to meet your requirements, we offer some of the largest cut to size capabilities in the industry. So if you require products that are cut to size, please do not hesitate to contact us. ABOUT OUR ELECTRICAL GRADE ALUMINIUM BUS PLATE In order to fabricate our electrical grade aluminium bus plate, which is categorized under AA1370 bus bar, we only utilize premium, heat treated aluminium cast ingots. With this product you receive the accompanying benefits of outstanding dimensional stability and weldability. As well, this product delivers superb electrical conductivity. As stated, electrical grade aluminium bus plate is perfectly suited for electrical applications. It comes in a variety of sizes and in order to ensure fast delivery for you, it is a readily stocked item in our inventory. When you need something for those complex electrical requirements then this product is perfect in order to reduce your energy losses. CUSTOMIZATION At PCP Aluminium, we deliver some of the highest quality cast aluminium products suitable for various industrial applications. Excellent dimensional stability and flatness characteristics are two features that you will find in our products. We are able to provide you with custom sized products as well to meet your specific requirements. In addition, our bus plate can be milled 2 sides and then coated with a protective plastic film on the milled sides. For additional information about what we offer in terms of electrical grade aluminium bus plate or our other products, please visit our website. You may also contact us directly to discuss your project requirements.

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ALCA 5 ALUMINUM PLATE OFFERS EXCELLENT BENEFITS

imago — Tue, 06 Nov 2018 22:33:44 +0000

The ALCA 5 cast aluminum plate is a hallmark of our product offerings at PCP Aluminium. We offer this plate to a wide range of customers in the general engineering industry. ALCA 5 aluminum plate is a cast precision plate that delivers superb dimensional stability, giving it a great advantage over other possible plate options. This results in a low level of internal stress that reduces considerably the possibility of plate deformation during and after the machining process. With ALCA 5, you receive a totally uniform plate.

ALCA 5 ALUMINUM PLATE AND STABILITY
Some of the applications in which ALCA 5 cast aluminum plate is used include jigs, molds, plates, machine parts and construction equipment.

ALCA 5 aluminum plate is a 5083 alloy aluminum cast plate that also provides a very good hard anodizing response. With a yield strength of 18000 psi and an ultimate strength of 41000 psi, this plate offers excellent strength characteristics that help it meet the most demanding applications.

SIZE, POLISHING, WELDING AND MORE
Available in a range of thicknesses from 1/4” to 4” and in a wide range of lengths and widths as well, the ALCA 5 cast aluminum plate delivers very good polishing and welding capabilities. It also offers excellent corrosion resistance for standard atmosphere conditions as well as good corrosion resistance for marine atmosphere conditions. In addition, this plate provides excellent machinability.

For additional detailed information about the characteristics, features and capabilities of ALCA 5 aluminum plate, please review our website and browse the product page for ALCA 5 cast aluminum plate.

At PCP Aluminium, we are committed to helping you purchase the right cast plate to meet your project needs. If you have any questions, we are here to help. We can discuss with you any specific project requirements and make recommendations as to the best plate selection for your needs.

When it comes to cast aluminum plate and blocks, we are the experts, so don’t hesitate to take advantage of our expertise. Our experience speaks for itself and we have a track record of helping our customers fulfill their project needs.

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