Sheet steel hot forming is something most people have heard about. But using the same technology on aluminum – is that really realistic? It is this question that engineers at SAPA's R&D center in Finspång, Sweden will now investigate using equipment from AP&T.
"The specific hot forming technology enables manufacturing of complex shapes, mainly since hot material can be stretched in an entirely different manner compared to room tempered aluminum. Amongst other things, this means that several processing steps can be skipped to produce a more rational product. The forming technique opens up for product geometries with mechanical properties that previously haven't been possible with aluminum," says Conny Falk, Technical Area Manager, SAPA Technology.
Secrecy
The specific aluminum hot forming process has not yet been commercialized, but in light of the potential the method appears to have, it is no surprise that testing at SAPA's R&D center is cloaked in great secrecy.
"Due to competition considerations, I would prefer not to go into how the technique works or for what we are planning to use the technology; just let me say that it is very interesting," says Conny Falk.
Having said that, it is not strange that SAPA – the world's largest manufacturer of aluminum profiles and leading supplier of rolled aluminum strips for the heat exchanger industry – turned to AP&T for the equipment it needs. AP&T has been a leader in sheet steel hot forming for quite some time, with know-how and experience that are well suited to the task at hand. AP&T already has an established relationship with SAPA, but within hydroforming.
Great challenge
"This is an incredibly exciting project for us that can pave the way for a new manufacturing method and new products. It has also posed a great challenge to us at AP&T, including very unique demands," says Jan Starck who is responsible for the sale on behalf of AP&T.
For example, forming must be done in a very stable sequence, with a high degree of precision and extremely small tolerances. From a testing and research point of view, it is also important to be able to run and evaluate the forming process with different process parameters and forming times, and still be able to maintain a controlled forming sequence.
Standard modules
However, tested standard modules can also be used to a large degree for unusual orders. A 200-metric ton ODEN press with a 1300 x 1000 mm press table forms the basis of SAPA's equipment. AP&T's numerical control system – HNC – is also included. It was developed for hydraulic presses and tools that are used in processes that require a high degree of precision in the forming sequence, with exact regulation of hydraulic cylinders, force and forming time.
The equipment was installed at SAPA in Finspång at the end of April, just over half a year after the order was signed.
"Cooperation has worked very well. AP&T has met our specification of requirements to a T, and has stuck to both the schedule and the budget. And the first tests are completely in line with our expectations," says Conny Falk.
Brief information about SAPA
- SAPA is the world's largest manufacturer of aluminum profiles with production in over 20 countries and a global sales organization.
- Sapa Heat Transfer is one of the world's leading companies within the manufacture of aluminum heat exchanger strips for the automotive industry.
- SAPA was founded in 1963 in Vetlanda, Sweden, and is currently wholly owned by Norwegian Orkla.
- SAPA's R&D center is located in Finspång, Sweden.
