Defence Aluminium

Contents

Defence Aluminium
... Solutions from Aleris
... Plate Products

3
4

... Extruded Products

11

... Component Manufacturing

13

ort
Customer Engineering Support
Research and Development

14

Quality Assurance
ality
Approvals Our Brand is Quality

15

Pictures used by courtesy of

General Dynamics European Land Systems - Germany GmbH, Krauss - Maffei Wegmann GmbH &
Co. KG, Textron Marine and Land Systems, BAE
Systems, Hyundai Rotem Company, Doosan DST
Co., Ltd. and CEFA (France).

Defence Aluminium

Defence Solutions from Aleris

Aleris with its European headquarter in

This continuous improvement has enabled

A comprehensive quality management

Switzerland is among the worlds head-

Aleris, via defence specialized plants in

system has been established for all speci-

ing suppliers of high-quality aluminium

Koblenz, Bonn (both in Germany) and

fied material properties, continually con-

rolled and extruded products, aluminium

Duffel (Belgium), to supply the interna-

trolled and documented during the entire

recycling manufacturing top-quality cast,

tional defence industry with innovative

fabrication processes, which guarantees

wrought and magnesium alloys, as well

aluminium materials and components

that the most stringent requirements of

as custom-made components for the

of the highest quality, which fulfil, not

both customers and governmental in-

defence industry.

only the highest industry standards but

stitutions worldwide are complied with.

also all conceivable individual customer

It ensures highly consistent quality and

As a result of more than five decades

specifications with respect to their di-

helps to continuously improve the prod-

of experience and knowledge, gained

mensions, properties and quality char-

uct quality.

by being the principal supplier to many

acteristics.
If you need further data or more ur-

industries, and continuous investment

in state-of-the-art production facilities,

Aleris know-how has been applied in de-

gent assistance, please contact us

research and development, quality as-

veloping niche products of various alloys

using the information provided at the

surance, as well as ongoing education

like thick and extremely wide defence

back of this brochure or simply visit

and training of employees, Aleris prod-

aluminium plates or sections in custom-

our website at www.aleris.com.

ucts are continuously improved.

ized sizes and large extruded products,

as well as custom-made components
which fully satisfy the requirements of
the worldwide defence industry.

Defence Aluminium

Defence Aluminium Plate Products

Alloys and specifications

Aleris in Europe with its two entities Al-

Aleris aluminium plates offer an opti-

Aleris supplies defence aluminium plate

eris Aluminum Koblenz GmbH in Ger-

mum solution for any kind of structural

products based on the following alloys

many and Aleris Aluminum Duffel BVBA

application with specific ballistic per-

and tempers according to the various

in Belgium operates two world-class

formance, if required. They allow the

relevant material specifications:

rolling mills with unique manufacturing

design of light-weight, reliable and cost

capabilities for flat rolled semi-finished

efficient components for light armoured

products for e.g. the automotive, aero-

civilian and tactical vehicles as well as

With ballistic requirements

space and defence industry.

for heavy constructions like military

Alloy*

Temper

Specification

bridges. They improve strategic and

AA 5083
EN AW 5083

H131

MIL-DTL-46027
TL 2350-0004

AA 5059
EN AW 5059
Alustar

H131

MIL-DTL-46027
TL 2350-0004

AA 5059
Alustar

H136

MIL-DTL-46027

AA 2519

T87

MIL-DTL-46192

Traditionally, the aluminium alloys used

tactical mobility of defence components

for armoured vehicles and other military

e.g. by transport aircraft into combat or

related applications are high strength,

disaster relief which gives aluminium a

heat-treatable 2xxx and 7xxx series al-

comparative advantage over steel.

loys but also low-density and cost efficient 5xxx series alloys with excellent

Aluminium armour plates with ballistic

ballistic properties, good weldability and

requirements are being tested at certi-

outstanding corrosion resistance.

fied testing laboratories such as BWB

(Germany), TNO (The Netherlands) or

As part of Aleris strategic plan to de-

APG (USA) with consideration of na-

velop new aluminium plate materials and

tional and international regulations and

solutions for armoured vehicles with the

standards.

AA 7017

T6

TL 2350-0004

EN AW 7020

T6

TL 2350-0004

AA 7039

T6

MIL-DTL-46063

* Other alloys on request

highest property performance in extreme

Without ballistic requirements

dimensions in particular with respect

Alloy*

to thickness and width various devel-

AA 5456

H116

ASTM

opment projects, investment programs

AA 2024

ASTM

as well as other activities have been

AA 6061
EN AW 6061

T6

AMS-QQ-A
EN 485-2

the Koblenz plant) to become one of the

EN AW 7020

T6

EN 485-2

most important suppliers of aluminium

EN AW 7022

T6

EN 485-2

armour plate products into the worlds

* Other alloys on request

carried out, enabling Aleris (especially

defence industry.

Defence Aluminium

Temper

Specification

Basic material properties

In the following tables Aleris aluminium

Additionally, typical mechanical proper-

armour plates with ballistic requirements

ties after fusions welding and friction stir

are characterized in detail and compared

welding (FSW) demonstrate the advan-

to minimum values specified in TL and

tage of Aleris the Alustar alloy in a cost

MIL standards.

efficient manufacturing process.

Chemical composition
Alloy*

Chemical elements
Si
Fe
Cu

Mn

Mg

Cr

Zn

Ti

Zr

Other
Individual

Other
Total

5083

Min. weight (%)

Max. weight (%)

0.00
0.40

0.00
0.40

0.00
0.10

0.40
1.0

4.0
4.9

0.05
0.25

0.00
0.25

0.00
0.15

0.00
0.05

0.00
0.15

5059
Alustar

Min. weight (%)

Max. weight (%)

0.00
0.45

0.00
0.5

0.00
0.25

0.6
1.2

5.0
6.0

0.00
0.25

0.4
0.9

0.00
0.2

0.05
0.25

0.00
0.05

0.00
0.15

2519

Min. weight (%)

Max. weight (%)

0.00
0.25

0.00
0.30

5.3
6.4

0.10
0.50

0.05
0.40

0.00
0.10

0.02
0.10

0.10
0.25

0.05
0.15

0.00
0.05

0.00
0.15

7017**

Min. weight (%)

Max. weight (%)

0.00
0.30

0.00
0.40

0.10
0.20

0.10
0.70

1.7
3.3

0.00
0.25

4.0
6.0

0.00
0.15

0.10
0.25

0.00
0.05

0.00
0.15

7020**

Min. weight (%)

Max. weight (%)

0.00
0.35

0.00
0.40

0.00
0.20

0.05
0.50

1.0
1.4

0.10
0.35

4.0
5.0

0.00
0.05

0.00
0.15

7039

Min. weight (%)

Max. weight (%)

0.00
0.30

0.00
0.40

0.00
0.10

0.10
0.40

2.3
3.3

0.15
0.25

3.5
4.5

0.00
0.05

0.00
0.15

0.08
0.20
0.00
0.10

* According to AA or EN AW
** According to TL 2350-0004

Physical properties
Alloy*

Density

E-Modulus

g/cm3

lbs/in3

MPa

103 ksi

Coeff. of thermal expansion

20-100C
68-212F
m/m K
in/in F

Thermal conductivity
20C
68F
W/(m * K) btu/(ft h F)

Electrical conductivity
20C
68F
m/( mm2)
%IACS

5083

2.66

0.096

69,200

10.0

24.5

13.6

131

75.7

17

29.3

5059
Alustar

2.64

0.095

70,400

10.2

23.0

12.8

130

75.1

16

27.6

2519

2.82

0.102

71,000

10.3

22.0

12.2

140

80.9

19

32.8

7017

2.77

0.100

70,500

10.2

23.3

12.9

130

75.1

21

36,3

7020

2.77

0.100

71,000

10.3

23.1

12.8

137

79.2

20

34,5

7039

2.73

0.099

69,600

10.1

23.4

13.0

125

72.2

19

32,8

* According to AA or EN AW

Defence Aluminium

Mechanical performance

Minimum mechanical properties

Alloy

Temper

Specification*

Test
direction

Plate thickness
mm
in

Tensile strength Rm
MPa ksi

Yield strength Rp0.2

MPa ksi

AA 5083

H131

MIL-DTL-46027
(table VI)

6.35 - 12.67
12.7 - 50.8
50.83 - 76.2

0.250 - 0.499
0.500 - 2.000
2.001 - 3.000

310
310
303

45.0
45.0
44.0

241
255
241

35.0
37.0
35.0

8
8
9

EN AW 5083 H131

TL 2350-0004

LT

6.35 - 12.67
12.7 - 50.8
50.83 - 76.2

0.250 - 0.499
0.500 - 2.000
2.001 - 3.000

311
311
304

45.0
45.0
44.0

242
256
242

35.0
37.0
35.0

8
8
9

AA 5059
Alustar

MIL-DTL-46027
(table VI)

6.35 - 12.67
12.7 - 50.8
50.83 - 76.2

0.250 - 0.499
0.500 - 2.000
2.001 - 3.000

393
393
344

57.0
57.0
50.0

303
296
289

44.0
43.0
42.0

8
7
8

EN AW 5059 H131
Alustar

TL 2350-0004

LT

0.236 - 2.362

370

54.0

300

44.0

AA 5059
Alustar

H136

MIL-DTL-46027
(table VI)

6.35 - 12.67
12.7 - 50.8
50.83 - 76.2

0.250 - 0.499
0.500 - 2.000
2.001 - 3.000

365
358
344

53.0
52.0
50.0

296
289
289

43.0
42.0
42.0

10
10
10

AA 2519

T87

MIL-A-46192
(table II)

12.7
38.1
50.8
76.2

0.500
1.501
2.001
3.001

1.500
2.000
3.000
4.000

455
455
462
469

66.0
66.0
67.0
68.0

407
407
414
421

59.0
59.0
60.0
61.0

10
9
8
7

AA 7017

T6

TL 2350-0004

LT

6
> 50
> 76

0.236 - 1.969
> 1.969 - 2.992
> 2.992

430
410
410

62.4
59.5
59.5

360
340
340

52.2
49.3
49.3

8
8
6

EN AW 7020 T6

TL 2350-0004

LT

< 25
> 25

< 0.984
> 0.984 - 2.362

350
340

50.8
49.3

280
275

40.6
40.0

10
8

< 1.5
> 1.5

414
393

60.0
57.0

352
331

51.0
48.0

9
8

AA 7039

H131

T6

MIL-DTL-46063
(table II)

< 38.1
> 38.1

- 60

38.1
50.8
76.2
101.6

- 50
- 76

- 60

* Mechanical properties according to table VI of MIL-DTL-46027 for standard dimensions up to 60 x 140 (width x length)
For wider plates with dimensions 60 < width < 100 mechanical properties are guaranteed according to MIL-DTL-46027 table II
Other dimensions on request

Minimum and typical mechanical properties are measured in L-direction

as specified in MIL standards, while
plates produced according to TL standards are tested in LT direction. Properties after welding are always measured across the weld seam, typically
in the LT direction.

Defence Aluminium

Elongation A
%

Typical mechanical properties (based on actual production values)

Alloy*

Temper

Test
direction

Plate thickness
mm
in

Tensile strength Rm
MPa
ksi

Yield strength Rp0.2

MPa ksi

Elongation A
%

5083

H131

6.35 - 12.67
12.7 - 50.8
50.83 - 76.2

0.250 - 0.499
0.500 - 2.000
2.001 - 3.000

345
330
320

50.0
48.0
46.4

285
275
265

41.3
40.0
38.4

10
10
11

5059
Alustar

H131

6.35 - 12.67
12.7 - 50.8
50.83 - 76.2

0.250 - 0.499
0.500 - 2.000
2.001 - 3.000

405
395
360

58.7
57.3
52.2

360
350
310

52.2
50.8
45.0

9
9
10

5059
Alustar

H131

LT

25.8

1.016

411

59.6

319

46.3

11

5059
Alustar

H136

6.35 - 12.67
12.7 - 50.8
50.83 - 76.2

0.250 - 0.499
0.500 - 2.000
2.001 - 3.000

375
380
355

54.4
55.0
51.5

310
320
295

45.0
46.4
42.8

12
11
12

2519

T87

12.7
25.4
38.1

0.500
1.000
1.500

484
488
484

70.2
70.8
70.2

455
464
458

66.0
67.3
66.4

12
12
12

7017

T6

LT

> 6 < 50

0.16

- 1.97

445

64.5

385

55.8

11

7020

T6

LT

> 4 < 25
> 25 < 60

0.16
1

- 0.98
- 2.36

360
355

52.2
51.5

300
295

43.5
42.8

13
11

7039

T6

< 38.1
> 38.1

< 1.5
> 1.5

435
425

63.0
61.6

375
355

54.4
51.5

11
10

Typical values after fusion welding

Alloy*

5083

Temper

Typical
filler wire
alloy*

after friction stir welding (FSW)

Typical plate
thickness
mm
in

Tensile strength Rm Yield strength Rp0.2

Tensile strength Rm

Yield strength Rp0.2

MPa

ksi

ksi

MPa

MPa

MPa

ksi

ksi

H131

5183

20 - 30

0.78 - 1.18

275

40.0

125

18.2

285

41.3

162

23.5

5059
H131
Alustar

5183
5556

20 - 30

0.78 - 1.18

300

43.5

160

23.2

340

49.3

180

26.1

5059
H136
Alustar

5183
5556

20 - 30

0.78 - 1.18

300

43.5

160

23.2

340

49.3

180

26.1

2519

T87

2319

101.1

280

40.6

204

29.6

**

**

**

**

7017

T6

5183
5356/5556

25 - 30

- 1.18

260

37.7

205

29.7

**

**

**

**

7020

T6

5183
5356/5556

25 - 30

- 1.18

275

40.0

205

29.7

325

47.1

240

34.8

7039

T6

5183
5356/5556

25 - 30

- 1.18

310

45.0

175

25.4

**

**

**

**

< 1.18

185

26.8

115

16.7

252

36.5

162

23.5

for comparison:
6061

T6

4043
5183

< 30

* According to AA or EN AW
All values are measured across the weld seam and rolling direction (LT-direction)

** To be determined

Defence Aluminium

Ballistic performance

The following Milne de Marre graphs have

They allow a simple estimation of the

been generated to offer a design guide

weight of an aluminium plate under con-

to engineers and designers of armoured

sideration of the ballistic performance ac-

vehicles, as well as to demonstrate the

cording to the appropriate MIL standard

ballistic performance and weight effi-

and the individual alloy density.

ciency of most commonly used Aleris

armour plate alloys.

Milne de Marre graph for armour plate materials (according to MIL)

Projectile .30AP M2 0

Projectile 20 mm FSP

V50 limit velocity

[m/s]

[ft/s]

V50 limit velocity

[m/s]

[ft/s]

950

3,117

950

3,117

900

2,953

850

2,789

850

2,789

750

2,461

2,625

650

2,133

750

2,461
Result:
Arial density = 115 kg/m2 (23.6 lb/ft2)

550

1,804

700

2,297

450

1,476

2,133

350

800

Example:
V50 = 800 m/s (2,625 ft/s)

650
70
(14.3)

80
(16.4)

90
(18.4)

100
(20.5)

110
(22.5)

120
(24.6)

130
(26.6)

140
(28.7)

1,148
70
(14.3)

Areal density [kg/m2 (lb/ft 2)]

AA 2519

AA 5059 Alustar

How to use the graph:

Requirement V50:
Arial density AA 5059 Alustar:
Assumed plate dimension:
Assumed plate weight:

Defence Aluminium

90
(18.4)

100
(20.5)

Areal density [kg/m2 (lb/ft 2)]

AA 7039

800 m/s
115 kg/m2
t x 2,000 x 3,000 mm
690 kg

80
(16.4)

AA 2519

2,625 ft/s
23.6 lb/ft2
t x 78.7 x 118.1 in
1,521 lb

AA 5059 Alustar

AA 7039

110
(22.5)

Corrosion performance

The Aleris Alustar alloy was originally

For example, not only for amphibious

Todays economic expectations are lead-

developed for the challenging corrosion

vehicles but also for other armoured

ing to extended life cycles for current and

requirements of the international ship-

vehicles in corrosive environments due

future military platforms requiring new

building industry. Alustar has been

to chemical / biological exposure or the

materials like Alustar with outstand-

further developed to make it applicable

extreme environment conditions seen

ing corrosion resistance and excellent

to the defence industry, where corrosion

through operational deployment through-

ballistic protection.

performance is an essential operational

out the life time of such vehicles.

requirement.

Natural sea water test

Alloy*

Temper

Thickness
mm in

Test time
month

MIG welded
with filler alloy

Remarks

5059
H136
Alustar

12.7

0.5

14

5183

insignificant attack on the water line, no visible attack on the weld seam
insignificant attack in the Heat Affected Zone (HAZ), pitting on the surface

2519

13

0.51

2319

corrosion on the rolled surface, insignificant attack on the weld seam and in the HAZ

T87

* According to AA or EN AW

AA 5059 H136
front side (final weld pass)

AA 5059 H136
back side (root pass)

AA 2519 T87
front side (final weld pass)

AA 2519 T87
back side (root pass)

Welded samples of AA 5059 and AA 2519 after natural sea water corrosion test

Defence Aluminium

Advantages

Based on Aleris unique manufacturing

and MIL specifications can be fulfilled

technologies, such as the worlds most

as a minimum. Moreover, armour plates

powerful 160 (4,064 mm) wide hot roll-

in extreme widths can be provided to

General dimensional
capabilities for armour plate*
up to

mm

in

254

10

ing mill and the 8,000 tons stretcher,

reduce the number of weld seams in a

Thickness

high performance plate products with

cost efficient manufacturing process

Width

up to

3,300

130

extraordinary dimensions can be pro-

a key manufacturing cost and design

Length

up to

24,000

945

duced, leaving nothing to be desired.

integrity advantage.

All dimensional requirements in terms

Through Alustar Aleris offers the broadest

* Subject to alloy, temper and

thickness x width combination
Larger dimensions on request

of thickness covered by the relevant TL

range and maximizes design flexibility.

Characteristics of aluminium armour alloys

Alloy*

Temper

5083

H131

5059 Alustar

H131

5059 Alustar

H136

2519

T87

7017

T6

7020

T6

7039

T6

Corrosion
resistance

Weldability

Ballistic requirements
according to MIL standards
.30 AP M2 0
20 mm FSP

* According to AA or EN AW

not suitable

Temper

Mine Blast

excellent

Conclusion

Specific manufacturing capabilities

Alloy*

Spalling

Specified
thickness (MIL)
mm
in

Specified
thickness (TL)
mm
in

Produced
thickness
mm
in

Produced width
mm

in

5083

H131

76.2

76.2

76.2

2,540

100

5059
Alustar

H131

76.2

60

2.36

76.2

2,921

115

5059
Alustar

H136

76.2

152.4**

6**

3,048

120

2519

T87

101.6

101.6

2,032

80

7017

T6

76

~3

76.2

2,000

~ 79

7020

T6

60

2.36

60

2.36

2,870

~ 113

7039

T6

101.6

101.6

2,108

83

Aleris offers a large variety of armour

plate materials for ballistic protection.
The product portfolio comprises high
strength, heat-treatable 2xxx and 7xxx
series alloys but also 5xxx series alloys,
such as Alustar with low density, excellent weldability and corrosion resistance.

* According to AA or EN AW
** Without ballistic requirements; other dimensions on request

10 Defence Aluminium

At the same time the ballistic protection

is comparable to the best performing
high strength alloys used in the industry today.

Defence Aluminium Extruded Products

Alloys and capabilities

Aleris in Europe operates a number of

In order to produce small, medium size,

High strength alloys are heat-treated in

extrusion plants, two of which are dedi-

wide and heavy extrusions, either as

one of the most modern horizontal so-

cated to the manufacturing of high per-

open or hollow sections out of 5xxx, 6xxx

lution-heat-treatment furnaces, built by

formance extruded rod, bars and shapes

and 7xxx series alloys, various extrusion

Ebner with an annual capacity of about

for the defence industry.

presses are operating in direct or indirect

4,900 tons. Based on a highly sophis-

mode up to 90 MN.

ticated quenching system, as well as a

The extrusion plants Aleris Aluminum

800 tons-stretcher for straightening and

Bonn GmbH (Germany) and Aleris Alumi-

stress relieving Aleris new equipment

num Duffel BVBA (Belgium) are equipped

Defence extrusion alloys*

with sophisticated production equipment

2618A
5049
5059 Alustar
5083

utilizing all the necessary machinery for

the production of approved defence ex-

6005A
6060
6061
6082

allows the production of complex shapes

7003
7010
7020
7021

7022
7049
7075
7175

* According to AA or EN AW
All alloys are subject to profile size and geometry
Other alloys on request

truded products.

with nearly no distortion. It increases

Aleris production capacity to a larger
range of sizes and shapes and brings
Aleris process capability to a higher
level for the entire product range.

Weight of compact solids

Alloy
du

mm
40

in
1.57

mm
60

in
2.36

mm
89

in
3.50

mm
225

in
8.86

mm
560

in
22.05

2xxx / 5xxx / 7xxx

Min. weight (kg/m; lbs/ft)

Max. weight (kg/m; lbs/ft)

1.0
0.67
102.5 68.9

1.5
1.01
102.5 68.9

2.4
1.61
102.5 68.9

11.8 7.93
102.5 68.9

26.6
350.0

17.87
235.2

6xxx

Min. weight (kg/m; lbs/ft)

Max. weight (kg/m; lbs/ft)

0.6
0.40
102.5 68.9

1.0
0.67
102.5 68.9

1.5
1.01
102.5 68.9

7.6
5.11
102.5 68.9

10.0
350.0

6.72
235.2

du

Weight of wide compact solids

Alloy
WxH

2xxx / 5xxx
7xxx

6xxx

mm
in
120 x 70 4.72 x 2.76

mm
150 x 30

in
5.91 x 1.18

mm
194 x 30

in
7.64 x 1.18

mm
in
700 x 120 27.56 x 4.72

mm
700 x 180
730 x 120
750 x 60

in
27.56 x 7.09
28.74 x 4.72
29.53 x 2.36

Min. weight
(kg/m; lbs/ft)

5.9

3.96

3.8

2.55

5.9

3.96

26.6

17.87

Max. weight
(kg/m; lbs/ft)

102.5

68.9

102.5

68.9

102.5

68.9

350.0

235.2

350.0

235.2

Min. weight
(kg/m; lbs/ft)

3.8

2.55

2.5

1.68

3.8

2.55

10.0

6.72

10.0

6.72

Max. weight
(kg/m; lbs/ft)

102.5

68.9

102.5

68.9

102.5

68.9

350.0

235.2

350.0

235.2

Defence Aluminium 11

Design guidelines

Minimum wall thickness of extruded hollows

Alloy*
du

mm
< 100

in
< 3.94

mm
< 200

in
< 7.87

mm
< 300

in
< 11.81

mm
< 400

in
< 15.75

mm
< 490

in
< 19.29

5083 / 5049**
6060 / 6005A
6082 / 6061
7020 / 7021 / 7003

5.0
1.0 - 1.5
2.5
3.5

0.20
0.04 - 0.06
0.10
0.14

5.5
2.5
3.0
4.0

0.22
0.10
0.12
0.16

6.5
3.5
4.0
4.5

0.26
0.14
0.16
0.18

7.5
4.5
5.0
5.5

0.30
0.18
0.20
0.22

8.0
5.0
6.0
6.5

0.31
0.20
0.24
0.26

du

** The aluminium extruded hollows can only be manufactured by mandrel (no porthole or bridge dies)
du

Minimum wall thickness of open extrusions

Alloy*
du

mm
< 100

in
< 3.94

mm
< 200

in
< 7.87

mm
< 300

in
< 11.81

mm
< 400

in
< 15.75

mm
< 500

in
< 19.69

mm
< 540

in
< 21.26

5083 / 5049
6060 / 6005A
6082 / 6061
7020 / 7021 / 7003

5.0
1.0 - 1.5
1.8
3.5

0.20
0.04 - 0.06
0.07
0.14

5.5
2.0
2.5
4.0

0.22
0.08
0.10
0.16

6.0
3.0
3.5
4.5

0.24
0.12
0.14
0.18

7.0
4.0
4.5
5.0

0.28
0.16
0.18
0.20

7.0
4.5
5.5
6.0

0.28
0.18
0.22
0.24

8.0
5.0
7.0
7.0

0.31
0.20
0.28
0.28

Minimum wall thickness of wide extruded hollows

Alloy*
WxH

mm
in
500 x 150 19.69 x 5.91

mm
550 x 200

in
21.65 x 7.87

mm
720 x 30
700 x 60

in
28.35 x 1.18
27.56 x 2.36

5083 / 5049
6060 / 6005A
6082 / 6061
7020 / 7021 / 7003

4.5
5.0
6.0

3.0
4.5
5.5

0.12
0.18
0.22

3.0
4.0
5.0

0.12
0.16
0.20

mm
720 x 30
700 x 60

in
28.35 x 1.18
27.56 x 2.36

0.18
0.20
0.24

Minimum wall thickness of wide open extrusions

Alloy*
WxH
5083 / 5049
6060 / 6005A
6082 / 6061
7020 / 7021 / 7003

mm
in
500 x 150 19.69 x 5.91
7.0
3.5
4.5
6.0

mm
550 x 200

0.28
0.14
0.18
0.24

* Other alloys on request

Individual sections and specific designs on request

12 Defence Aluminium

7.0
3.0
4.0
5.5

in
21.65 x 7.87
0.28
0.12
0.16
0.22

7.0
2.8
3.0
4.5

0.28
0.11
0.12
0.18

Defence Aluminium Component Manufacturing

Aleris Aluminum Bonn GmbH is spe-

On-site aluminium welding facilities and

Machining and milling

cialized in large extrusions and project

machining equipment are designed to

Aleris Bonn has two high performance

business. With Europes most modern

handle heavy duty profiles and over-

cutting CNC Machining Centers designed

large 90MN extrusion press and extra

sized modular assemblies. Customers

for milling of tailor-made aluminium sec-

long run-out length the plant in Bonn is

appreciate a single point of contact be-

tions, in particular for:

well prepared to cope with the demands

fore, during and after the projects and

coming from general engineering, electri-

the ability to receive all goods from a

cal power supply and distribution, rail-

single partner.

for structural parts

welded subassemblies e.g.

floor plates, roofs, bulkheads, hulls.

way, waterway, road transport, and the

aircraft and defence industries.

single main extrusions

Welding of assemblies
The applied welding processes are: MIG

Aleris key to success is to support the

for automated and MIG / TIG for manual

OEMs with expertise and engineering

welding. The equipment for the auto-

know-how in extrusions and components

mated welding of long panels like floors,

manufacturing as part of the product

roofs, bulkheads, hulls, ramps, etc. has

development with professional project

a range of 26,000 x 3,600 mm.

Machine specifications
Type

Axes

Working area

Fooke 1

30,000 x 4,200 x 1,500 mm

(~ 1,180 x 166 x 59 in)

Fooke 2

25,000 x 4,000 x 1,250 mm

(~ 984 x 157 x 49 in)

handling.

Defence Aluminium 13

Customer Engineering Support

Research and Development

Customer Engineering Support

Research and Development Our New

Areas of research:

It is one of our strategic goals not only

Product and Technology Pipeline

alloy and technology development

to supply material to our customers but

Research and development is a collec-

casting technology

also to provide them with comprehen-

tive exercise and is based on a close

hot and cold rolling technology

sive engineering support. Our team of

cooperation between R&D teams in our

Product Engineers and Process Spe-

customers, our plants and external par-

cialists will take any challenge to de-

ties, e.g. a strategic cooperation with a

velop together with our customers new

partner laboratory located in IJmuiden

technologies and processes to improve

(The Netherlands), which acts as a central

their products. They are the technologi-

research facility for fundamental work,

NDT-technology

cal link between customer demand and

with excellent facilities and highly quali-

corrosion and surface technology

our production capabilities.

fied, motivated researchers.

forming technology

welding technology

The customer engineering team gives

The R&D activities focus on the devel-

support by technical consulting, product

opment of innovative technologies to

and material training, problem solving in

improve both processes and products

their special field of application as well

to exceed todays and to shape tomor-

as service on the basis of experience

rows requirements.

gained in different global industries.

optimization of heat treatment

processes

numerical and physical modelling

of processes and product
performance

(e.g. LBW, FSW)

other joining techniques

(brazing, adhesive bonding,
mechanical joining)

high speed machining

product design support and

Aleris metallurgical knowledge enables

numerical simulation in close

the transfer of customers requirements,

cooperation with OEMs.

specific applications and newly defined

properties into metallurgical fabrication
practices for both standard and new
products.

14 Defence Aluminium

Quality Assurance
Approvals Our Brand is Quality

The quality concept is an essential ele-

requirements set by the aerospace in-

Certified external testing laboratories

ment of the company policy. Its objec-

dustry. Since then the quality system

conduct ballistic testing of armour plates

tives are a continuous improvement in the

has been continuously up-dated and

according to national and international

quality of Aleris products and services

expanded in scope.

standards and specifications.

quality principles are formulated by the

Process control ensures that production

The quality philosophy means zero

company management, implemented

takes place under controlled conditions.

defects. The quality system takes into

and known on all levels and by all em-

Quality inspections are regularly carried

account the customers continuously

ployees within the corporation.

out in various production facilities.

rising requirements and specific qual-

to fulfil all customer requirements. The

ity standards as well as legislative and

To ensure these quality principles, a

In-house laboratories with state-of-the-

regulatory measures which may have

documented quality system has been

art equipment control proper compo-

an additional effect.

implemented. The first quality manual

sition of alloys and their mechanical

was established in 1979 based on the

performance.

Aleris Aluminum Koblenz GmbH

Aleris Aluminum Bonn GmbH

Aleris Aluminum Duffel BVBA

Defence related

Defence related

Non defence related

EN ISO 9001

ISO/TS 16949

BWB according to TL 2350-0004

DIN 2303 Q2

Non defence related

Non defence related

DIN EN ISO 9001

DIN EN ISO 9001

Environment

ISO/TS 16949

ISO/TS 16949

DGR 97/23/EG

Environment

DIN EN 15085 CL 1

DIN V 4113-3

DIN EN ISO 14001

Ballistic testing

Environment

Bundeswehr, Wehrtechnische

EN ISO 14001

DIN EN ISO 14001

Dienststelle fr Waffen und

Munition, Germany

TNO Prins Maurits Laboratory,

The Netherlands

U.S. Army Aberdeen Test

Center (APG), USA

Defence Aluminium 15

www.aleris.com

Aleris
European Headquarter

Defence Department

Aleris Switzerland GmbH

Aleris Aluminum Koblenz GmbH

Balz Zimmermann-Strae 7

Carl-Spaeter-Strae 10

8058 Zurich Airport Switzerland

56070 Koblenz Germany

T +41 44 828 1400

T +49 (0) 261 891 7479

Care has been taken to ensure that this information is

accurate, but Aleris, including its subsidiaries, does not
accept responsibility or liability for errors or information
which is found to be misleading.

Contact: T +49 (0) 261 891 7545 info.europe@aleris.com www.aleris.com

2010, Aleris Switzerland GmbH

Issue 10/10 3rd release