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EDU '18 Program

The EDU ’18 program is packed with practical, valuable information about aluminum extrusion design, processes and applications. Top-notch speakers from some of the most knowledgeable aluminum industry companies will share their expertise on a wide variety of topics. Check back often as program details unfold. Note: AEC reserves the right to alter the program and substitute speakers as needed.

Regarding Professional Development Hour Credits for Engineers

If you are an engineer licensed in a state that pre-approves course providers or individual courses (such as Florida, New York, New Jersey, Maryland, Indiana, or North Carolina), we do not yet have pre-approved status in those states. However, if your state's licensing board does not pre-approve course providers (any other state besides those listed above), then it is the individual engineer’s responsibility to determine whether an activity meets their particular state board’s acceptance criteria.

AEC will provide you with an agenda, a certificate of attendance, or any other documentation (within reason) that your state board requires in order to consider approving the continuing education PDH credits at EDU '18. More information will be provided on-site at the event to ensure that you attended and can submit the PDH credit with your state licensing board.

AEC is an approved provider through the American Institute of Architects (AIA). Courses that have been approved as AIA CES Registered are noted below. Please check back often for updates.



Topic-Specific Tracks

Sessions will be presented in four topic-specific tracks (click on the track name to jump to the sessions):

Automotive

Architecture/Building & Construction

Engineered Products/Industrial

Taste of ET


Automotive Track

Specifying & Achieving Desired Extrusion Performance for Automotive Extrusions

Mark Butterfield, Magnode, A division of Shape Corp.

Since 2012, the usage of extruded aluminum shapes in North American light vehicles has grown by more than 50%, to over 25 pounds per vehicle. Today, aluminum extrusions can be found in applications as varied as crush cans, trim members, rocker sections and seat backs – each with a unique set of performance requirements. As automotive aluminum extrusion applications continue to grow, engineers seeking optimized performance are increasingly going beyond the “shorthand” of alloy and temper designation by specifying the desired microstructure for the final component. Mini cases will be used to illustrate successful application of microstructure specification.

Aluminum Alloys Extrusion for Lightweighting Transportation Programs

Jerome Fourmann, Rio Tinto Aluminium

Engineered products using aluminum extrusions provides a number of options and solutions. This presentation will discuss how aluminum extrusion can help meet tomorrow’s fuel economy targets while providing the comfort, safety, and performance that consumers demand. A variety of alloys suited to transportation applications will be reviewed along with their characteristics, industry standards and performance impact.

Al-Mg-Si Alloys with Improved Crush Properties

Jostein Røyset, Hydro Aluminum R&D and Technology

Crush performance is a critical parameter in alloy selection for many extruded aluminum structural automotive components. In the event of a crash, such components are supposed to absorb large amounts of kinetic energy while retaining their structural integrity (i.e. not break into pieces). The common way of testing the deformation behavior is by applying a controlled load in the extrusion direction of profile samples until their length is reduced to typically 30-80% of the original length. Such tests are normally referred to as uniaxial crush tests. The degree of cracking of the profile in these crush-tests is a good indication on how the component will behave in an actual crash.

For soft Al-Mg-Si alloys with yield strength requirements of 180MPa (26 ksi) or below it is fairly easy to obtain good crush-properties, with ample degree of freedom for alloy composition and processing conditions. With increasing yield strength requirements it is getting increasingly difficult to obtain the desired crush-properties, and yield strength levels such as 240MPa (35 ksi) and above may require a carefully selected alloy as well as a rigid control of process parameters.

This session, first presented at the Ninth International Aluminum Extrusion Technology Seminar (ET ’08) and recently updated, summarizes a systematic approach for developing Al-Mg-Si alloys optimized for crush properties. The experimental work has been of an iterative character, and the experimental results are presented in terms of cases in order to substantiate the principal findings in the course of the investigation.

Alloy Selection: Caught between a Rock and a “Hard” Place

Jason Weber, VP Sales and Marketing; Taber Extrusions

As automotive (and other OEM’s) strive to lighten structures and use stronger alloys, 7xxx alloys continue to gain favor with engineers and specifiers. However, many call outs for 7xxx and other “hard” alloys like 2xxx and 5xxx aluminum in extruded profiles may be unknowingly limiting sources for extruded product. This session will review the do’s and dont’s for designing with “hard” alloys as well as cover potential opportunities in costs savings through designing larger circle size profiles with common extrusion alloys.

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Architecture Track

Sessions in this track are AIA CES registered. The CES credit is noted at the end of the course description.

Aluminum Extrusion Anodizing for B&C Applications: What You Should Know

Eric Koger; Finishing Manager, Bonnell Aluminum

Attend this informative session to better understand the requirements deemed “critical to success” to anodizing for aluminum extrusions in building & construction applications. Understanding the differences between various anodizing types (Class I, II and III), clear versus 2-step, the relative strengths and weaknesses of each anodizing type, comparisons with AAMA 2603 and 2605 coatings, corrosion resistance and common types of corrosion, the effect of alloys and temper and the importance of die maintenance to achieve finish consistency. The cleaning and maintenance specifications (AAMA 609-610) required to maintain finish durability and testing requirements to ensure anodizing quality will be discussed.

At the end of this presentation, participants will be able to:

  1. List the different architectural classifications of anodized aluminum and electrolytic color.
  2. Explain the performance characteristics of the different types and classifications of anodized aluminum which are commonly available in architectural markets.
  3. Compare the advantages and disadvantages anodic coating to mill finish or painted aluminum finishes.
  4. Identify common requirements deemed “critical to success” to anodizing for aluminum extrusions in building & construction applications including profile design, alloy, temper, environmental, and maintenance of the finished product.

Credit: 1.0 AIA LU Hour

Curtain Wall & Façade Architectural Metal Restoration & Maintenance

Chris Incorvaia and Rex Dean, Stuart Dean

Explore and study the “skin” of the building and capture what the speakers discover using digital photography, field measurements, and detailed notes. The instructors view the façade of the building in a holistic manner focused on the architectural metals and their protective coating systems. By doing so, they determine the current functionality and condition of various building materials originally designed to provide a safe, durable and attractive building enclosure. Topics covered include observations of Class 1 & 2 anodized aluminum as well as AAMA 2603, 2604, and 2605 finishes and methods of maintenance and repair.

Credit: 1.0 AIA LU Hour

Architectural Applications for Liquid & Powder Fluoropolymer Paint

Scott Moffatt, Architectural Sales Manager-Building Products, PPG Industries

This course was developed so architects would understand the advantages and disadvantages of liquid and powder coating technologies for the architectural markets. Participants will learn about the markets, the different coating technologies, manufacturing processes and application methods. The main benefit of the course will be to aid architects in the coating selection process. This includes information on appearance, end use, cost and other factors.

Following this course, participants will:

  1. Understand the markets for liquid and powder coatings
  2. Identify the different types of architectural coatings
  3. Understand application and manufacturing differences between liquid and powder coatings
  4. Recognize the benefits of liquid and powder coatings and how this can be applied to specific end uses.

Credit: 1.0 AIA LU Hour


Energy and Green Building Codes 101 – Aluminum Extrusions and Fenestration

Thomas Culp, Birchpoint Consulting

Building codes have been around since the Babylonian King Hammurabi in 1758 B.C., but the focus has always been fire, safety, and structure. It is only recently that codes related to energy efficiency and sustainability have gained such important attention and influence over the market. This presentation will give a “101” introduction to how energy and green building codes work, and how they impact aluminum extrusions in the B&C sector, including aluminum framed windows, sun shades, and PV panels. In addition, we will attempt to give a preview of where the codes are headed in the next 5+ years, and the impact on different technologies.

At the end of this session, participants wil be able to:

  1. Identify the two national model energy codes affecting building construction
  2. Describe recent overall trends in energy and green codes
  3. Identify which energy code requirements directly affect the use of aluminum extrusions
  4. Identify new green building requirements affecting aluminum extrusions beyond just recycled content.

Credit: 1.0 AIA LU Hour

Optimizing Performance in Commercial Fenestration

Patrick Muessig, Azon USA

This session provides an overview of optimizing commercial fenestration with thermal barriers and high-performance glazing components in aluminum windows, storefront, and curtain wall framing in the building envelope. Learn about the importance of optimizing efficiency in commercial buildings and initiatives to reduce energy consumption. The performance of aluminum window, storefront, and curtain wall fenestration systems in will be evaluated. Material sustainability, thermal and structural performance, noise abatement and condensation resistance will also be discussed. Through the use of multiple case studies, a range of fenestration product types, measured performance outcomes and energy savings, LEED, PassiveHouse and Cradle-to-Cradle contribution will be highlighted.

At the end of this one-hour course, participants will be able to:

  1. Discuss the importance of optimizing energy efficiency in commercial buildings and initiatives to reduce energy consumption.
  2. Evaluate the performance of aluminum window, storefront, and curtain wall fenestration systems in the building envelope through the application of structural thermal barriers and high-performance glazing.
  3. Investigate performance and comfort-related topics in aluminum fenestration systems including material sustainability, thermal and structural performance, noise abatement and condensation resistance.
  4. Observe a range of fenestration product types, measured performance outcomes, energy-savings, LEED, PassiveHouse and Cradle to Cradle? contribution through the use of multiple case studies.

Credit: 1.0 AIA LU Hour

What EPDs Tell us about Aluminum Extrusions for B&C

Shayne Seever, Sierra Aluminum

While Environmental Product Declarations (EPDs) must be developed in accord with ISO standard 14025, EPD results can vary significantly based on the representativeness and completeness of the primary data considered, the secondary data sets utilized, and the assumptions, allocations (e.g.: for key inputs) and end-of-life treatments that have been employed.

This one-hour session will help the participant assess EPD validity and analyze the impact of specifier decisions on the environmental footprint of extruded aluminum products by reviewing the industry-wide EPD recently completed for the Aluminum Extruders Council (AEC). The AEC EPD—one for standard aluminum extrusions and one for the thermally-improved aluminum extrusions favored for fenestration—is the most comprehensive EPD to date for North American aluminum extrusions. It is based on data from 11 extruders, with a total of 30 facilities, over 85 presses and 25 paint, anodizing, and thermal treatment lines in the U.S. and Canada.

The presenter – one of the participating extruders – will review the EPD development in depth, covering the:

  • Actual data collected from the participants
  • Key assumptions – and their implications – regarding secondary data sources and input allocations
  • End results for standard and thermally-improved extrusions, in mill finish, painted or anodized
  • Drivers of the end result data
  • Factors to consider when reviewing different EPDs

At the end of this session, participants will be able to:

  1. Analyze the implications of key assumptions and data source on EPD validity
  2. Analyze the impact of critical variables on extrusion’s environmental footprint
    Compare the impact of alternative finishes and thermal treatments on the environmental footprint of aluminum extrusion
  3. Assess the in-use environmental impact of alternative extrusion configurations
  4. Assess alternative EPDs and understand the risks in doing so

Credit: 1.0 AIA LU Hour

Storefront or Curtain Wall? Seeing Through the Difference

Doug Dietrich, AIA, CSI, CDT; Tubelite Inc.

This session includes a basic review of storefront and curtain wall glazing systems. The program will examine industry standards and performance attributes for commercial glazing systems, enabling the design professional to select the appropriate system for a specific site. Course participants will be able to select between storefront and curtain wall systems for commercial applications as they relate to occupant safety, environmental factors, system performance attributes, system limitations and proper product installation in terms of indoor environmental quality, human health and safety, and examine advancements in system performance in regards to energy-saving thermal performance.

At the end of this course, participants will be able to:

  1. Identify Storefront & Curtain wall systems
  2. Evaluate the differences between storefront and curtain wall in relationship to structural integrity & water management
  3. Comply with thermal codes
  4. Understand performance cost considerations

Credit: 1.0 AIA LU Hour

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Engineered Products/Industrial Track

Utilization of Aluminum Extrusion in LED Fixtures

David Lee, Almag Aluminum

Aluminum extrusions are present in a multitude of components that make up a light fixture in today’s lighting industry – and with very good reason. The recent advancement of extrusion technology, as well as the inherent properties of aluminum, make choosing aluminum extrusions as a light fixture component an easy choice. Aluminum has a high strength-to-weight ratio and great corrosion resistance, which make it great for light housings, as well as high thermal conductivity making it great for heatsinks. Aluminum extrusions are also soft enough to be formed prior to age hardening, yet hard enough to have good machinability afterwards. Knowing the limits of aluminum extrusions will help provide a better solution to light fixture designs.

Extrusion Design through Visual Applications

Rob Nelson, Almag Aluminum

Aluminum extrusions are used in all types of applications that support the Signage industry. Aluminum’s high strength to weight ratio and great corrosion resistance make it an optimal choice for frames and fixtures for visual displays. Whether the application is in an indoor retail space or harsh external environment Aluminum meets the challenge. In most cases the signage is not about the extrusion but about the advertisement and this presentation will explore fit form and function of a rapidly growing industry.

Specifying Aluminum Extrusions: Understanding ASTM B221/B221M Standard

Greg Lea, Hydro Aluminum

ASTM B221 and B221M is a material specification standard for aluminum extruded bars, rods, wire, profiles and tubes. The requirements are in place to give the purchaser confidence that the product is produced to their expectations and are consistent with the same products regardless of the producer. This presentation provides an overview of the ASTM B221/B221M standard and walks through pertinent sections of the standard to help the learner better understand the ordering process for aluminum extrusions when ordering to an ASTM standard, and what to expect from the manufacturer. Sections covered include Tensile Properties, Heat Treatment and Tempers, Chemistries, Dimensional Tolerances, Certifications, Quality and more.

At the end of this session, participants will be able to:

  1. Know where to find the ASTM standard documents
  2. Judge which products are covered by ASTM B221 and B221M
  3. Identify the Basic Temper Designations
  4. Explain where to find ordering requirements within the standard
  5. Analyze which ordering requirements have to be specified and which are implied
  6. Assess how to handle issues that are not covered by the standard

Credit: 1.0 AIA LU Hour

Fabrication: Adding Value to Aluminum Extrusions, When & How

Mark Butterfield, Magnode, A division of Shape Corp.

Over the last two decades extruders have extended their offerings to the marketplace in the way of fabricated aluminum extrusions. From precision cutting to CNC machining, extruders are adept at delivering a final part straight to your production line. However, the question is: where in the manufacturing continuum should you ask your supplier to deliver? This session will help you determine what options are available and how they can transform the way you make your products.

Standards, Specifications & Tolerances

John Weritz, The Aluminum Association

Aluminum is a versatile modern metal found in numerous applications serving a host of market sectors. The standards system developed in the 1950’s provides a common language through which material characteristics are accurately communicated throughout the value chain. From the smelter, through the end use, as well the recycling stream where this valuable metal is reincarnated as another product, aluminum standards provides the foundation from which other standards and specifications define the explicit needs of the user.

The wrought alloy system rolled out in 1954 comprised a list of 75 alloys. Today, over 540 alloys populate the Teal Sheets that document the chemical composition requirements of each of them. This internationally recognized system is continually updated to include new alloys as they develop. Aluminum tempers and dimensional tolerance requirements are also maintained through the Aluminum Association, the ANSI accredited secretariat representing US aluminum producers.

The Aluminum Association also publishes other reference documents that are useful in identifying commercially viable solutions for any given application. Knowledge of the standards is fundamental to the process of developing new products.  This session will discuss the various aluminum alloy and temper designation systems and explain how new alloys and tempers are registered.


Alloy Selection: Caught between a Rock and a “Hard” Place

Jason Weber, Taber Extrusions

As automotive (and other OEM’s) strive to lighten structures and use stronger alloys, 7xxx alloys continue to gain favor with engineers and specifiers. However, many call outs for 7xxx and other “hard” alloys like 2xxx and 5xxx aluminum in extruded profiles may be unknowingly limiting sources for extruded product. This session will review the do’s and don'ts for designing with “hard” alloys as well as cover potential opportunities in costs savings through designing larger circle size profiles with common extrusion alloys.

Optimizing Your Extrusion Design

Shane Tredup, Custom Aluminum Products

This session will outline the design and fabrication options available to you when creating your next part or product. Take a holistic view of the design and manufacturing process using aluminum extrusions to understand which element of your part should be custom designed in the profile versus fabricating or machining. Understanding the principles that make hollow and semi hollow shapes different, designing a profile to eliminate additional steps and using multiple extrusions to reduce circle size and thin walls are just some of the topics covered in this informative session. Knowing these techniques can save your company time and expense by finding the right balance.

At the end of this course, participants will be able to:

  1. Identify different tooling types (solids, semi hollows, hollows, etc.)
  2. Apply the use of calculations such as wt/ft, container ratio and void ratio calculations to determine extrudability and relative cost.
  3. Apply effective profile design to eliminate secondary operations
  4. Identify design methods that allows for fasteners to be integral into joining profiles.

Credit: 1.0 AIA LU Hour

Aluminum Extrusion & Sustainability

Angelena Ellis, Alcoa Corporation

The importance and number of sustainability-related concepts are constantly growing, in North America as well as globally. This session aims to describe the processes and opportunities for product differentiation in the aluminum extrusion industry in regards to sustainability. Alcoa as a recognized sustainability leader with 15 years on the Dow Jones Sustainability Index and member of the Aluminum Stewardship Initiative will give their views on this hot topic.

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‘Taste of ET’ Track

The following award-winning papers, presented at ET ’16 -the Eleventh International Aluminum Extrusion Technology Seminar in May 2016, represent some of the best technology research and best practices that the aluminum extrusion industry is engaged in to stay ahead of the curve. These papers will be presented at EDU ’18.

Innovations in Billet Casting and Homogenization

Richard Dickson, Hydro

A new casting technology that nearly eliminates the inverse segregation zone has enabled homogenization cycle development that provides extrudability and profile surface quality advantages. In homogenization of 6xxx alloys, past focus has been on dissolving MgSi, transformation of AlFeSi to AlFeSi, and on spheroidization of AlFeSi particles, largely ignoring the amount of Fe and Mn in solid solution after homogenization. An overview of several trials shows that by using homogenization cycles designed to minimize Fe and Mn amounts in solid solution while fulfilling the other criteria expected from proper homogenization, significant improvements in press performance and profile surface quality are measured. Examples of the impact of these innovations on extruded profile surface quality are given.


HybrEX® - An Innovative Extrusion Press with Hybrid Drive Technology

John Bergman, SMSTechnical Services

 Radical new approaches are reducing the hydraulic drive of the extrusion press, minimizing energy consumption, increasing productivity, and implicating an unmatched dynamic to the extrusion process. These recent developments target increased energy efficiency and productivity. A hybrid drive concept with highly dynamic servo drives for fast movements, a new unique hydraulic design combined with the novel HMI-system with joystick controls are highlights of the HybrEx press. Its integrated housing includes a safety concept bringing contemporary industrial design into the press shop. PICOS-TO-GO allows for online monitoring of the extrusion press by mobile devices, and includes a smart platform-independent browser-based application.

Extrusions Alloys and Process Parameters for Automotive Crash Applications

Jerome Fourmann, Rio Tinto – Aluminium

One major extrusion automotive application is crash structures: crash rails, crash cans, bumpers and structural body components. Extruding thin-wall multivoid extrusions contributes to optimizing energy absorption for a given structural weight, but the alloy used plays a significant role in producing required geometry and strength, which to a large extent controls energy absorption capability and ductility or fracture behavior, which controls the strain applied locally during crush deformation before cracking. A test program examining crush behavior for a range of alloys for automotive applications is described as a function of processing parameters, including artificial Aging and quench practices.

 

Modelling the Effect of Mn on Extrudability, Mechanical Properties and Grain Structure of AA6082 Alloys

Richard Dickson, Hydro

This award-winning paper demonstrates the effect of manganese (Mn) in 6082-type alloys on extrudability, as-extruded grain structure, and mechanical properties by the use of Through Process Modeling (TPM). In order to separate the effect of Mn in dispersoids and Mn in solid solution, a rather comprehensive experimental program was designed including six different levels of Mn (0-1.2 wt%) within the 6082 window, and two specific homogenization cycles prior to extrusion and mechanical testing. The TPM methodology includes physical-based microstructure models for precipitation of Mn-dispersoids and MgSi-phases, as well as models for generation of deformation and recrystallization structures in combination with finite element (FE) simulations of the extrusion process. The input parameters to the TPM models comprise the chemical composition of the alloys and the processing parameters from casting, homogenization, extrusion, and annealing to the final artificial aging. Comparisons between simulation results and measurements have confirmed the ability of the present TPM methodology to predict changes in extrusion forces, grain structures, and mechanical properties without any tuning or calibration of the modeling parameters.

 

A Novel Methodology for Optimization of Properties , Costs and Sustainability of Aluminum Extrusions

Richard Dickson, Hydro

An innovative methodology is described for optimizing product properties, production costs and environmental impact in fabrication of 6xxx-series aluminum extrusions. Operations use predictive models, for material, mechanical, cost, and sustainability. An optimization platform combines models into a common software environment. Software optimizes mechanical properties and electrical conductivity by manipulating microstructure characteristics like grain structure, precipitates, dispersoids and solid solution concentrations. Material and production costs, and CO2 emissions along the value chain were kept at minimum levels. Optimization models range from physically-based material models and Finite Element (FE) codes, to models for raw-material and processing costs and CO2 footprint.

Surface Topography of Aluminum Extrusions after Caustic and Acid Etching and Its implications for Streaking Defects

Jerome Fourmann, Rio Tinto – Aluminium

Caustic or acid etching is used to pretreat aluminum extrusions in an anodizing line. Apart from surface cleaning, it removes die lines, pickups and rough surface patches on extruded profiles, and reduces substrate gloss, obtaining consistent surface appearance post-anodizing. Commercially anodized extrusions are examined, comparing surface topography of caustic-etched and acid-etched extrusions. Streaking defects are investigated, illustrating defect formation mechanism differences due to different etching methods. Acid etching is shown to significantly reduce occurrence of compositional and die streaks. However, certain streaking defects may still be visible on anodized extrusions. Root causes of streaking defects are discussed and preventive measures are recommended.

Advanced Aluminum Alloys used in the Manufacture of Products in Extrusion Process

Pawel Kazanowski, Hydro

Research was conducted on AlCuMgMn alloy with addition of Zirconium (Zr) and Scandium (Sc) manufactured as extruded bars, profiles or tubes. Results of structure evolution and mechanical properties are presented for different tempers of precipitation strengthening. AlCuMgMn(ZrSc) alloy produced in powder form is also investigated. This alloy powder was subjected to consolidation during direct hot extrusion. The study aims to optimize the Al alloy powder hot extrusion process using conical dies. Results (Rm above 500Mpa for AlCuMg alloy) show significant possibilities for manufacturing from aluminum alloy powder products with ultrafine grain structure.

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