Qc 10 Brochure 6gy5b

The aluminum mold alloy that

out-machines, out-cools,

out-cycles, out-produces

and outsmarts steel.

Aluminum:

GAMECHANGING It’s time to think differently about mold materials for production-READY plastic injection molding. It’s time to think aluminum instead of steel.

As Alcoa’s next generation mold alloy, QC-10® expands mold design options and brings new performance capabilities to high volume manufacturing. It machines 8-10 times faster than steel, reducing finishing costs and lead times by 20-30%. Plus it conducts heat nearly 5 times faster than P-20 tool steel, shortening production cycle times by 20-40%. No wonder it’s the new mold material of choice.

FOR MOLD MAKERS:

Faster and easier machining For mold makers, aluminum offers significant benefits over tool steels – benefits that allow them to expand their design options and take advantage of its unrivaled thermal and machining properties. A lighter metal, aluminum is easier to cut and faster to machine into molds, translating into faster machining rates, shorter mold production time, and extended tooling life. Fewer water lines are required for gun drilling,

reducing machining time. And because heat developed during machining stays largely in the chips, cutting tools stay sharp and last longer. Not only that: with one-third the density of steel, aluminum’s lighter weight makes it easier and less expensive to handle and transport.

QC-10 Comparison Mold Material

Thermal Conductivity (Btu/ft/hr/ft2/°F)

Density lb/in3

Hardness

Yield Strength (ksi)

Coefficient of Expansion

QC-10

7xxx Aluminum

92.2

0.103

150-170 HB

66 - 76

13.7

7075 - T651

7xxx Aluminum

75

0.101

150 HB

48-73

13.1

6061 - T651

6xxx Aluminum

96

0.098

95 HB

40-42

13.1

2618 T6

2xxx Aluminum

102

0.101

95 HB

28-30

12.9

P20 Grade Steel

Carbon Steel

20

0.285

28-36 Rc

130-135

7.1

MoldMax HH

Beryllium Copper

75

0.302

40 Rc

140-145

9.7

®

15-25% savings in tooling,

depending on mold simplicity*

*www.moldmakingtechnology.com/articles/120801.html

fewer

machine hours per mold

Aluminum: SAVINGS OVER S FOR MOLD S:

Faster cycle times, lower production costs Aluminum’s shorter lead times mean mold s can be up and running parts while steel tools are still being built. In addition, mold startup time is shortened since tools come up to temperature so quickly. And because aluminum heats up and cools down faster than steel, molders can increase parts-per-hour on existing presses with fewer rejections. Parts are ejected more quickly, with less distortion, warpage, and post-mold shrinkage than parts from a steel mold on a comparable cycle. Better thermal conductivity creates 20-40% faster cycle times and uses less energy, which lowers production costs. Plus aluminum’s ability to manage temperature evenly across the surface of a mold eliminates hot spots, resulting in better-formed plastic parts with less residual stress.

Aluminum tooling for mainstream injection molded auto parts is continuing to gather interest,



with Ford Motor

Aluminum molds are more efficient than steel molds 80 70 60

Company execu-

Steel

tives urging

Aluminum

mold makers

50 40

and molders alike

30 20

to learn more

10 0 Tool build (weeks)

Cycle time (seconds)

Material weight (pounds)

Below: This series of six photos illustrates a machining time of 11 minutes from start to rough-cut core features. QC-10 mold alloy is ideal for lights-out machining and boosting process efficiency.

lower production costs

ing it.

Posted 10-26-09 by plasticsnews.com

STEEL ACROSS THE SUPPLY CHAIN FOR OEMs:

Lower piece cost, high piece quality Aluminum delivers critical advantages for OEMs as well. Spurred by increased globalization, increased demand for worldwide product availability is shortening already short product life cycles. Aluminum molds help mold s meet the demanding delivery needs of OEMs. Faster cycle times for mold s mean faster delivery times for end s, leading in turn to faster manufacturer throughput. To keep costs down, OEMs are turning to their suppliers for greater process efficiencies. Lower production costs for aluminum mold s are reflected in lower piece costs for end s – as well as lower overall manufacturing costs. In addition, the improved quality and consistency of aluminum-molded parts is a definite plus for OEMs.

less energy used

:

MOLDMAKING You know the positives of aluminum as a mold material. Now know this: QC-10 is the best of the best.

Specifically designed for high production injection and blow mold applications, QC-10 offers greater strength, stability, and durability than any other high-grade aluminum mold alloy on the market today. Its improved alloy composition provides outstanding, 1"- 24" thick section strength and hardness equal to that of rolled plate. While its quench insensitive microstructure allows minimal strength drop-off and unequalled machinability.

Large plastic pallets are easily molded using Alcoa QC-10 mold block.

QC-10 Mechanical Properties Strength Inches Millimeters

FOR MOLD MAKERS:

The fastest machining hardness and extended mold life. In fact, QC-10 molds in use today have achieved hundreds of thousands of shots. The superior strength of QC-10 allows mold makers to design molds with deeper parts. And its consistent through-thickness hardness is critical for holding a sharp edge along the parting line.

These kinds of speeds mean QC-10 production molds can be made in hours or days rather than weeks or months, resulting in 20% faster mold delivery times. In addition, a cutting force one-third of that required by P20 steel means cutting tools last longer machining QC-10.

Alcoa’s Signature Stress Relief SSR cold-worked technology gives QC-10 consistent strength in the middle of the block, differentiating it from other aluminum mold alloys. Fully wrought and heat-treated, it offers greater process efficiency as it requires no postmachining heat treatment.

14-18 300-450

>20 >450

KSI MPA

76 525

72 500

68 470

66 455

Ultimate

KSI MPA

82 565

77 530

74 510

72 500

10

8

6

3

YS, UTS, and elongation values at center (L/T direction)

QC-10 PHYSICAL PROPERTIES PARAMETER

UNITS

Thermal conductivity

BTU/°F W/m-K

92 160

Coefficient of thermal expansion

10-6/°F 10-6/°C

13.7 24.7

psi GPA

10.4E x 10-6 70

lb/in3 g/cm3

0.103 2.85

Btu/lb/°F J/g/°C

0.210 0.844

Brinell

150 - 170

Modulus of elasticity Density Specific heat Hardness at center

QC-10 THICKNESS COMPARISON 100

QC-10® 7xxx Series Al

90

 ”General Guidelines for QC-10 Injection Molds”, July 2009

1

Yield Strength (ksi)

Specifically designed for production molds, QC-10 balances strength, toughness, and corrosion resistance to provide optimal

8-12 150-300

Yield

Elongation (%)

A high hard type of aluminum mold material, QC-10 machines 8-10 times faster than P20 steel for rough milling. In fact with high-speed spindles, rough machining of QC-10 can occur at cutting speeds of 20,000 rpm1 and feed rates of 0.325 mmpt – significantly faster than the 2,000 rpm and 0.127 feed rates of P20 steel.

2-6 50-150

80 70 60 50

Faster cycle times use

less energy

y ilit ab

Av ail

wi de st

he

Industrial housing for irrigation systems

t of

Can be textured and polished

range of

ria e t ma

s for e z i ls

40 Surface

3"

6"

3" Surface

enhanced mold design

Improved hardness strength Sporting goods

: GREATER PRODUCTIVI FOR OEMs:

Lower piece-p

FOR MOLD S:

The fastest cycle times

160 140 120 100 80 60

By offering reduced molding cycle times of 20-40%, QC-10 aluminum tooling has clear cost advantages for original equipment manufacturers. Currently, as much as 50% of the cost of an injection-molded part is cycle time2. Cutting cycle time increases production and decreases piece-part costs, creating significant savings that can be ed onto OEMs. What’s more, the advent of shorter product life cycles, combined with increasing consumer

40 20

With as much as 75% of the heat dissipating in the mold, parts cool more quickly, without the “hot spots” and molded-in stresses common to parts from steel molds. That means QC-10 tools offer the kind of improved finished part stability that translates into better all-around quality.

l tee 0S P2

-1

0®

0 QC

Thermal Conductivity (W/m-K)

QC-10’s outstanding thermal conductivity is key to faster cycle times. The aluminum mold block conducts heat nearly 5 times faster than P-20 tool steel, reducing molding cycle times by 20-40%. Reduced cycle time increases productivity. Plus because QC-10 molds heat and cools faster than steel molds, plastic flows better and resin is processed more efficiently.

QC-10 THERMAL PROPERTIES

QC-10 automotive applications include: • Rear deck trays

• Rocker s

• Trunk liners

• Bumpers/bumper components

• Wheel well liners

• Instrument end caps

• Center consoles

• Cup holders and bins

• Glove box interiors

• Spare tire and underbody covers

• Climate control/HVAC components

• Engine protection covers

turning, milling and drilling operations

are easily performed

ITY THROUGHOUT THE CHANNEL. Decked Out Like Never Before.

part pricing demand for variety, choice, and customization, have lowered production runs. For example in automotive, the shift towards a wide variety of vehicles with a mix of trim levels has created shorter production runs, making QC-10 molds even more feasible. Similarly, automotive’s increasing use of polypropylene, thermoplastic polyolefin, and polyethylene materials have also expanded QC-10’s viability for production injection molding.  http://www.plasticstoday.com/imm/articles/moldmakingaluminum-honda-0210

2

Traditionally, injection molds for plastic automotive components have been made of P-20 steel. But with the creation of Alcoa’s QC-10, there’s now a better way. Working tly with an automotive interior parts supplier, a rear deck mold was made from forged QC-10 aluminum and put into full production. The results were impressive: • Mold machining costs were cut and development time was significantly shortened. • Cycle times were reduced by as much as 25% for faster part production. As of September of 2010, over 700,000 shots3 on rear deck tray have been produced, proving aluminum molds capable of highvolume production runs.  “Honda Sets the Stage for Broader Use of Aluminum Molds,”

3

www.plasticstoday.com/imm/articles/moldmaking-aluminum-honda-0210

Alcoa:

PARTNERCREATING Working tly with mold makers and mold s/OEMs, we use a collaborative design approach to challenge conventional practices and provide innovative solutions that deliver greater value. By working with our scientists and engineers, as well as the experts at the Alcoa Technical Center – the world’s largest and most advanced light metals research and development center with more than 120 Ph.D.s – you can benefit from our in-depth knowledge. In fact, no other company in the world can offer you Alcoa's combination of aluminum engineering expertise and world-class fabrication facilities – facilities that span two continents and include the world's largest forging presses and widest rolling mills.

Looking to the long term. We are continually investing to make sure our QC-10 manufacturing capabilities can meet the promise of our proprietary advanced alloys, our technical and engineering expertise, and our collaborative design capabilities. Not only that: with plants located in Cleveland, Ohio, and Samara, Russia, Alcoa is uniquely positioned to provide high quality QC-10 in thicknesses up to 24" virtually on demand.

Interested in the

opportunities

presented by

QC-10?

Alcoa at (216) 641-4162 for more information. Or visit: www.alcoaqc10.com.

About Alcoa Forgings and Extrusions Alcoa Forgings and Extrusions (AFE) produces QC-10 mold block in thicknesses above 7". The business unit is a part of Alcoa’s Engineered Products and Solutions Group, and is the leading global supplier of hard-alloy forged and extruded aluminum products. The world’s number one producer of aerospace and defense forgings and extrusions, AFE also provides innovative solutions for the industrial, transportation, and oil & gas markets.

North American Rolled Products Manufacturing QC-10 in thicknesses up to 6", Alcoa North American Rolled Products produces the widest variety of aluminum plate and sheet in the world. They are a leading valueadded supplier to the aerospace, automotive, commercial transportation, building and construction, industrial, and packaging markets.

Alcoa Forgings and Extrusions 1600 Harvard Avenue Cleveland, OH 44105-3092 Phone: (216) 641-3600 www.alcoa.com ©2010 Alcoa Inc. __M MK 11/10