Intelligent logistics is far more than just efficient storage and transport. A closed logistics cycle throughout the entire value-added chain is an expression of our ecological responsibility. This encompasses both the use of intermediate stores and the recycling of in-house scrap for the production of the extrusion billets.

The two foundries in Ranshofen (Austria) and Santana (Romania) have a total capacity of 180,000 t/year.

Extrusion billets
Extrusion billets are cast exclusively using „Wagstaff AirSlip” moulds.

Standard formats 
Ø 178 mm 7“
Ø 203 mm 8“
Ø 229 mm 9“
Ø 254 mm 10“
Ø 279 mm 11“
Ø 305 mm 12“
Ø 381 mm 15“
Delivery lengths: 500 – 7,200 mm
Further dimensions on request!

Rolling slabs 
Rolling slabs are cast exclusively using „Wagstaff LHC” moulds.

Standard formats
Width: 1,350 – 1,570 mm
Thickness: 480 – 500 mm
Length: < 7,000 mm
Further dimensions on request!

Two-piece ingots
Weight: 7 – 9 kg
Width: 108 mm
Height: 55 mm
Length: 700 mm
Stack form: 11 layers + 2 base-layer ingots
Stack weight: 553 – 711 kg
Alloys: 226, 231
Other cast alloys on request!

Secondary sows
2.0 to 2.5 MT sows, also reprocessing of dross or swarf on request.

Alloys
HAI covers the whole spectrum of wrought alloys:
1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx and special alloys (crash and gloss alloys)

Reprocessing of
Short and long scrap, clean and contaminated scrap (such as painted profiles, oily swarf, etc.)

Logistics
Just-in-time, intermediate stores

Quality certification
3.1 test certificate
Certified according to ISO 9001, ISO/TS 16949, ISO 14001, OHSAS 18001

With our two foundries in Ranshofen (Austria) and Santana (Romania), we offer the highest technological standards: Three modern two-chamber melting furnaces, a hearth furnace with electromagnetic stirrer, and a tiltable rotary furnace.

Inline degassing 
Alpur, SNIF, STAS to reduce hydrogen and impurities

Ceramic filters
CF filters to remove even the finest oxides

Wagstaff AirSlip moulds
The “Wagstaff AirSlip” technology allows casting with thin edge zones <0.3 mm (300 µm). Higher extrusion speeds and surface demands can thus be satisfied for high-end applications.

Wagstaff LHC moulds
Allow very thin edge zones; significantly less requirement for further processing.

Ultrasonic inspection
100% full-body ultrasonic inspection is performed to examine ingots and billets for inclusions, core and surface cracks in accordance with the requirements of the ASTM B594-09 standard (Class A B & C).

Homogenisation
Batch and continuous-pass homogenisation with cooling rates of up to 800 K/h.

Material
Alloy groups
EN AW-3103, EN AW-6060, EN AW-6063, EN AW-6005, EN AW-6005A,
EN AW-6082, EN AW-6401, EN AW-7020 und EN AW-7108A
Customised alloys and special alloys on request!

Gloss alloys
Various EN AW-6401 and EN AW-6060-based alloy variants (for achieving the defined gloss level and strength properties).

Crash alloys 
Various EN AW-6060, 6005, 6063 6082 and EN 7xxx-based alloy variants (for achieving the defined forming behaviour and strength properties).

Material states:
Standard heat treatment T1 to T7 in accordance with EN 755, as well as tailor-made solutions for special requirements and customer requests.

Micro and precision profiles 
Tolerance: +/- 0.05 mm
Minimum wall thickness: 0.4 mm
Profile weight/metre: above 40 g
Alloys: 1xxx, 3xxx, and 6xxx series Polished and special alloys on demand

Presses
Machines: eight direct presses
Press forces: 800, 2,000, 2,200, 2,500, 2,700, 3.300, 4,000, 4,400 t
(The new 33 MN-Press will be commissioned by the end of 2017)
Profile cross-sections: up to 265 mm circumscribed circle or maximum width of 440 mm
Metre weights from 0.04 to 40 kg

Surface treatment
We have been working together with our highly qualified and acknowledged partners for many years for the production of the different surface finishes on our profiles and components.

ISO composites
Production of heat-insulated profiles for the building industry.

In our research & development departments, we create new properties for our profiles, enabling us to also meet future customer demands. An important core competence here is the setting of specific product properties in the extrusion press profile – according to the customers’ individual wishes. This is carried out in our in-house laboratories, where we can perform a wide array of examinations:

• Measurement of the chemical composition of the material
• Light microscopic examinations
• Tensile test of mechanical properties
• Measurement of the surface roughness
• Hardness measurements
• Measurement of the profile geometry using several transmitted light methods
• Compression testing (e.g. for crash-related vehicle components)
• Measurement of electrical conductivity

Improved properties achieved include:

• Crash properties for automotive components
• Electrical conductivity
• Wear properties for functional surfaces
• High-gloss properties for highly decorative design components
• Improved corrosion properties
• Improved strength properties
• High-ductility properties as primary material for subsequent bending processes
• Fine-grain microstructure qualities for improved forming behaviour

Friction stir welding is a key process in our manufacturing. The process itself is still relatively young, but offers a wide range of benefits.

FSW – the process: Perfect joints thanks to frictional heat

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A wear-resistant rotating tool exerts pressure on the joint area. This generates the necessary process heat. The fixing of the component and a solid underlay ensures the absorption of the horizontal and vertical process forces.

What can be joined?

• Possible weld forms: Butt joint, overlap weld, T-joint, fillet weld
• Material combinations:
  • All aluminium alloys, including mixed compounds
  • Different materials such as aluminium-magnesium, aluminium-copper or aluminium-steel joints
• Different production methods:
  • Castings with profiles
  • Plates with profiles
  • Different plate thicknesses (tailored blanks)
• Two-dimensional weld seams can be produced using the application variants shown.
• Welding speeds: High speeds are typical of the process and contribute significantly to the cost-effectiveness of the method.
• Preconditions here are close tolerances at the joint, or optimised clamping conditions.

What quality can I expect?

• Level and practically notch-free surfaces
• No gas pores in the joint due to the low process temperature – no molten aluminium
• No hot cracks due to the exerted process forces
• Low distortion due to the low heat input
• High fatigue strength due to the low strain softening and practically notch-free surface

Selected examples taken from practice:

Application limits of the FSW technique at HAI

Inert gas welding
The inert gas welding technique for aluminium components is a process that we have perfected over many years in our company. We choose the right welding method for each particular application – with the economic factor playing a significant role. The following methods are possible: MIG or TIG welding and the energy-reduced CMT process from Fronius. We employ the latter particularly for thin-walled profiles to reduce deformation and loss of strength within the welded joint. The MIG and CMT methods can also be performed with a welding robot. For this, however, the components have to satisfy the following demands:

• Maximum component size: 2,400 x 1,400 mm
• Maximum component weight: 500 kg
• Weld seam accessibility checked (simulation)

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The components manufactured by us can, of course, also include additional connecting elements such as rivets and self-clinching nuts. In the case of large series, this is performed by riveting robots. For small volumes, riveting is performed at manual workstations (with monitored rivet setting tools).

A large proportion of the profiles extruded in our works are machined or prepared for the subsequent work steps as required by the customer. High-precision sawing (as required by the customer or as a preparatory work step) is performed on short, long or universal high-speed saws, on automatic saws or on double mitre saws. All common milling methods are used for this. We have 3-axis and 5-axis CNC milling machines – as upright millers or as pendulum milling machines. Components with the maximum dimensions (20,000 x 4,000 mm x 1,500 mm) can be milled on the Fooke aluminium machining centre. The milled parts are then cleaned in a washing machine to reliably remove impurities caused by the cooling lubricants.

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We employ the latest bending technologies – from stretch-bending to roll bending and press brake bending. It is predominantly automotive applications that require a preliminary forming process.

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Whenever the quantity to be produced exceeds a critical size, only special machines can be used for production. These are designed for the specific demands of the products and are specialised to such an extent that very short production times can be achieved with minimum production costs. We have experienced partners at our side for planning and design.

The production of prototypes is always the first important step for us on the road to the series production order. Through the intensive assessment of the component, we are also able to submit successful series production offers – at a time when geometric and process engineering optimisation is still possible.