Alamo

Development of innovative high-performance anodised aluminium moulding tools for the thermoplastic processing sector to achieve competitive advantage

The use of aluminium mould tools for thermoplastic processing is becoming increasingly popular within the EU, driven by cost, reduced cycle times, reduced lead times & reduced energy cost. The growth rates for aluminium tools for thermoplastic processing applications are expected to increase significantly over the next few years. However, limitations of aluminium tools with regard to their corrosion, wear & abrasion resistance have prevented even greater uptake. Traditional anodising technologies, which produce surfaces with regular pore structures, have failed to overcome these limitations, as the surfaces produced develop microcracks under mechanical or thermal strain (at temperatures as low as 200 °C), leading to a reduction in the wear resistance, corrosion resistance & other properties.

Innovative technologies have been developed by UK SMEs anodisers that allow for the production of anodised surfaces that prevent microcrack formation. These technologies make possible the production of aluminium tools that have wear resistance better than that of steel, with cyclic heat resistance up to 500 °C & very high thermal emissivity.

Alamo aimed to develop these technologies for the manufacture of aluminium tools with optimised mechanical & thermal properties for thermoplastics processing applications.

The main objective of the project was to develop precompetitive, innovative anodised aluminium mould tools for injection moulding, blow moulding & rotational moulding. These moulds have surface mechanical & thermal properties, exceeding those presently on the market in terms of wear resistance, thermal emissivity & corrosion resistance. The SME participants have obtained a technological edge from the results of this project, which has increased their competitiveness. In line with the objectives of the EU & Framework 6, the product & process developed will contribute towards sustainable manufacturing.

Start date: 01/11/2004
Completion date: 30/10/2006