RF - FOIL PRESS PROCCESS
By F. A. Mull
Index:
The layout of the RF – foil press mal
Press process
Material and Suppliers
Foil analyses
Mold and foil 3 D test
Welding
Vacuum test
Torlon coating
Neg coating
The layout of the RF – foil press mal:
The produced foil
Materialist:
Aluminium foil:
DIN 1712, 1725, 1745, 1783
EN 485, 515, 573
AlMg3, G 15, 5005A, H 24, NQ
Thickness 0, 3 mm
Supplier:
MANFRED J.C. NIEMANN
NEDERLAND B.
Postbus 311, 3800 AH Amersfoort
Printerweg 7, 3821 AP Amersfoort
Tel: (033) 450 82 00
Fax: (033) 456 05 41
Email:
Website:
Isolation plate:
Mono lux 500 (19,1mm thick à € 76,29/m2)
Supplier:
B.V. Profiltra
Meerpaalweg 4
1332 BB Almere
Tel. (036) 532 42 28
Fax. (036) 532 42 68
Email:
Website:
Aluminium pressmal
Material: ACP 5080 (anodize).
Heatherelement:
Type: ELE
Power:1kW
Connection power:400V/50Hz
Heather lengths 1100 mm (2x150 mmnot heated)
Type element: closed tubeelement
Mantel material: RVS 321
Electricconnection: 2x AMP Fashion
Supplier:
O – Ring cord:
Ø 6mm
Article 11038465
Snoer Viton A 75 black
Material: FPM VITON®
Tolerations: DIN 7715 E2
Supplier:
Eriks
Saffierstraat 3
1812 RM Alkmaar
Postbus 280
1800 BK Alkmaar
Tel. (072) 514 17 17
Fax (072) 514 16 25
Pressprocess:
Before we start the foil and the mal must be ferry cleaned.
All the seams have to be closed by glass tape.
All the expansionspaces have to be covered with Stanley steel foil (0.2 mm).
The pores of the aluminium mal (anodize) must be fill and polished with carbon powder.
All the rest powder must be removed.
Put a sheet (1300 mm x 400 mm) of aluminium foil(AlMg3) on the mal.
Close the press mal with the top isolation frame.
First the temperature must be rising up at 330°C and is controlled by a thermo element and a REX-D400digitaltemperature controller.
When the mal is on temperature (this takes ~ 1 hour) the presser can start.
The aluminium foil on the mall has to be clamped between the frame and the O – rings spacer with wedges.
The press process starts when the aluminium foil(AlMg3) is 1 quarter clamped by the mal temperature of 330°C.
For the presser we use N (Nitrogen) gas.
The presser rising starts every20 minuteswith 1.5 bars until 12 bar.
The last step is, pressurise the presser up to 21 bars(in one step) during 1 quarter.
When the presser is finessed open directly the mal and take of the foil.
Top foil in the mould
The produced foils
Electronmicroscopy:
Outside surface
Walls surface
Inside surface
Vacuum sniffle method:
Vacuum Box welding:
Vacuum test:
3 D lengthsmeasuremends:
Right mold 11-09-2007
Left mold ...-…-2007
Left mold 18-09-2007
Neg coating:
1