Aluminum Training

ALUMINUM TRAINING

You have introduced a new technology in your company and need qualified employees? The EBNER Academy contributes to the qualification of your executives, engineers, technicians and operators with seminars, workshops and training courses. We backup you on current topics and technology in the fields of processes, automation systems and heating know-how. With international conferences and congresses, we support the exchange of expertise at expert level.

As a company, you secure your economic success by investing in training and further education. You promote the knowledge as well as the motivation and commitment of your employees which in turn strengthens your efficiency and global competitiveness. As an education service provider, the EBNER Academy is your long-term partner and companion, the common goal is your enduring and solid development.

LEVEL 1 - BASIC TRAINING ALUMINUM

Description

With this course you will acquire the necessary knowledge and skills for the safe handling of the heat treatment plant. You will learn the requirements of an efficient process using practical examples.  

  • Explanation of the annealing process
  • Create annealing programs
  • Diagram of pressure control, valve position and gas heating
  • Plant maintenance

Audience                                           

Personnel from production, maintenance

Prerequisites                                    

Basic knowledge of heat treatment, basic knowledge of plant operation

Benefits                                             

Safe and efficient operation of the EBNER system

Content – Theory & Practice          

  • Preparation for heat treatment
  • Activate media (electrical switchgear, ZBS, PLS, gas supply, cooling water supply, hydraulics, …)
  • Basics ZBS/PLS (common equipment, base overview, annealing protocol, process data, operation, curves, …)
  • Creating annealing programs in ZBS/PLS (central operating system/process control system) (temperature program, protective gas program, explanation of general parameters)
  • Procedure for batching the material (batch diameter and height, weight, …)
  • Operating sequence (transfer annealing program, fit and press on protective hood, fit heating hood, …)
  • Basics Operator Panel
  • Explanation Scheme of pressure control, valve position and gas heating depending on the current annealing process
  • Dealing with fault messages
  • Plant maintenance (weekly, monthly, quarterly, …)
  • Annual service by EBNER

Methods                                            

EBNER Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Training Type

Hands on at Customer System

Duration                                            

1 day

Price on request

START A REQUEST   REGISTRATION

Description

Programmable Logic Controller (PLC) are without doubt an essential part of production plants of various kinds.

Using the Simatic S7 as an example, participants are given a broad overview of the efficient use of the control system and how to eliminate malfunctions. Subsequently, the courses Simatic S7 Software and PLS – Visual Furnace 6, provide the necessary knowledge to read, understand and optimize PLC programs.

Audience                                           

Personnel from production, electrics and maintenance

Prerequisites                                    

Basic knowledge Simatic S7 control

Benefits                                             

Understanding of the software components and their diagnosis when troubleshooting the system

Content – Theory & Practice          

  • Basic terms in PLC
  • Program structure setup
  • Graphical representation of controls in the logic diagram
  • Overview of the functions in the individual program sections

Methods                                            

EBNER Academy offers a targeted, practice and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Classroom or Customized

Duration                                            

1 day

Price on request

START A REQUEST   REGISTRATION

Description                                       

The process control system is used for central plant operation and monitoring of the process flow, reporting, maintenance and repair support, material planning and its assigned functions.

The Visual Furnaces® 6 process control system is an EBNER proprietary development based on the Microsoft .NET Framework and was implemented in C#.

Microsoft SQL Server is used as the database. A powerful process data acquisition module ensures the data supply for the user interface and long-term data management modules.

Data exchange with the subordinate controllers is based on communication using OPC technology.

Visual Furnaces® 6 can be equipped with a variety of optional modules for planning, analysis, maintenance support and a thermal model.

Audience                                           

Personnel from production, automation technology

Prerequisites

Basic knowledge heat treatment, process control engineering, automation technology

Benefits                                             

Optimized annealing process through targeted use of Visual Furnace 6

Content – Theory & Practice          

  • Explanation of the basic functionalities
  • Functions and benefits of the differentVF6 modules
  • Use of the various tools and their setting options
  • Understanding the parameters for the different modules
  • Introduction to the mathematical models and their parameterization
  • Optimization of annealing processes through targeted use of VF6 modules

Methods                                            

EBNER Academy offers a targeted, practice and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Classroom or Customized

Duration                                            

1 day

Price on request

START A REQUEST   REGISTRATION

Description

The CQI-9 Heat Treat System Assessment is standardized in the automotive industry, published by AIAG (Automotive Industry Action Group), the North American association of leading automobile manufacturers. The CQI-9 is supposed to ensure a uniform quality standard in heat treatment.

In addition to a theoretical part in which the contents of the CQI-9 are conveyed, practical training, either directly at the furnace or in EBNER’s own laboratory, is provided to specifically address the required periodic measurements (IT, SAT, TUS).

In the additional module “Application SURVEYperfect” the software tool SURVEYperfect developed by EBNER is covered in theory and practice. SURVEYperfect offers a CQI-9 compliant, simplified and fast execution as well as documentation of IT, SAT and TUS measurements.

Audience

Engineers, technicians and front men from quality management, maintenance and production.

Prerequisites

Basic knowledge of heat treatment and measurement technology

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will get an introduction to the contents of the CQI-9, optimized execution of the measurements IT, SAT, TUS.

Content – Theory & Practice

  • General information about the AIAG CQI-9
  • Heat Treat System Assessment (a catalogue of audit questions)
  • Content and application of the process tables
  • Requirements on thermocouples
  • Instrumentation requirements
  • Instrument Test (IT)
  • System Accuracy Test (SAT)
  • Temperature Uniformity Survey (TUS)
  • Application of the module SURVEYperfect (additional software module)

Methods

Ebner Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Training Type                                   

Classroom or Customized

Duration

2 days

Price on request

START A REQUEST   REGISTRATION

Description

The AMS2750 is standardized in the aerospace industry, published by the SAE International Group. The AMS2750 is part of the NADCAP accreditation program and supposed to ensure a uniform quality standard in heat treatment.

In addition to a theoretical part in which the contents of the AMS2750 are conveyed, practical training, either directly at the furnace or in EBNER’s own laboratory, is provided to specifically address the required periodic measurements (IT, SAT, TUS).

In the additional module “Application SURVEYperfect” the software tool SURVEYperfect developed by EBNER is covered in theory and practice. SURVEYperfect offers a AMS2750 compliant, simplified and fast execution as well as documentation of IT, SAT and TUS measurements.

Audience

Engineers, technicians and front men from quality management, maintenance and production.

Prerequisites

Basic knowledge of heat treatment and measurement technology.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will get an introduction to the contents of the AMS2750 optimized execution of the measurements IT, SAT, TUS.

Content – Theory & Practice

  • General information about the AMS2750
  • Requirements on thermocouples
  • Instrumentation requirements
  • Instrument Test (IT)
  • System Accuracy Test (SAT)
  • Temperature Uniformity Survey (TUS)
  • Application of the module SURVEYperfect (additional software module)

Methods

EBNER Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Training Type                                   

Classroom or Customized

Duration

2 days

Price on request

START A REQUEST   REGISTRATION

Description                                       

This basic seminar is intended to provide you with the fundamentals of the physical and material engineering of heat treatment.

Questions will be answered on how the strength and ductility of metallic materials can be specifically adjusted by heat treatment or how to

State diagram reads and interprets. It also explains what happens inside the metal during heat treatment and why such different heat treatment processes are necessary.

Audience                                           

Personnel from production, R&D, quality management, purchasing

Prerequisites

Basic technical understanding of heat treatment processes and/or materials science

Benefits                                             

Understanding the metallurgical processes in the course of a heat treatment process

Content – Theory & Practice

  • Structure of metallic materials
  • Introduction of near-equilibrium heat treatment of steel (iron-carbon diagram, normalizing and annealing)
  • Introduction of heat treatment of steel (martensite, bainite, retained austenite, hardening and tempering)
  • RTD diagrams
  • Location of different heat treatments in Fe/C and ZTU diagrams
  • Influence of alloying elements
  • Basic information on heat treatment of aluminium (Al-Cu phase diagram, solution heat treatment, precipitation hardening)

Methods

EBNER Academy offers a targeted, practice- and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Open theory course or individual course

Duration                                            

2 days

Price on request

START A REQUEST   REGISTRATION

Description                                       

By means of easily understandable examples, knowledge is obtained about further program technical possibilities in order to consolidate and furthermore extend the physical and material fundamentals of heat treatment.

Various annealing cycles, optimization possibilities and software tools are explained and deepened in hands-on training.

Audience                                           

Personnel from production, R&D, quality management, purchasing

Prerequisites

Basic knowledge of heat treatment processes and optimization of EBNER furnaces

Benefits                                             

Understanding and optimization of the heat treatment process; optimized output at the plant

Content – Theory & Practice

  • Temperature and inert gas cycles of different heat treatments or alloys
  • Optimization possibilities in the temperature and inert gas cycles to increase quality and the output or reduction of media consumption
  • Optimization possibilities in the process parameters
  • Explanation of supporting software tools

Methods

EBNER Academy offers a targeted, practice- and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Open theory course or individual course at customer’s facility (if available)

Duration                                            

1 day

Price on request

START A REQUEST   REGISTRATION

LEVEL 2 - ADVANCED TRAINING ALUMINUM

Description

Aluminum is a preferred choice material for reduction of weight of automotive vehicle to satisfy the stringent CO2-emission standard. Because of this up to 15 % growth is predicted till 2025 in usage of aluminum sheet. A strong competition in the Aluminum industry has now started to capture the aluminum sheet market growth by targeting production of high-quality aluminum sheet.

Light weighting by aluminum in manufacturing of non-structural parts like inner and outer panels by cold forming are already practiced by OEM’s. However, for structural parts like B-Pillar, A-pillar, C-pillar, cross beam and impact beam requires high strength aluminum alloys. But the high strength aluminum alloys are not formable at room temperature. Therefore, requires another forming approach.

Audience

Engineers and technicians in the fields of production, process, tooling, material testing and QM & QS.

Prerequisites

Understanding in heat treatment and hot forming and quenching.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will have the opportunity to experiment with various parameters and experience hot forming and quenching in the field of aluminum and acquire a deep insight into the most efficient skills in technology.

Methods

EBNER Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Content

Hot forming and quenching of aluminum similar to press hardening of steel is a newly developed forming technology that is able to form complex shape structural parts made from high strength aluminum alloys (Fig. 1). In this processing technology, aluminum sheet is solution heat treated between 450-580°C for 0-10 min in a furnace. Thereafter it is transferred into the press. During transfer, the aluminum blanks cools. During pressing, it acquires the shape and necessary quenching. The formed and quenched parts artificially aged to T6 condition. Improvement in formability due to elevated temperature of high strength aluminum facilitates forming of complex shape parts which are not possible by cold forming. The major advantages of the hot forming and quenching process are follows:

  • The reduction of the number of individual steps means there are fewer opportunities for contamination of the metal within each process, and uncontrolled air-cooling.
  • Less energy is needed due to the reduction in the number of times the material is reheated.
  • The formability of the material is higher, due to the hardening stages being performed during or after the forming stage.
  • Spring back can also be reduced by the combination of quenching and forming stages. This, in turn, increases the geometrical tolerances of the component, allowing components to be assembled easily.
  • Distortion of the component is also limited due to the quenching stage being contained in the cold die.
  • The time of production for each component is reduced, because the component no longer has to be transferred between as many different items of process equipment. This consequently leads to financial savings.

T1: Introduction and fundamentals in HFQ

  • Recapitulation Process fundamentals
  • Which quality characteristics have to be fulfilled? – Critical quenching rate, Interface between tool/press/cooling, Thermal expansion, Form- ability, etc…
  • Product design, most important process parameters, tool concepts, thermal treatment

T2: Process Parameters for Tools

  • Cooling approaches, handling of problem areas
  • Segmented construction
  • Tool design
  • Failure possibilities (drawing clearance, wear, blank holder, positioning ejector, etc.)
  • Failure criteria by replica or drawing clearance measuring
  • Process control

T3: Virtual Engineering

  • From the component geometry to the tool
  • Interface definition and using software
  • How the product geometry has to be? Are there possibilities for optimization? What is not?
  • Active surface construction
  • Blank shape
  • Simulation
  • CAD (Catia)
  • Trimming

T4: Tool Materials and Coatings

  • Hot forming tool steel (mechanical and thermal properties)
  • Tool coating
  • Recent developments

T5: Practical Examples

  • Case Studies

P1: Practical Examples

  • Case Studies in the laboratory at the furnace

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Duration                                            

2 days

Price on request

START A REQUEST   REGISTRATION

EFFICIENCY TRAINING - HICON® air floater furnaces

Description

In this course you will get a general overview of the floater furnace and the installed aggregates.

Audience

Engineers, technicians and plant operators from the production and maintenance sectors.

Requirements

No basic knowledge is required.

Benefits

After you have completed this training you will be able to better understand the extensive individual components and their interaction.

In addition, you will be explained which additional equipment can be installed in order to increase/optimize your production.

Content – Theory & Practice   

The following topics will be covered:

  • Intended use of the system
  • Which alloys are annealed
  • Process Features
  • Total configuration depending on the planned production
  • Technical specification
  • References

Methods                                

EBNER Academy offers a targeted, practice and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type

Theory and practice at the customer’s plant.

Duration

1 day (4h theory, 2h practical training at the plant)

Price

€ 2.600,- per day
Travel expenses according to the costs | Participants maximum 6 persons

START A REQUEST   REGISTRATION

Description

In this course you will be given an overview of the system manual and its individual chapters.

Audience

Engineers, technicians and plant operators from production and maintenance.

Prerequisites

General technical understanding.

Benefits

After completing this training, you will understand the functions of the system and its components. You will be able to carry out maintenance work or fault analyses with the help of the system manual.

ContentTheory & Practice   

The following topics will be covered:

  • Safety
  • Technical data of your furnace
  • Operating and process control system
  • Description of your stove
  • Description of your quench
  • Operation of the system
  • Alarms and their meaning and subsequently the troubleshooting
  • Explanation of the plant inspection record

Methods     

EBNER Academy offers a targeted, practice and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type

Theory and practice at the customer’s plant

Duration

1 day (4h theory, 4h practical training at the plant

Price

€ 2.900,- per day
Travel expenses according to the costs | Participants maximum 6 persons

START A REQUEST   REGISTRATION

Description

With this course you will acquire the necessary knowledge to carry out maintenance work on the gas heating system of your furnace.

Audience

Engineers and technicians from the production and maintenance sectors.

Requirements

  • Basic knowledge of P&I diagrams
  • Basic knowledge of handling gases

Benefits

After successful completion of this training you will be able to carry out maintenance work and safety checks on the components of the gas heating system.

Among other topics, the following points can be carried out independently

  • Exchange and recalibration of components
  • Burner troubleshooting
  • Optimization work on the burners
  • Function tests of safety-relevant components

ContentTheory & Practice   

The following topics will be covered:

  • General theoretical introduction
  • Explanation of the schematic drawings
  • Functional descriptions of the various components
  • Safety relevant functions
  • Calculation of the gas/air ratio
  • Setting the pressure reduction and burner in practice

Methods 

EBNER Academy offers a targeted, practice and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type

Theory and practice at the customer’s plant.

Duration

1 day (2h theory, 6h practical training at the plant)

Price

€ 2.900,- per day
Travel expenses according to the costs | Participants maximum 6 persons

START A REQUEST   REGISTRATION

Description

In this course you will acquire the necessary knowledge how to carry out an efficient and meaningful drag element measurement on the airborne belt system.

Audience

Engineers, technicians and plant operators from the production and maintenance sectors.

Requirements

Experience with the plant.

Benefits

After the training you will have the necessary knowledge to carry out a drag element measurement on the conveyor belt system.

Content

The following topics will be covered:

  • Explanation of the required measuring instruments
  • Joint implementation of the preparatory work
  • Fixing the towing elements to the material
  • Starting the measurement
  • Removing the elements from the material
  • Evaluation of the data

Methods  

EBNER Academy offers a targeted, practice and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type

Practice at the customer’s plant.

Duration

4 hours  

Price

€ 2.100,- per day
Travel expenses according to the costs | Participants maximum 6 persons

START A REQUEST   REGISTRATION

Description

In this course you will learn how to remove the top of the furnace to carry out various maintenance work in the furnace.

Audience

Engineers, technicians and plant operators from the production and maintenance sectors.

Requirements

Mechanical maintenance personnel with permission to operate the hall crane.

Benefits

After you have completed this training you are qualified to lift the ceiling of the oven by crane.

Content

The following topics will be covered:

  • Removal/reinstallation of the seals
  • Removing/reinstalling the thermocouples
  • Removing/reinstalling the motor
  • Removing/reinstalling the ceiling

Methods

EBNER Academy offers a targeted, practice and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type

Practice at the customer’s furnace.

Duration

3 hours

Price

€ 2.100,- per day
Travel expenses according to the costs | Participants maximum 6 persons

START A REQUEST   REGISTRATION

QUALITY MANAGEMENT
MAINTENANCE
ENERGY EFFICIENCY
SAFETY
OPERATION & PROCESS