1050 調理器具用アルミサークル: 包括的な技術仕様 & 製品マニュアル
1. Executive Product Overview
1.1 の紹介 1050 調理器具専用アルミニウムサークル
の 1050 Cookware-Specific Aluminum Circle represents the pinnacle of high-purity forged aluminum disc substrates available in the global cookware manufacturing industry.
Engineered for versatility, this product adheres strictly to the American Aluminum Association (AA) standards and China’s national standard GB/T 3190-2020. 最低アルミニウム純度が保証されています。 99.5%, this product sits at the apex of the industrial pure aluminum series.
Unlike generic aluminum discs, this variant is the result of years of metallurgical refinement aimed specifically at solving the unique challenges faced by cookware OEMs and ODMs worldwide.
1.2 冶金の起源とプロセス フロー
Our production cycle integrates a closed-loop quality control system spanning from molten metal to finished coil. The process initiates with the smelting of virgin aluminum ingots, followed by homogenization, 熱間圧延, 冷間圧延, そして最後に, our proprietary 精密傾斜アニーリング.
The circles are then blanked, leveled, and inspected. Each stage is monitored via Spectrometer analysis and ultrasonic scanning to ensure zero inclusions or pinholes. This meticulous process ensures the material is not merely a piece of metal, but a high-performance substrate ready for the most demanding forming operations.
1.3 Addressing Industry Pain Points
The primary historical challenge with standard aluminum circles in cookware production has been unpredictable failure during forming.
深絞り加工時のエッジ割れなどの問題, 回転中のオレンジの皮のテクスチャー, and inconsistent wall thickness have plagued manufacturers, 高いスクラップ率につながる. 私たちの 1050 Cookware-Specific formulation directly targets these issues.
By optimizing the grain structure and eliminating intermetallic compounds through advanced fluxing and degassing techniques, we have developed a material that offers unparalleled plasticity.
This document will focus heavily on how our superior 伸び率 translates directly into higher profitability and product quality for your operations.
2. ディープダイブ: Core Alloy & Temper Parameters
2.1 化学組成と冶金純度
私たちの化学指紋 1050 合金はその性能の基盤です. We maintain a stringent protocol where total impurities are capped at ≤0.5%.
- 鉄 (鉄) ≤ 0.40%: Controlled to optimize the formation of Al-Fe-Si phases which contribute to strength without sacrificing ductility.
- シリコン (そして) ≤ 0.25%: Kept low to ensure high plasticity and prevent the formation of hard silicon particles that can initiate cracks.
- 銅 (銅) ≤ 0.05%: Minimized to enhance corrosion resistance, particularly important for cookware exposed to acidic foods.
- 微量元素: Lead (鉛), 砒素 (として), and Cadmium (CD) are virtually eliminated to ensure 100% food-grade safety compliance.
競争環境: 1050 対. 1060 対. 1100
To illustrate why 1050 です “スイートスポット” for cookware manufacturing, consider the following expanded technical comparison:
| パラメータ | 1050 (Our Standard) | 1060 (Premium Alternative) | 1100 (Economic Alternative) |
|---|---|---|---|
| 純度 | ≥99.5% | ≥99.6% | ≧99.0% |
| 伸長 (に) | 28% – 32% | 30% – 33% | 22% – 26% |
| 抗張力 | 90 – 120 MPa | 85 – 115 MPa | 110 – 145 MPa |
| 粒子構造 | 大丈夫, ユニフォーム, 等軸 | 非常に細かい, Highly Uniform | 粗い, Less Uniform |
| コスト効率 | 高い (ベストバリュー) | 中くらい (Premium Cost) | 高い (Lowest Upfront Cost) |
| Scrap Rate Potential | < 1% | < 0.5% | 5% – 15% |
| 評決 | に最適 90% of mass-market and semi-premium cookware. | Best for extreme artistry/ultra-thin walls. | Risky for deep drawing; only for flatware. |
2.2 Specialized Temper Designations for Cookware
We do not offer just “材料”; we offer “process-ready” solutions through specific tempers:
- に (完全に焼きなまされた – 柔らかい): Achieved by heating above the recrystallization temperature and cooling slowly. これにより延性のピークが発生します. 応用: Essential for pots requiring a depth-to-diameter ratio greater than 1:1, such as stockpots, 中華鍋, and high-sided saucepans.
- H14 / H24 (ハーフハード):H14はひずみ硬化です; H24 is strain-hardened and partially annealed. They offer a balance. 応用: Perfect for fry pans and sauté pans where the base requires rigidity to avoid oil pooling (“oil canning”) ただし、側面にはわずかな曲率が必要です.
- H18 (Full-Hard): Cold-worked to the hardest possible state for this alloy. 応用: Lids, IH調理器具用ベースプレート, and pizza trays where zero deformation is required.
3. Critical Performance Analysis: Focus on Elongation
3.1 Understanding Elongation (A50 Standard)
Elongation is the percentage increase in the gauge length of a test specimen before it breaks under tension. In cookware terms, it measures how far the metal can stretch before fracturing. We utilize the A50 standard (50mm gauge length) because it provides the most accurate simulation of real-world stretching in a press.
Detailed Mechanical Properties Table
| 気性 | 伸長 (A50) | 抗張力 (MPa) | 降伏強さ (MPa) | n値 (加工硬化指数) | r値 (塑性ひずみ比) |
|---|---|---|---|---|---|
| に | 28% – 32% | 90 – 120 | 40 – 80 | ~0.30 | ~0.60 |
| H14 | 8% – 18% | 130 – 160 | 110 – 140 | ~0.15 | ~0.50 |
| H18 | 3% – 5% | ≥160 | ≥140 | ~0.05 | ~0.40 |
- Why these numbers matter:当社のHOテンパーの高い伸び (28-32%) provides a massive “safety margin.” 描画操作が必要な場合 20% ストレッチ, 標準 1100 might fail, but our 1050 performs flawlessly. 高い r値優れた深絞り性を示します (resistance to thinning), 一方 n値 ensures uniform deformation rather than localized necking.
3.2 Physical Properties and Thermal Dynamics
- 熱伝導率 (230 W/m・K): Aluminum dissipates heat 3x faster than stainless steel. 私たちの 1050 circles ensure there are no “ホットスポット” which cause food to burn. During the spin-forming process, this property also helps dissipate frictional heat, preventing die sticking.
- 密度 (2.70 g/cm3): This low density allows for thicker gauge walls (for durability) without increasing the final product weight, improving the end-user experience.
- 弾性率:おおよそ 69 GPa. This ensures that while the material is ductile, it retains enough spring-back control for accurate dimensional stability after forming.
4. 仕様, 公差, と次元の整合性
4.1 Comprehensive Size Range
We offer the widest range of diameters and thicknesses to suit every niche of the kitchenware market:
- Thickness Window: 0.3mm to 10.0mm.
- サブ-0.5mm:Used for disposable foil containers or ultra-light camping cookware.
- 0.5mm – 3.0mm:The sweet spot for consumer cookware.
- 3.0mm – 10.0mm:Heavy-duty commercial braising pans and induction bases.
- Diameter Window: 20mm to 1600mm.
- 小さい (<200mm):家電製品のコンポーネント, 蓋, and butter warmers.
- 大きい (>1200mm):Commercial paella pans and industrial mixing bowls.
4.2 Precision Tolerance Standards
Our tolerance standards are twice as strict as typical commodity aluminum:
- 厚さの許容差: Held to ±0.02mm for thin gauges. なぜ? Because a 0.05mm deviation in thickness can cause a 10% variation in stretching force, leading to inconsistent forming heights and premature tool wear.
- エッジ品質: Cut edges are deburred and rounded (半径 > 0.1mm) to prevent stress risers. A sharp edge acts as a pre-existing crack, drastically reducing the effective elongation during drawing.
5. 高度な製造プロセス
5.1 DC Casting vs. CC Continuous Casting
ダイレクトチルの両方を運営しております (直流) and Continuous Casting (CC) さまざまな市場セグメントに対応するライン:
- DCキャスティング (ダイレクトチル): Molten aluminum is poured into a water-cooled mold. This creates a thick slab with a highly directional solidification structure. It is excellent for thick-gauge products requiring high structural integrity.
- CC Casting (連続鋳造 & ローリング): Molten aluminum is fed through a twin-roll caster, creating a thin strip directly. This results in a much finer, more isotropic grain structure. アドバンテージ: Superior surface finish (いいえ “ピンホール”) and approximately 30% better elongation consistency compared to DC cast material. Recommended for high-end non-stick cookware where surface perfection is mandatory.
5.2 The Science of Precision Annealing
Annealing is where the magic happens. 私たちの Gradient Annealing Furnaces utilize a 5-zone temperature profile.
- 回復: Heating to remove internal stresses from rolling.
- 再結晶化: Heating to ~350°C to form new, strain-free grains.
- Grain Growth Control: Precisely holding temperature to achieve the “Goldilocks” grain size (~30-40 microns). Too small = stiff; too large = “orange peel.”
- 制御された冷却: Slow cooling to prevent re-introduction of thermal stress.
This scientific approach ensures that every circle leaving our facility possesses the exact elongation required for the job.
6. Surface Technology and Finishing Compatibility
6.1 Native Surface Characteristics
圧延したままの表面は薄い層で保護されています。, invisible oxide layer that prevents staining during transit. It is chemically clean, free of rolling oils, and ready for immediate processing. There are no “ローラーマーク” (ghosting) which can telegraph through to the final polished cookware surface.
6.2 Pre-Treatment and Conversion Coatings
私たちの 1050 alloy is the ideal substrate for value-added processes:
- 陽極酸化処理:高純度なので厚みが確保できます, ユニフォーム, and clear anodic layer. We recommend our CC-cast material for hard anodizing to prevent pitting.
- ノンスティックコーティング (PTFE/Ceramic):表面はエッチング可能 (化学的または機械的に) to create a micro-anchoring profile. Our material’s low impurity content ensures zero “はじける” or outgassing during the high-temperature curing of non-stick coatings.
- 研磨: Due to the absence of hard intermetallic particles, our circles polish to a mirror finish faster and with less abrasive consumption than lower-purity alloys.
7. Strategic Product Advantages
- 収量の最適化: Our consistent elongation (28-32%) reduces your scrap rate from an industry average of 5% まで <1%. 本番稼働中 100,000 単位, this saves 4,000 物資と労力の価値を円にします.
- Tooling Longevity: Consistent material properties reduce shock loading on presses and spinning machines, extending tool life by up to 20%.
- 規制上の安心感: Full compliance with FDA 21 CFR, EU規制 1935/2004, and LFGB standards. Our material is certified for direct food contact, 重金属を含まない (鉛, CD, として).
- Logistical Efficiency:JITを提供します (ジャストインタイム) 配信プログラム. Our circles are interleaved with neutral craft paper or PE film to prevent scratching during automated feeding.
8. 拡張されたアプリケーションポートフォリオ
- 消費者強硬派:高級鍛造フライパン, clad stainless steel cookware cores, Dutch ovens.
- Small Appliances: Air fryer baskets, 炊飯器の内釜, 電気ケトル本体, coffee machine boilers.
- コマーシャル/ホレカ:ホテルパン (スチームテーブルパン), ビュッフェ式チェーフィング料理, heavy-duty stockpots, ベーキングモールド.
- Specialty Items:照明用反射板 (純アルミニウムの高い反射率を利用), 電子機器用ヒートシンク.
9. Quality Assurance Infrastructure
9.1 検査室の能力
Our in-house lab is equipped with:
- Instron Universal Testing Machine:精密な引張試験用 (伸長, UTS, ＹＳ).
- 金属顕微鏡:粒度分析用 (ASTM E112).
- Spectrometers: For instant chemical composition verification.
- 塗装密着性試験機: To simulate non-stick application performance.
9.2 認定ポートフォリオ
- ISO 9001:2015: Quality Management System.
- ISO 14001:2015:環境マネジメントシステム.
- FDA (アメリカ合衆国), DGCCRF (フランス), LFGB (ドイツ): Food Contact Compliance.
- 到着 & RoHS: Restriction of Hazardous Substances.
10. ロジスティクス, 包装, and Support
10.1 輸出標準梱包
- 目から空または目から壁:顧客の好みに基づいたオリエンテーション.
- Moisture Barrier: Each bundle is wrapped in LDPE sheeting and sealed with desiccant packs to prevent oxidation during sea freight.
- 木箱:熱処理済み (ISPM-15準拠) wooden crates for maximum protection against forklift damage.
10.2 技術提携
私たちはアルミを売るだけではありません; 私たちはエンジニアリングサポートを提供します. Our technical team can assist with:
- ブランク直径の計算: Helping you determine the exact circle size needed for your specific pot shape to minimize trim scrap.
- 描画削減率: Advising on the number of drawing stages required for deep pots to maximize success with our material.
- サンプル提供: Free samples (5kgまで) are available for press trials and laboratory verification.