Broken tips, as a result of machining operations on the housing reels of fly-fishing reels, were casting a shadow on an upscale reel manufacturer. The protruding tip was part of a thin walled section and a number of parts were broken in production. When the CNC operation starts to cut the curved shape with the roughing tool, it removes metal in a circular pattern. There is no way to support the thing protruding wall of the housing during this operation. As the tool exits the part, the tip on the small thin section breaks off.

Alcoa Global Cold Finished Products evaluated the housing reel in our materials characterization laboratory. There, an application engineer suggested that the reel manufacturer try UltrAlloy® 6020. The tighter tolerances along with the good anodizing response and excellent machinability of the alloy convinced the manufacturer to give it a try. A 1-1/2 inch diameter rod was evaluated for the hub part.

Machine operators at the factory reported a 30% increase in productivity as a result of improved machining with the UltrAlloy® 6020 and were very impressed with surface finish. The anodizability of the alloy was then evaluated and found to be positive, gaining a fine finished appearance. Plus, the chip management improvement was a real bonus for the manufacturer's operation. Approximately 90% of the original aluminum slug is machined away as scrap in order to make this particular project

The small chips from the UltrAlloy® 6020 product require far fewer chip tubs and are much easier to handle than the 6061 stringy chips they had been using Alcoa UltrAlloy® 6020 added value all the way down the line.

UltrAlloy® 6020 was developed in response to an industry need for a lead-free, enhanced machining product with the inherent benefits of a 6xxx-series alloy. Find out about all the benefits and potential applications of the first unleaded aluminum alloy in the world with A-rated machinability at www.alcoa.com/gcfp.