In the world of high-quality LED lighting equipment, usefulness, performance, functionality and durability are required. But in the highly competitive consumer market, appearance also matters. One lighting manufacturer could deliver on performance but was experiencing inconsistent anodize appearance when using the clear and dye anodizing processes.
AlcoaGlobal Cold Finished Products' application engineering team solved the anodizing appearance challenge. Their suggestion: UltrAlloy® 6020 to improve the anodizing while maintaining the machinability required for the product design.
The excellent anodizing and machining attributes of Alcoa UltrAlloy® 6020 met the manufacturer's product design challenges exactly. Additionally, the alloy's strength level proved to be very important for the durability of the light - police quality high dent resistance aluminum casing.
Alcoa UltrAlloy® 6020 provided the improved anodize appearance quality required for the product launch - high yield and high quality appearance after anodize. Alcoa UltrAlloy® 6020 also allowed the machining productivity levels typically seen with only aluminum alloy 2011. And, the strength levels of Alcoa UltrAlloy® 6020 met the rugged demands of a flashlight in service by hunters, police, and even the United States Military.
UltrAlloy® 6020 was already commercially available in the marketplace at the time of the product development. Alcoa GCFP's vast tooling availability also enabled timely delivery of material during the final development stages, providing a swift solution to the material challenge.
UltrAlloy® 6020's excellent machinability proved to be advantageous because the flashlight casing produced on high productivity rate machining centers, where extensive outside diameter turning and milling are performed for the outside appearance features of the handle. Simultaneously, the metal is being drilled, reamed, and recessed to allow for the electronics, LED elements, and battery compartment.
To date, Alcoa UltrAlloy® 6020 has been so successful for this manufacturer that they have begun using it for other models of flashlights.
