Detailed Project Report on aluminium ingots of various grades from aluminium scraps

ALUMINIUM INGOTS OF VARIOUS
GRADES FROM ALUMINIUM SCRAPS
[CODE NO. 3041]


Ingots are very large casting products, greater in size and shape than blooms, billets and slabs. Ingot generally has rectangular/square cross section, but it is not necessary that it should be uniform through out its length. (Ingot may have variable cross section.)

Aluminium Alloy Ingots Iike LM-2, LM-4, LM-6 which are commonly used in Gravity and Sand Casting, Pressure Die Casting Alloys like LM-13, LM-14, LM-24, ADC-12, ALSI-132 etc are also being manufactured as per the Indian and International standards.
 
Classification of aluminum alloys

Classification of aluminum alloys is established by the International Alloy Designation System (IADS), based on the classification developed by Aluminum Association of the United States.

This classification is accepted by most countries.

    wrought aluminum alloys
    cast aluminum alloys

Wrought aluminum alloys

Wrought aluminum alloys are used in the shaping processes: rolling, forging, extrusion, pressing, stamping.

There are two principal groups of the wrought aluminum alloys:

    Non-heat-treatable alloys
    Heat-treatable alloys
    Phase composition of wrought aluminum alloys

Non-heat-treatable alloys

Non-heat-treatable alloys cannot be strengthened by heat treatment.

Alloys of 1xxx, 3xxx, 4xxx and 5xxx series are non-heat-treatable.

The initial strength of these alloys is achieved due to the hardening effect of the alloying elements: manganese (Mn), silicon (Si), magnesium (Mg).

Additional hardening of these alloys is done by cold work (strain hardening).

Non-heat-treatable alloys are ductile and moderately strong (depending on the alloying elements concentration).

The alloys from this group are supplied either in O condition (annealed) or in H condition (cold worked at various degrees).

Non-heat-treatable alloys are used for manufacturing deep drawn parts, sheets, foil, tubes, wire, extruded parts, pressure vessels.

COST ESTIMATION

Plant Capacity                                            12.00 MT./day
Land & Building  (5000 Sq.Mtr)                   Rs. 3.79 Cr    
Plant & Machinery                                       Rs. 36.30 Lacs
W.C. for 2 Months                                       Rs. 6.35 Cr
Total Capital Investment                              Rs. 11.32 Cr
Rate of Return                                            17%
Break Even Point                                         60%

INTRODUCTION    
CLASSIFICATION OF CAST ALUMINUM ALLOYS    
CHEMICAL COMPOSITIONS OF SOME CAST ALUMINUM ALLOYS    
ALUMINIUM ALLOY INGOT CHEMICAL COMPOSITION    
USES AND APPLICATION    
B.I.S. SPECIFICATIONS    
MARKET SURVEY    
EXPORTS OF ALUMINIUM ALLOY INGOT    
IMPORTS OF ALUMINIUM ALLOY INGOT    
MANUFACTURERS/SUPPLIERS OF ALUMINIUM ALLOY
MANUFACTURING PROCESS    
PROCESS FLOW DIAGRAM    
PLANT AND MACHINERY
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF RAW MATERIAL    


APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT