Sollight® User Manual
Contents
1. structure which considerably increases the inertia of the compound while keeping the mass low 11 Description Sollight is a composite sandwich product consisting of 2 thin steel pre painted sheets less than or equal to 0 4 mm thick 1 thermoplastic polymer core 1 to 1 8 mm thick The product is delivered in coils 1 2 Production process Sollight is produced by a continuous process in which a sandwich composite consisting of a polymer film inserted between two pre painted steel strips paid out from two coils is passed through heated rolls The composite is then rewound after cooling Sollight and its applications Total Polymer Steel Specific Bending thickness Width thickness thickness Zinc coating mass Bending modulus Standard size mm mm mm mm g m kg m stiffness MPa Typical size tor r way Cenet 2 1220 1 5 0 25 Z100 5 3 88341 120590 Industry and interior building 2 6 1220 1 8 0 4 Z225 7 98 223385 138789 Typical size for exterior building 2 3 1220 1 5 0 4 Z225 1 71 166615 149539 1 For other sizes please contact us 2 Standard colour White G9002 for other colours please contact us 1 3 Presentation of the Sollight range 1 5 General indusiry Different pre painted finishes are available for the guaranteed Sollight has a wide variety of uses it can be considered for surface any application that requires a flat surface with good rigid Primer for post painting or bon2. is usually considered the maximum temperature for non continuous use Standard range of temperatures for use 20 to 80 C Sollight 2 mm 60 40 20 variation in bending modulus temperature C 20 0 50 100 For other uses at higher temperatures please contact us as a new polymer core is under development The thermal expansion coefficient of Sollight is similar to that of its steel skins i e AL 15 10 This gives a linear expansion of under 1 mm per metre for a 60 C rise in temperature 2i1 Thermal and electrical insulation The polymer inserted between the two steel skins eliminates any thermal or electrical bridge The thermal insulation can be expressed using the thermal conductivity of the polymer A 0 3 W C m Thus for equal thicknesses the thermal insulation provided by Sollight is around 100 times better than that of steel and 700 times better than that of aluminium 2 5 Fire performance The fire performance of Sollight has been assessed by in dependent laboratories according to European standard EN 13501 1 sections 10 6 10 9 2 and 10 10 1 Fire class measures the fire resistance of the product and fume class measures smoke droplet debris emission during combus tion both quantitatively and qualitatively Fire behaviour Smoke production B s1 do Flaming droplets and debris The lower the index the better the product s fire perform ance NB Sollight wi
3. A gt ArcelorMittal Sollight User Manual Sollight User Manual Sollight and its applications 11 122 3 1 4 1 1 6 Description Production process Presentation of the Sollight range Building sector General industry Railway rolling stock 2 Performance 2 1 7222 Zo 2 4 225 2 6 ZA 2 8 229 2 10 Rigidity weight ratio Durability Temperature range Thermal and electrical insulation Fire performance Acoustic performance Impact resistance anti vandalism Magnetic properties Safety Recycling 3 Processing 31 3 2 3 3 3 4 3 5 3 6 OI 3 8 St Cutting Direct bending without machining Reverse bending Bending with machining milling Roll bending Roll forming Joining Painting Examples of use BB HB WW WwW M NNADAAN YN Pre painted steel 0 25 to 0 4 mm thick Thermoplastic polymer 1 to 1 8 mm thick User Manual Sollight ArcelorMittal Sollight and its applications For several years now ArcelorMittal has been developing a range of composite products that widen the scope and performance of steel Sollight is the latest in this range Sollight is a steel polymer composite it is the only thin flat steel product that offers a significant reduction in the weight of parts subjected to bending loads 50 To achieve this thin steel sheets skins are combined with and complement a thermoplastic polymer core to form a sandwich
4. Mittal Processing 3 1 Cutting Sollight is well suited to most cutting techniques Shearing A guillotine shear can normally be used There are no burrs and the upper skin is only slightly pressed down during the operation However care should be taken not to deform the Sollight panel with the blank holders small diameter clamps or clamps that straddle the piece Sawing Sollight can be cut with both circular and band saws the appropriate blades and cutting speeds must be used With these techniques Sollight can be cut with hand tools Punching Machine punching does not pose any particular problem with Sollight The automatic clamps on numerical control ma chines do not deform the product The operation causes no more deformation than with a monolithic steel sheet even when the part punched has large cut outs There are practi cally no burrs if a very tight clearance is maintained between the punch and the die Holes with a diameter smaller than the Sollight thickness can be punched High pressure water jet If the cuts are not straight excellent results can be achieved with high pressure water jets For example with a 3000 bar jet and an abrasive additive cutting speeds of 1 to 3 metres minute can be attained depending on the Sollight thickness NB Sollight is not suitable for laser cutting systems 10 Processing 3 2 Direct bending without machining One of the advantages
5. ce the Sollight thickness the sandwich can be machined be fore bending In this case the bending limit is the same as for a monolithic steel sheet This makes it possible to obtain bends with radii of about 2 mm without any difficulty 92 milling ECS Bending after cutting a V shaped channel Note that a component bent in this way has a lower stiff ness in the bending area than in the case of bending without machining 3 5 Roll bending Sollight performs well in roll bending whatever type of ma chine is used pyramid rolls or conventional Small bending coefficients can be achieved with this technique ratio be tween the diameter of the curved product and the diameter of the curving roll while avoiding the formation of flat sides fluting phenomenon User Manual Sollight ArcelorMittal 3 6 Roll forming The minimum achievable radius of roll formed components with Sollight is similar to the minimum value of the radius defined for the direct V bending process This value is used to determine the different steps in the process roll forming flower Nevertheless it should be noted that the forces required to roll form Sollight are related to the stiffness of the product which is linked to the total thickness of the product not to the total thickness of the two steel skins 37 Joining Mechanical assembly systems are recommended for Sollight welding is not feasible Riveting and self pie
6. ding ity such as equipment casings It can advantageously replace Polyester for industry or the building sector thick aluminium parts Finally where lightness is a requisite it provides a very effective lightweight steel solution with high The reverse side is coated with a standard primer rigidity Its acoustic properties are a definite advantage for machine 1 4 Building sector casings and cowlings Sollight can be used in the construction of facade items boxes curved wall cladding bands etc 1 6 Railway rolling stock The larger sizes can also be used for applications such as ceil In this sector the need for lighter structures and lower costs ing tiles or interior linings pillars etc is a decisive factor penalties for excess weight The acoustic properties and fire performance offered by Sollight are also Advantages important advantages Finally Sollight is simple to process thus facilitating adaptation to modifications in the design ts aesthetic properties flatness pre painted finishes make this a high quality product Sollight can be used for linings particularly for ceiling tiles in ts high rigidity means it can be used with large spans all types of rolling stock High Speed Trains trams etc reducing the need for panel supporting framework ts formability and ease of installation facilitate the adaptation of the design to the shapes of the building t is easy to handle and safe to work thanks to its low w
7. eight and smooth blunt edges ts vibration insulation properties reduce impact noise un User Manual Sollight ArcelorMittal Flexural rigidity Steel 2 mm Aluminium 2 mm i Sollight 2 mm 0 10 20 30 100 Rigidity weight Steel 2 mm Aluminium 2 mm BSS TH Sollight 2 mm ESEREN Equivalent Rigidity Modulus 0 5000 10000 15000 Eeq in MPa User Manual Sollight ArcelorMittal Performance 21 Rigidity weight ratio Sollight is a steel product that provides an excellent com promise between rigidity and weight The flexural rigidity of a sandwich structure subjected to a bending load Df can be expressed by the following simplified formula _ Etd 2 1 vi unit width where E 210 000 MPa Young s modulus for steel V 0 3 Poisson s coefficient for steel t thickness of steel skins h total thickness of Sollight d h t This formula shows the notable effect of the core thick ness squared on rigidity The equivalent rigidity modulus of Sollight can be expressed as td teq 6 E h3 In the two tables on the left the various products in the Sollight range are compared with monolithic materials of the same thickness Performance 2 2 Durability The skin on each side of the Sollight composite is made of pre painted steel sheet The organic coatings are applied over a crack resistant galvanised layer The pre painting systems used
8. for Sollight ensure good resistance to forming stresses and to aggressive environments finish primer anti corrosion treatment zinc steel substrate zinc polymer core Corrosion protection is provided both by the galvanised sub strate and by the corrosion resistant primer applied to each steel skin As the sheet is thin the cut edges are perfectly protected by the combination of zinc primer For normal environments a 5 um primer coat can be used however for severe environments a 15 um coat is recom mended Sollight has a rotproof polymer core which guarantees the long term cohesion of this composite The organic coatings applied on Sollight products give excellent resistance against corrosion and photochemical attack Finally cyclical thermal shock tests see diagram below have demonstrated the resistance of the composite to debonding under the effect of repeated thermo mechanical stresses 100 cycles temperature water spray G 15 C BAIE 2350 time User Manual Sollight ArcelorMittal 219 Temperature range The performance of Sollight at different temperatures is de termined by the thermo mechanical behaviour of its polymer core The standard product is not suitable for use at tem peratures below 20 C due to the brittleness of the core at low temperatures At the other end of the range the poly mer melts at around 160 C but softening occurs at a lower temperature Thus 80 C
9. ight panel gt 3 times denting performance is determined by the overall mechanical strength of the sandwich For example Using the DIN ISO Braive instrument model 1615 M002 a weight of 2 kg will impact on the test sample from a height of 100 cm 50 cm 10 cm and 5 cm Sollight Steel 2mm 2 6 mm 0 95 mm 0 5 mm User Manual Sollight ArcelorMittal Static denting tests with 2 and 5 strain were carried out on Jovignot cups to compare Sollight with monolithic steel sheets Residual deformation mm Thickness wiji ae win ko strain strain Monolithic steel sheet 0 7 1 10 0 34 Monolithic steel sheet 0 8 0 33 0 11 Sollight 2 0 0 03 0 02 The static denting resistance provided by Sollight is clearly superior to that of a monolithic steel sheet of the same mass at least 5 times better than that offered by a mild steel sheet 0 80 mm thick 2 8 Magnetic properties In some light applications the magnetic properties of ferritic steels allow fastenings to be made directly using magnets 2 9 Safety Sollight can be worked safely thanks to its low weight easy to handle and its smooth blunt edges 210 Recycling Like other steels Sollight can be recovered by magnetic sorting systems and recycled through existing routes For all questions concerning the processing of Sollight we recommend that you contact ArcelorMittal to define the optimum process parameters User Manual Sollight Arcelor
10. ions or any information that is found to be misleading As this document may be subject to change at any time please consult the latest information in the section Maga zines and brochures at www arcelormittal com fce ArcelorMittal Flat Carbon Europe 19 avenue de la Libert L 2930 Luxembourg fce technical assistance arcelormittal com www arcelormittal com fce
11. of Sollight is that it can be bent di rectly without any preparation Its excellent performance in this operation is due to the use of steels for cold forming which have evolved from the steel grades developed for th automobile sector The polymer core combines high rigidity 0 with a remarkable capacity for cold forming and undergoes bending without any reduction in the thickness of the sand wich Thus the high rigidity of the sandwich structure is re tained at the bends which do not need reinforcing Taking into account the excellent bond between the skins and core the bending limit is determined by the ultimate elonga tion of the steel sheets and the geometry of the dies Classic V bending process With this process it is necessary to use an appropriate punch radius and V opening see amp cells in the table If the process is not carried out properly cracks or a gull effect will occur Sollight thickness mm with 0 4 mm skin a Punch rodius mm 4 6 6 16 V opening mm 22 35 Minimum outer radius 3 t t thickness of Sollight User Manual Sollight ArcelorMittal If there is a need for a smaller radius this can be achieved with the same process by using an original punch shape which limits the strain on the outer skin For example with a 40 mm V opening the minimum outer ra dius on a bent component can be 6 mm for Sollight 2 6 mm instead of 9 mm with
12. out this shape Flanging process A similar minimum radius can be obtained with this process For example if the height of the flanging is 25 mm the min imum value for the outer radius can be 5 mm for Sollight 2 mm skin 0 25 mm Numerical simulation of the V bending process A method has been devised to simulate Sollight behaviour The optimum process parameters can be defined by analysing The distribution of stresses in the different layers of the product The strain value on the outer skin Maximum strain on the outer skin Stress distribution at an intermediate step in the process User Manual Sollight ArcelorMittal 3 3 Reverse bending This process is necessa radius The idea is to stretch to form a fold in the the punch Folding m Mi ry if the design requires a very tight the layer between one skin and the polymer during a f rst V bending step during a second step with the same die it will then be possible for this skin inner side of the radius During the second step this skin will be in contact with inimises the strains on the outer skin inimum outer radius lt 2 t t thickness of Sollight Fold in the inner side of the radius Outer radius 4 mm with Sollight 2 6 mm Final shape of the compo nent with a 90 angle 12 Processing 3 4 Bending with machining milling In order to make bends with very small exterior radii lt twi
13. rcing rivets rivets that make their own holes without prior drilling crimping and adhesive techniques can be used 3 8 Painting The heat resistance of the polymer core does not allow post coating with heat hardening powder paints which require a typical baking cycle of 30 minutes at 180 C On the other hand the strip can be post coated with liquid paints baking curing at 80 C does not pose any problem Sollight can be supplied with a primer coat suitable for direct painting or for serigraphy 3 9 Examples of use Corners of boxes can be obtained easily with an appropriate process if small radii are made on the 4 edges and the quality of cut edge in the corner before bending is good The aesthetic appearance of the panel is thus improved thanks to the minimised gap in the corner Interesting applications for Sollight include cassette panels roof panels etc Credits Cover photograph by Tom D Haenens p 3 flat panel Promisol Fi4CN PAB DR p 5 Jacques Van den Berghe p 9 Tom D Haenens Copyright All rights reserved No part of this publication may be repro duced in any form or by any means whatsoever without prior written permission from ArcelorMittal Care has been taken to ensure that the information in this publication is accurate but this information is not contractual Therefore ArcelorMittal and any other ArcelorMittal Group company do not accept any liability for errors or omiss
14. th a thickness of 2 mm and an organic coating on both sides 25 um Test protocols available on request User Manual Sollight ArcelorMittal 2 6 Acoustic performance Two different criteria can be applied for the assessment of the acoustic performance of Sollight Acoustic insulation in transmission Acoustic insulation in transmission which evaluates the capac ity of a Sollight partition to insulate two adjacent spaces with regard to noise transmitted through the air Acoustic insulation effect R 27 dB according to EN 20717 1 R 26 dB A rose Vibration insulation Vibration insulation which evaluates the capacity of Sollight to attenuate the vibrations transmitted through the structure and therefore to reduce the acoustic radiation from a parti tion Vibration insulation 0 01 at 200 Hz Oberst method insulation at 23 C loz wa w Aluminium Steel Sollight NB 2 mm thick Sollight with organic coating finish 25 um on both sides If the thickness is increased to 3 mm attenuation is improved by 1 dB Finally as regards acoustic absorption it is obvious that the use of fully airtight skins makes it impossible to obtain good performance Acoustic insulation protocols available on request Performance 2u Impact resistance anti vandalism Sollight is highly resistant to piercing or denting Indeed when the size of the punch is large compared to the thickness of the Soll
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