Alloying Material Specification - Alcoa

1 B Alloying Material Specification Specification No. MS 2-2610-W Applies To: Aluminum Hardener Revision No. Original Issue Type: 10%Zr Effective Date 02/15/2011 Form: Open Mold or Waffle Page 1 of 19 TABLE OF CONTENTS Section Page 1. Scope and Classification ..2 2. Applicable Reference Documents ..2 The Aluminum Association European Standard American Society for Testing and Materials American National Standards Institute Government and Industry Standards 3. Product Requirements ..4 Material Condition Chemical Composition Metallurgical Requirements Microstructure Requirements Performance Requirements Dimensional Requirements 4. Quality Assurance Requirements ..6 Identification Quality Control / Statistical Process Control Record Retention Vendor Audits Product Testing Packaging Certification Documentation Shipping Basis of Acceptance 5. Ordering Information ..12 6. Informational Notes ..12 Product Approval / Qualification Process Change Evaluations / Approvals Specification Change History / Approvals Appendix I: Test Procedure for Determining the Solution Rate and Recovery of Aluminum Master Alloys and Briquettes.

2 15 Signature Page ..18 b Alloying Material Specification Specification No. MS 2-2610-W Applies To: Aluminum Hardener Revision No. Original Issue Type: 10%Zr Effective Date 02/15/2011 Form: Open Mold or Waffle Page 2 of 19 SUPPLIER / CUSTOMER INFORMATION This document may contain sensitive technical information that has been reviewed in confidence between Alcoa , Inc. and the manufacturer ( vendor ) of Alloying materials. Therefore, the contents of this Specification should be divulged only to persons who by nature of their duties require access to such information. 1. Scope and Classification This purchase Specification defines metallurgical, chemical, dimensional, quality and general requirements of materials used to produce aluminum alloys for re-melting and/or fabrication. 2. Applicable Reference Documents Current revisions of the following documents in effect on the date of purchase order, unless a specific issue is referenced, form a part of this Specification to the extent specified herein.

3 In the event of conflict between the requirements of this Specification and the requirements of any other applicable document, the requirements of this Specification shall prevail. The Aluminum Association Registration Record of Aluminum Association Designations and Chemical Composition Limits for Aluminum Hardeners European Standard EN 575:1995 Aluminium and aluminium alloys Master alloys produced by melting - Specifications American Society for Testing and Materials ASTM E3 Preparation of Metallographic Specimens b Alloying Material Specification Specification No. MS 2-2610-W Applies To: Aluminum Hardener Revision No. Original Issue Type: 10%Zr Effective Date 02/15/2011 Form: Open Mold or Waffle Page 3 of 19 ASTM E29 Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications ASTM E88 Practice for Sampling Nonferrous Metals and Alloys in Cast Form for Determination of Chemical Composition American National Standards Institute ANSI/ASQC Q-1 Generic Guidelines for Auditing of Quality Systems ANSI Designation for Aluminum Hardeners ANSI Self Certification by Producer or Supplier ANSI Calibration Laboratories and Measuring and Test Equipment General Requirements Government and Industry Standards ISO 10012 Quality Assurance Requirements for Measuring Equipment ToSCA Toxic Substance Control Act CONEG Coalition of Northeastern Governors Requirements CFR 29, CFR 49 Code of Federal Regulations Hazardous Materials CFR 40 Part 82 Protection of Stratospheric Ozone, Subpart E: Labeling of Products Using Ozone Depleting Substance.

4 Alcoa Test Procedure for Determining the Solution Rate and Recovery of Aluminum Master Alloys and Briquettes (Appendix I) b Alloying Material Specification Specification No. MS 2-2610-W Applies To: Aluminum Hardener Revision No. Original Issue Type: 10%Zr Effective Date 02/15/2011 Form: Open Mold or Waffle Page 4 of 19 3. Product Requirements Each shipment shall be subject to inspection by the receiving location. NOTE: The term commercially free of is a subjective (non-quantified) statement that defines quality that must meet industry norms. If, in the buyer s opinion, the product does not meet expected normal industry standards, the Material may be subject to rejection. Material Condition External: Product shall be skimmed and free of surface or entrained oxides, salts, and reaction products. Edges and surfaces shall be free of sharp protrusions, spurs and/or flash that might present hazards in handling.

5 Internal: Surfaces shall be smooth and free of internal voids that connect to the surface, open shrinkage, porosity, seams and/or folds. Contamination: Materials shall be commercially free of contamination and products of corrosion. The presence of foreign substances, surface or imbedded, such as discrete non-aluminum fragments, iron, oxide flakes, rust, fertilizers, nitrates, oxidizers, and hygroscopic salts shall be cause for rejection. Abrasive mechanical, or other means of cleaning ingot, shall not include ferrous materials. Purity: The base Material shall be aluminum of sufficient purity to meet the specified chemical composition. Chemical Composition Element(s) Minimum Target Maximum Zr (zirconium) Fe (iron) Si(silicon) Mn (manganese) MgO (magnesium oxide) Sn Nb Pb+Cd (lead+cadmium) < Al (aluminium) Remainder Others Each Max Others Each Total b Alloying Material Specification Specification No.

6 MS 2-2610-W Applies To: Aluminum Hardener Revision No. Original Issue Type: 10%Zr Effective Date 02/15/2011 Form: Open Mold or Waffle Page 5 of 19 Metallurgical Requirements Structures shall display cleanliness and uniformity characteristic of consistent metallurgical practices and acceptable solidification processing. This master alloy shall display microstructures consistent with morphology established at the time of product qualification, or as described under paragraph Microstructure Requirements Products that must meet specific microstructure requirements and features or characteristics of Material quality shall be sampled by the vendor and checked for conformance. Based on a sample size of 2 sq. cm., microstructures shall display metallurgical features consistent with established standards of solution rate, recovery, and other parameters of performance, and shall display evidence of sound supplier process and product quality control.

7 The following lists specific characteristics and what is acceptable. Drosslike Cause for Rejection ZrAl3 Majority <80 microns with max <500 microns ZrAl3 Undesirable. Max 10 up to 500 microns and 1 at 500 to 1000 microns acceptable. Performance Requirements Using the test procedure, described in Appendix I, a minimum recovery of at least 99% of the Alloying element is required within 5 minutes of starting the test. Ultimately, 100% should be recovered. Dimensional Requirements The following represents typical ordered dimensions and weights. Specific requirements and alternate dimensions shall be specified on the order: Form Dimension Weight Open Mold or Waffle inch ( ) X 9 inch (229mm) X 18 inch (457mm) 19 lb. ( kg.) +/- 10% Open Mold or Waffle 2 inch (51mm) X 4 inch (102mm) X 20 inch (508mm) 12 lb. ( kg.) +/- 10% b Alloying Material Specification Specification No. MS 2-2610-W Applies To: Aluminum Hardener Revision No.

8 Original Issue Type: 10%Zr Effective Date 02/15/2011 Form: Open Mold or Waffle Page 6 of 19 4. Quality Assurance Requirements The vendor s Quality System shall conform to requirements of ISO 9001 (current revision). The Quality System shall be available at all times for review and approval by Alcoa personnel. Identification Alphanumeric Marking: Each pallet or packaged unit shall display easily referenced and legible identification that includes the name of the vendor, product identification (product type), heat identification traceable to the manufacturing process, lot identification if separate, and producing location. Bar coding, supported by written information, is desirable. Color Coding: Each package of Material shall be color coded in accordance with the following table. In most cases, these color codes are the same as those registered and published in the Aluminum Association (AA) Designation and Chemical Composition Limits for Aluminum Hardeners based on ANSI or in the European Committee for Standardization (CEN) - EN 575:1995.

9 NOTE: Some colors listed in the AA and CEN standards present a risk in product identification due to 1) same color codes for different Material specifications or 2) different color codes for the same Material specifications. Under these conditions, the color codes listed in this Alloying Material Specification shall prevail. Form Color Coding Special Marking Open Mold or Waffle Each stack shall be marked with one (1) dark blue stripe using ink or paint. (AA color code 2005) NOTE: If produced to EN 575 chemistry specifications, color code shall be one (1) dark blue stripe and two (2) red stripes. Package shall be labeled with producer's name, type of product and heat number. Open Mold or Waffle Same as above. Same as above. Quality Control / Statistical Process Control Quality Systems & Procedures: Manufacturing facilities (vendors) shall maintain consistent operations and demonstrate adherence to their formal Quality Systems.

10 Quality Systems shall consist of written or electronic b Alloying Material Specification Specification No. MS 2-2610-W Applies To: Aluminum Hardener Revision No. Original Issue Type: 10%Zr Effective Date 02/15/2011 Form: Open Mold or Waffle Page 7 of 19 controls including Standard Operating Procedures, inspection and testing procedures (methods, frequency, acceptance limits) and records retention. Procedures shall ensure timely delivery and product performance consistent with terms of this Specification . Calibration Requirements: The vendor s calibration system shall conform to ISO 10012 and be compliant with the requirements of ANSI , or an approved equivalent standard. Statistical Process Control: Vendors should use Statistical Process Control (SPC) techniques relevant to their processes to evaluate state of control, to determine process capability, to verify product acceptability, to evaluate measurement/testing process repeatability and reproducibility, and to aid in improvement of process and product performance.