RUSAL, one of the world's largest aluminium producers, has successfully completed development and begun industrial tests of a new generation of MaxiFlow cylindrical billets, version 2.0. This innovation will enable RUSAL's customers to significantly increase extrusion speed and overall production efficiency. The predecessor of this new product—MaxiFlow 1.0—has already become one of the most in-demand products within RUSAL's product line.
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MaxiFlow 2.0 represents a high-quality cylindrical billet composed of the 6060 alloy within the Al-Mg-Si system. It was developed by RUSAL's proprietary research centre, the Institute of Lightweight Materials and Technologies (ILMT). MaxiFlow 2.0 billets will allow for a 10-15 per cent increase in extrusion speed when producing final products, compared to the previous version of MaxiFlow. This will ensure increased production efficiency for RUSAL's customers.
"The predecessor of the new product, MaxiFlow, was introduced to the market by RUSAL in 2019. MaxiFlow ingots combine the fastest possible extrusion process with high strength that meets international standards such as ASTM and EN. Compared to the standard line of 6XXX series alloys, MaxiFlow has allowed RUSAL customers around the world - from Taiwan and Russia to Turkey, Germany and Italy - to increase extrusion speed by 10-25 per cent. This speeds up the production process and allows us to resolve bottlenecks within the process chains," said Technical Director of RUSAL, Victor Mann.
According to Dmitry Ryabov, Director of Science at The Institute of Light Materials and Technologies (ILM&T), "The enhanced features of MaxiFlow 2.0 are primarily achieved through specialised heat treatable technology, alongside optimised chemical composition and homogenisation treatment. The development of MaxiFlow 2.0 took about a year, during which the product's declared performance was confirmed through laboratory and industrial tests. Industrial testing will conclude by the end of 2024."
The financial gain to customers from using MaxiFlow, compared to the standard line of billets, ranges from 30 to 70 Euros per tonne of metal. The product has quickly become one of RUSAL's most sought-after offerings: the Compound Annual Growth Rate (CAGR) of sales from 2019 to 2023 maintained an impressive rate of over 60 per cent. Currently, MaxiFlow accounts for over 70 per cent of all RUSAL billet production volume. Europe has become a leading region in capturing the provided benefits, strengthening both its domestic and international business projects.
When ordering MaxiFlow, RUSAL provides customers with technical support to help maximise productivity. Since 2019, over half a million tons of MaxiFlow cylindrical billets have been supplied to extrusion manufacturers worldwide, from Taiwan and Russia to Türkiye, Germany and Italy. Designed for diverse end-use industries, MaxiFlow alloys have, among other benefits, improved the production efficiency of window and door profiles, architectural and design elements, and automotive components. In particular, MaxiFlow billets meet the needs of fast-growing industries, such as frames for solar panels and batter trays for EV batteries.
MaxiFlow billets, made of ALLOW metal, incorporate an additional benefit of a low carbon footprint. RUSAL undergoes an independent audit of aluminium's carbon footprint, which, combined with the company's sustainability certifications, ensures transparency of supplies throughout the entire production chain. RUSAL's commitment to sustainability is underscored by its high ESG ratings, including the A-CDP climate rating from the Carbon Disclosure Project, highlighting the company's dedication to the green economy.
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