Aluminium Alloys
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Transcript of Aluminium Alloys
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Aluminium Alloys – OverviewNaveed Akhtar
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Contents
1. Introduction
2. Chemistry
3. Classification
4. Applications
5. Manufacturing
6. Heat treatment
7. Common Defects
8. Conclusions
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Introduction Abundance
Oxygen
Aluminum Oxide / Bauxite
Silicon
Iron
All Others
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Introduction Advantages
• High strength to weight ratio
• High electrical and thermal conductivity
• High reflectivity and resistance to
corrosion
• Non-toxic (ideal for packaging and cooking
material)
• Ductility-easy to cold work and fabricate
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History Aluminum Production
• The first commercial batch of Aluminum
was produced in 1888
• Production Capabilities Lower the Price
– Between 1888 and 1893 Aluminum dropped
from $4.86/lb to $.78/lb
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• Early uses for Aluminum
– Cooking utensils
– Electrical wire and cable
– Foil
– Auto bodies
– Engine parts used by the Wright Brothers’
History Use
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Chemistry Alloying Elements
Ti, B, Zr, Cr, Ni, Bi, Pb
Cu, Mn, Mg, Si, Zn, Fe
Principal
Alloying
Elements
Additional
Alloying
Elements
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Role of Alloying Elements
Al
Cu
1. Increases strength and hardness2. If >12% makes the alloy brittle
3. Hot cracking tendency
4. Decreases corrosion resistance
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Role of Alloying Elements
Al
Mn
1. Increases yield and tensile strength
2. Improves ductility
3. Good resistance to corrosion
4. Decrease resistivity
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Role of Alloying Elements
Al
Si
1. Increases tensile strength and hardness uptil 13% wt.
2. Decrease the hot cracking
3. Good resistance to corrosion
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Role of Alloying Elements
Al
Mg
1. Increases strength and hardness
2. Good resistance to corrosion
3. Increase weldability and machinability
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Role of Alloying Elements
Al
Zn
1. Gives heat treatable alloys when combined with Mg
2. Increase strength and hardness
3. Increased toughness but susceptible to stress corrosion cracking
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Classification Alloy Designation System
Al
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Applications 1XXX
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Applications 2XXX
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Applications 3XXX
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Applications 4XXX
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Applications 5XXX
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Applications 6XXX
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Applications 7XXX
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Production Wrought Al Alloys
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Extrusion Process
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Heat Treatment Al Alloys
Annealing Treatment
Solution heat treatment
Precipitation (Hardening) treatment
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Before Solution Heat Treatment After Solution Heat Treatment
Heat Treatment
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Heat Treatment
Al-Cu phase diagram showing three steps in precipitation hardening 25
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Common Defects
Defect
Casting Defects
Extrusion Defects
Forging Defects
Heat Treatment
Defects
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Casting Defects
Cracks Porosity
Inclusions Segregation
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Cracks Types
Radial Loop TransverseCentric
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Cracks 7075
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Cracks 2024
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Inclusions Optical Images
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Inclusions SEM Images
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Inclusions SEM Analysis
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Inclusions Fracture surface
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Inclusions Fracture surface
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Extrusion Defects
Extrusion tears/ cracks
Scratches
Fish scalingUn-even wall thickness
Layer Formation
Coarse grain ring
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Drawing Defects
Scratch Bumped ring
Un-uniformity of wall thickness
Crack
Wrinkle End break
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Cracks in Extrusion Unetched form
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Cracks in Extrusion T6 etched form
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Heat treatment Defects
Unqualified mechanical properties
Over firing
Coarse grain Quenching cracks
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Grain Coarsening
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Control of Grain Coarsening
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