Aluminum and its Alloys Properties & Uses

Dr. Muhammad Riaz Bhatti

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Aluminum
Obtained from Bauxite (hydrated Al oxide) ore Main impurities of ore are silica, clay & Ti oxide Manufacturing:
Bauxite is first purified, then dissolved in fused cryolite (double fluoride of Al & Na) Al is then separated from solution by electrlysis at over 910 C
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Facility for producing aluminum sheet re-rolled directly from molten aluminum
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General Properties Aluminum

Some of the properties of Al are:
Light weight (sp gr = 2.7) Good electrical & thermal conductor Can be easily alloyed with elements such as Cu, Si.Mg, Zn, Mn etc

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Non-magnetic
Non-toxic
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Contd.General Properties Aluminum

Some of the properties of Al are:

High reflectivity for heat & radiant energy

Has high (atmospheric) Corrosion & oxidation resistance but correded in sea water Both ductile & malleable Tensile strength varies 95 to 157 MPa Has high strength to weight ratio Can be die-cast Pure Al has silvery colour & luster, while in commercial grades shows bluish tinge

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Uses of Aluminum
Food containers & packaging (25 %)

Construction/Architectural application such as

windows & sidings (20%) Electrical conductors, Machines, automotive & aeronautic industries, cooking utensils, due to light weight & corrosion resistance, (10%)

Rolled into sheets & wires, forged/extruded products Deoxidizer in steel making, Finely divided Al flakes used as pigments in paints
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Aluminum alloys

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Aluminum alloys

Drawing Aluminum Cans Forms and strengthens but need right alloy

Mechanical strength of Al-alloys enhanced by cold-working and alloying. Principal alloying elements include Cu, Mg. Si, Mn, & Zn.

Non-heat-treatable alloys consist of solid-solution hardened single-phase. Heat-treatable alloys are precipitation-hardened, where non-Al-elements usually form an intermetallic compound, e.g. MgZn2. 9 1/23/2013

Aluminum Alloys
Two major groups: cast & wrought Al alloys Cast alloys achieve their shapes as they solidify in molds or dies. Attractive features for cast alloys includes: low melting points high fluidity attractive as-solidified structure & properties
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Aluminum Alloys
Two major groups: : wrought & cast Al alloys Wrought Alloys are those that are shaped as solids (foil, sheet, plate, bar, rod, wire. tubing., & structural shapes such as channel, angles & Is) & have good forming characteristics e.g., low yield strength,

high ductility,
good fracture strength & good strain hardening
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AWS Welding Handbook

Chemical Composition of Aluminum Alloys

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Classification of Aluminum Alloys

Heat-Treatable Alloys Non-Heat-Treatable Alloys Can obtain increased strength Strengthened by worklevels through precipitation hardening and solid hardening solution strengthening Typical hardening additions include Cu, Mg, Zn, Si Elements such as Mn, Si, Fe, & Mg are typical solidsolution hardening agents

These additions show increasing solid solubility with Alloys of this type include increasing temperature the 1000, 3000, 4000 and 5000 series Alloys of this type include the 2000, 6000 and 7000 series
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Precipitation Hardening
Particles impede dislocations. Ex: Al-Cu system
Adapted from Fig. 11.22, Callister 6e.

Procedure:
--Pt A: solution heat treat (get a solid solution) --Pt B: quench to room temp. --Pt C: reheat to nucleate small crystals within structure

Other systems: Cu-Be, Cu-Sn, Mg-Al

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Formation of the compound

T a a+q

100% a

a+q
Coarse Fine

alloy composition

CB
By length of annealing time

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Important Al alloys
Al- Cu alloy: Duralumin ( Cu=3-4.5%, Mg, Si, Mn, Fe = 0.5% each) Cu increases hardness & strength of Al. Cu also increases corrosion resistance of this alloy, Si in combination with Mg increases hardness on heat treatment Mn acts as strengthening agent & prevents the formation of coarse grain structure during H/T Used in wrought condition for forging, stamping, bars, sheets, tubes & rivet Due to its high strength & high shock resistance, this alloy is used for making automobile & aircraft parts
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Important Al alloys
Al- Si alloy: Si increases the fluidity & casting characteristics of Al. Increase in Si contents improves mechanical properties, corrosion & oxidation resistance, Si also lowers the co-efficient of thermal expansion used for making pistons Sand & die casting (5% Si for general purpose), with higher Si content used for radiators, sumps, gear & large castings
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Important Al alloys
Y-alloy: This alloy contains 4% Cu, 2% Ni, 2.5% Mg & 91.5% Al. This combination of metals enables Al to have: High strength & corrosion resistance at high temperatures Easily cast & hot worked Y- alloy is used for making piston cylinder heads & crank cases of internal combustion engines, which are exposed to high temperatures Also used for die casting, pump rods & in sparking chisels in place of steel
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Some Applications of Aluminum Alloys

Heat-Treatable Alloys Non-Heat-Treatable Alloys 2014 Hydraulic fittings 1060 Chem Processing for aircraft and Tanks automotive 1100 Architectural 2036, 6009 Automotive 3003 General Purpose, Body Tanks 2219 tanks 5052 Sheet Applications 6061 Structural 6101 Electrical Conductors 7075 High Strength Aircraft
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Non-Heat Treatable Alloys Temper Designations

Designation O F H1 H2 H3 Description Annealed, Recrystalized As Fabricated Strain Hardened Strain Hardened & Annealed Strain Hardened & Stabilized Application Lowest Strength, High ductility Fabrication with no special control over thermal or strain hardening Strain hardened without subsequent anneal Strain hardened more than the desired amount and then partially annealed to strength Strain hardened and low temp stabilization treatment to prevent age softening

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Heat Treatable Alloys Temper Designations

Designation O F W T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 Description Annealed, Recrystalized As Fabricated Solution Heat Treatment Application Lowest Strength, High ductility Fabrication with no special control over thermal or strain hardening Unstable temper application with subsequent period of natural age Cooled and naturally aged Cooled, cold worked & Naturally aged Solution heat treated, cold worked & naturally aged Solution heat treated & naturally aged Cooled and artificially aged Solution heat treated and Stabilized Solution heat treated, stabilized to provide special property Solution heat treated, cold worked, artificially aged Solution heat treated, artificially aged, then cold worked Cooled, cold worked, then artificially aged
th

For a more extensive description see the table in AWS Welding Handbook, Vol 3, 8 Ed. Page 9
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Thanks

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Mechanical Properties of some Aluminum Alloys

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Mechanical Properties of Some Aluminum Alloys

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Mechanical Properties of Some Aluminum Alloys (CONT.)

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Effect of Temperature on Mechanical Properties of Aluminum Alloys

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Effect of Temperature on Mechanical Properties of Aluminum Alloys (CONT.)

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Effect of Temperature on Mechanical Properties of Aluminum Alloys (CONT.)

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Mechanical and Physical Properties of Some Automotive Alloys

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