Quality Issues

of
6000 Series Billets
…..By S.Nanda, NALCO
 Extruders’ Viewpoint

- Good Extrudability
- Good Surface finish
- Adequate mechanical properties
 Billet Quality Determined by..
• Pot Line metal + Scrap / Scrap + Re-
melt ingots
• Alloying materials
• Casting process and skill of operators
• Homogeneity of process
 Chemical Attributes

• Major elements : Mg + Si

• Hardening mechanism
– Solution + Precipitation
(Excess Si / Mg) Hardening (Mg2 Si)
Quality of Billets Measured by..

• Chemical attributes

• Physical attributes

• Metallurgical attributes
 Minor Elements
• Na > 100 ppm Extrudability

• Fe > 0.15 % Brightening

(combines with Si, % Mg2Si and

and reduces strength.)
• Copper but corrosion resistance

• Mn extrudability
aids beta to alpha transformation
• Cr and Zr Dispersoid elements inhibits
recrystalisation
 Physical Attributes
Dimensional

Attribute Measured by Tolerances

Diameters Gauges + / - 0.5%
Lengths Gauges + / - 25 / 5
(Cast/sawn)
Sawn face straight edge 90 Deg + 1 Deg
 Surface Related
Free from
• Cracks
• Porosity
• Laps
• Folds
• Bleds
• Bleed outs
• Entrained oxides
• Non metallic particles
 Metallurgical Attributes
• Grain Size
– Measure of product consistency
• Sampling : from butt or head
• Preparation: Fine machining and macro etching
• Method:
– Macro: Graticuled eye–piece with stereo microscope
estimated to nearest 50 micron
• Micro:
– Sections from edge, mid radius and centre of slices
– Polished etched and observed under polarised light
– Intercept Method
Recommended grain size < 180 microns
 Segregation and chill zone

• Chill Zone: Sub-surface area

of different grain structure.
Typical values for quality billet
< 3 mm
• Segregation Zone: Forms at
surface because of partial re-
melting of the solidified
aluminium.

Typical Values < 200 microns

Relation between
surface finish and near
surface structure

• Poorer the surface

finish deeper the
segregation zone.
 Secondary Dendrite Arm Spacing
(SDAS)
• Finer SDAS  Hot strength of billet skin
 more effective in homogenising
process

( SDAS )2 = Dx . T

Dx = Diffusion co-efficient of element x in Al

T = time
Typical SDAS value
Conventional cast – 50 micron
Air slip – 25 micron
 Hardness
• Measurement at mid radius position of slices using
500 kg load with a 10 mm ball
• Indication of consistency of homogenisation

Low Hardness
– large undissolved Mg2Si
- Incomplete beta to alpha
transformation
 Inclusions

• Measurements on billets
– Dye penetratant test
– Ultrasonic

For inclusion > 4 mm - 100 % co-relation

1.5 – 2 mm – 40% correlation
< 1 mm - < 1 % correlation
 Measurement in Liquid metal

• LAIS, Podfa + Limca

• Origin
– Poor furnace practice
– Launders
– TUrbulence
• Effect
- Streaking
- Streaking index – (No of die
changes between 3rd to 30th
log)
(Recommended values < 0.02
mm2/Kg of metal)
 Hydrogen

• Cause: Difference in solubility between

liquid and solid aluminium
• Effect: Porosity  Mechanical strength
– Blisters
– Tears
• Measurement
- Alscan
(Recommended values < 0.2 cc/100 gm of metal)
 Precipitation and inter metallic phase

• Objectives of homogenisation:
1) Dissolution of Mg and Si in Al Matrix and
reprecipitation in fine uniform manner
– Just visible at 500 X magnification and etching in
0.5% HF
– Cooling rate > 200 Deg C / Hr critical

2) Transformation and refinement of beta to alpha Al –

Fe - Si
– Temperature controlled
 Microstructural analysis of homogenised
samples
• Mg2Si - Dark grey or black
– Sub micron to 2 microns
– Within and at grain boundaries
– Align along <100> direction
• Beta Al Fe Si
– Charcoal grey
– At grain boundaries
– Acicular, high aspect ratio
– 5 – 15 microns
• Alpha Al Fe Si
– Smaller size
– Rounded, lower aspect ratio
Microstructure of Homogenised samples
Recommended values for good extrudability
• Beta to Alpha transformation greater than
or equal to 95%
• Fe phase size
– Minimum 85% less than or equal to 10
microns
– Maximum 15% 10 to 30 microns
– Size of beta phase 10 micron max.

• Mg2Si Size
– 0.3 to 1 micron