Aluminum

alloys

Production engineering department

Alexandria University

Lecture report

MATERIAL

Name : kounoz elsaid Mohamed

elsaid khattab

SEC:5

SEAT NO:118

Aluminum extrusion dies for hollow parts

Hollow dies
Take a variety of forms. Bridge, porthole, and
spider dies, for example, include a fixed stub
mandrel as an integral part of the die. Each
type of hollow extrusion die serves certain
functions and carries its own advantages and
disadvantages. The manufacturing methods
and costs vary widely. The choice of design,
and even manufacturing methods, will depend
on the profile, press and container size, and
.production requirements

A critically important characteristic of extrusion dies is

that the effective bearing length controls the metal
flow through the die.
The objective is to have all parts of the profile emerge
from the die at the same speed.
The longer the bearing length, the greater the
resistance to the flow of aluminum and the shorter the
bearing length, the less resistance to flow.
Through effective design, the thick parts of a profile
can be slowed through the use of longer bearings to
match the speed of the thinner parts with short
bearings.

ALLOY SELECTION
:The most common aluminum alloys for extrusion are

It's soft and has essentially no added 1100

ingredients. Although not heat treatable, it can be
extruded into complex shapes that have a good bright
finish. This alloy finds use in appearance items and
.heat-exchanger tubes
The 3000 Series alloys are usually only extruded 3003
.for heat-exchanger tube
A good match for decorative purposes with a 6063
good surface finish or for features difficult to extrude
such as thin walls or fine details. It extrudes fairly
easily and is available in multiple tempers. The alloy
also has 25,000 psi minimum yield and 30,000 psi
minimum ultimate strength when T6 tempered. It
resists corrosion but has a low weld strength though it
.welds readily
Stronger than 6063, this alloy is a structural 6061
staple in the transportation and machined parts
industries. It has a proven track record and an
extensive database of properties which include
minimum ultimate yield and tensile strengths of 35,000
and 38,000 psi, respectively. The alloy extrudes and
welds readily. These attributes coupled with high
fracture toughness and good fatigue strength have
made it a shoe-in for welded structural members which
include auto, truck and trailer frames, railroad cars,
.and pipelines
One in a family of "low end" 7000 Series (Al-Zn) 7004
alloys that are press heat treatable, reasonably
extrudable, and cost a little more than 6061. High-weld
strength, over 30,000 psi compared to 20,000 psi for
6061, is a major plus. The 7000 Series has historically
been widely applied in the sporting goods, bicycle, and
motorcycle industries. The 7004 alloy has ultimate
yield and tensile strengths above 40,000 and 50,000
.psi, respectively

Aluminum for Rigid Containers

manufacturing
Rigid Containers
Rigid containers are stiff packages, usually of metal sheet
and usually round in shape. This type, known familiarly as
"cans", originated in the days of Napoleon. Some rigid
containers employ foil laminated to a stiff nonmetallic
backing sheet. Others are smooth-wall containers drawn
from heavy-gage foil. Rigid containers should protect the
product and withstand reasonable handling without
deformation or breakage.
The can industry is the largest segment of the packaging
complex. Cans are generally made from steel, tin-coated
steel, aluminum, a combination of fiber and aluminum foil,

or plastic. Most rigid containers are cylindrical. This shape

utilizes the container material efficiently, but the greatest
advantage is that it permits manufacturing, drilling, and
closing at high speeds with exacting control. Almost all beer,
beverage, vegetable, fruit, dog food, and motor-oil
containers are cylindrical.

Aluminum Alloys

The aluminum alloys commonly used are 1100, 3003, 5052,

5082, 5086, and 5154.
The alloys with low yield strength and high elongation are
easy to form, whereas those with high yield strength and
low elongation can be used only for simple forms such as
can ends.

Aluminum for electrical equipment

manufacturing

Category
of the
Products

Product
Descriptio
n

Electrical Enclosures
and
electronics

Alloy Name

Other Applications

High quality anodized

aluminum alloy sheets
(A-series)
6000 series sheets for
enclosure (AX61, MX61)
Dream Lube (Pre-coated
high lubricating
aluminum)

Automotive and
transportation,
equipment and
machine parts

Battery
cases

Aluminum alloy sheets

for lithium-ion battery
cases (LB series)

Heat
dissipatin
g parts

High electrical
conductivity aluminum
alloy sheets (997B,
E601, N601, N52S)

Automotive and
transportation

Plated aluminum alloy

sheets

Automotive and
transportation