Documente Academic
Documente Profesional
Documente Cultură
EF420 Lecture 11
John Taylor
Qualmet Services
Features
Qualmet Services
Extraction
Al2O3 obtained from bauxite by the Bayer
process
Al2O3 reduced electrolytically by the HallHeroult process to make aluminium
Qualmet Services
Fabrication
Ductile metal easily fabricated by rolling and
extrusion
Qualmet Services
Aluminium products
Cast alloys
Wrought products
Structural applications
Static building structures AS1664 series
Scaffolding and ladders
Transportation
Consumer durables
Reflectors
Qualmet Services
Miscellaneous applications
Packaging
Qualmet Services
Limits of use
Temperature range of -240C to +200C for
normal alloys
Up to 350C for special alloys
Up to 480C for short periods for dispersion
strengthened alloys
Low modulus of elasticity, requires stiffening
Inferior wear, creep, & fatigue properties to
steel
Qualmet Services
10
Designation
1xxx
Al-Cu
2xxx
Al-Mn
3xxx
Al-Si
4xxx
Al-Mg
5xxx
Al-Mg-Si
6xxx
Al-Zn
7xxx
Al + other element
8xxx
Qualmet Services
12
Description
-O
Annealed
-F
-H1x
-H2x
-H3x
Qualmet Services
13
Qualmet Services
14
Solution treatment -
alloy is heated into
temperature range to
dissolve all B. Quenching
retains B in solution
(supersaturated)
Pure A
Percentage B
Qualmet Services
Strengthened condition
15
Composition effects
Alloys with low levels of B will only display a weak age
hardening effect
Alloys with a high level of , which cannot be dissolved on
solution treatment only display a weak hardening effect
Alloys with with intermediate levels of B have the highest
strengthening effect
These alloys only display a narrow temperature range for the
single phase () phase field
These alloys also have a wide solidification range, are likely to
crack during welding, and therefore have low weldability and
castability
Qualmet Services
16
Qualmet Services
17
Temper designations
T1
T2
T4
T5
T3
Qualmet Services
18
Temper designations
T6
T7
T8
T9
T10
Qualmet Services
19
Qualmet Services
20
3000 Series
Up to 1.2Mn + Fe in some alloys
Eg 3004: 1.2Mn-1.0Mg
3004-H38
22
Eg 5083: 4.4Mg-0.7Mn-0.15Cr
Qualmet Services
25
6000 series
Combination of Mg and Si allows precipitation
hardening with Mg2Si precipitates
Eg 6061: 1Mg-0.6Si-0.3Cu-0.2Cr
Alclad
Many multiphase alloys have inferior corrosion
resistance
These alloys are available as Alclad sheet or
plate
This material has a thin layer of pure aluminium
roll bonded to one or both surfaces to provide
corrosion resistance
Fabrication must be undertaken so as to
maintain the integrity of this coating
Qualmet Services
28
Dispersion strengthened
Precipitates resist dissolution at high temperatures
(up to 340C)
Powder metallurgy (P/M) products
SAP - sintered aluminium product (Al2O3)
Metal matrix composites
Rapid solidification (RS-P/M) hypereutectoid iron
alloys (plus other systems)
Mechanical alloying
Qualmet Services
39
Dispersion strengthening
Proprietary and standard alloys
Can be welded but with some loss of properties
Aerospace applications
Qualmet Services
40
Aluminium lithium
1 to 4% Lithium raises strength, raises elastic
modulus by up to 6%, lowers density by up to 4%
Strengthened by Al3Li, Al2CuMg, AL2CuLi precipitates
on aging (depending on composition)
41
Fabrication
Qualmet Services
42
Qualmet Services
43
Joining processes
GTAW and GMAW are the most common processes
OFW and MMAW require powerful fluxes
Resistance and pressure processes can be used for
many alloys
Brazing and soldering some application
Adhesives and mechanical fastening widely
applicable
Qualmet Services
44
Weldability
Depends on welding process and alloy
composition
Varies from readily weldable (eg wrought
alloys by GTAW or GMAW) to not
recommended (eg brazing of 2014)
Qualmet Services
45
Fusion welding
Qualmet Services
46
GTAW technique
Power type
Qualmet Services
48
GMAW technique
Fine electrode wire tends to suffer feeding
problems
Feeders and guns
Qualmet Services
49
Metal transfer
Spray transfer
Pulsed GMAW
Qualmet Services
50
Technique
Porosity
Cleanliness
Preheat
Weld craters
Qualmet Services
51
Avoidance of cracking
Tensile strength of weld
Weld ductility
Service temperature
Corrosion resistance
Colour match after anodising
Qualmet Services
52
Solidification cracking
Use matching filler for strain-hardened grades
No autogenous welding
Avoid high dilution
Medium copper grades are unweldable
Qualmet Services
53
Crack sensitivity
5
6
7
Percentage Copper
5
6
7
Percentage Magnesium
Qualmet Services
54
HAZ cracking
Liquation cracking can occur in the HAZ of
age hardenable grades
Qualmet Services
55
HAZ properties
Heat of fusion welding causes softening of work
hardened grades
Effect of temper
HV 110
6061-T4, PWA
100
90
6061-T6, PWA
80
6061-T6, AW
6061-T4, AW
70
60
Qualmet Services
10
15
20
Distance from fusion line mm
58
Qualmet Services
59
Brazing
Restricted range of alloys
Qualmet Services
60
References