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A project report On

To study the effect of heat treatment processes on the properties of Aluminum 6063 alloy
Submitted for partial fulfillment of award of BACHELOR OF TECHNOLOGY Degree In Mechanical Engineering By Navneet Verma 0713340063 Bhuvneshwar Prasad Panchal 0713340029 Nikhil Kumar Singh 0713340064 Ajay Kumar 0713340003

Name of guide Mr. Sandeep Chauhan

MECHANICAL ENGINEERING DEPARTMENT NOIDA INSTITUTE OF ENGINEERING & TECHNOLOGY Greater Noida

DECLARATION
We hereby declare that this submission is our own work and that, to the best of our knowledge and belief, it contains no material previously published or written by another person nor material which to a substantial extent has been accepted for the award of any other degree or diploma of the university or other institute of higher learning, except where due acknowledgment has been made in the text. Bhuvneshwar Prasad Panchal Navneet Verma

Nikhil Kumar Singh Ajay Kumar

CERTIFICATE

Certified that Navneet Verma, Bhuvneshwar Prasad Panchal, Ajay Kumar, Nikhil Kumar Singh have carried out the research work presented in this project entitled To study the effects of heat treatment processes on the properties of Aluminum 6063 alloy for the award of Bachelor Of Technology Degree from Uttar Pradesh Technical University, Lucknow under my supervision. The project embodies result of original work and studies carried out by Student himself and the contents of the project do not form the basis for the award of any other degree to the candidate or to anybody else.

Mr. Sandeep Chauhan Sr. Lecturer NIET, Gr.Noida Date: June 2011

ACKNOWLEDGEMENT

I believe that hard work is the only way to success to achieve something worthy. With feeling of immense gratitude and respect, I extend my deep sense of gratitude to thank my guide Mr. SANDEEP CHAUHAN for their continuous support throughout this work. Their incredulous guiding spirit and helping hand at every step of my project has led to its successful completion. This project was a learning experience for me. Workings in different labs provide a real time experience of engineering. & technology being used, currently, in manufacturing industry. Finally I would like to thank Mr.Mahipal without their help this project would not have been possible and their support during this period has been inspired me to accomplish it. Bhuvneshwar Prasad Panchal (0713340029) Ajay Kumar Navneet Verma Nikhil Kumar Singh (0713340003) (0713340063) (0713340064)

TABLE OF CONTENTS

Declaration Certificate Acknowledgement Table of Contents List of Figure List of Table Abstract Chapter 1- Introduction 1.1 Introduction of Heat Treatment 1.1.1.Stages Of Heat Treatment And Its Purposes

i ii iii iv v vi 01-19 01 03

1.2 The Objects Of Heat Treating Aluminium And Its Alloys 1.3. Classification Of Heat Treatment 1.4. Tempering 1.5. Annealing 1.5.1. Objectives Of Annealing 1.5.2. Stages Of Annealing 1.6. Normalizing 1.6.1. Objectives Of Normalizing 1.7. Hardening 1.7.1. Objectives Of Hardening 1.8. Heat Treatment: Capabilities And Limitations 1.9. Introduction Of Aluminium

05 06 07 07 08 08 08 09 09 10 10 11

1.9.1. Characteristics 1.9.2. Applications 1.9.3. Aluminium Alloys 1.9.3.1. Aluminium Alloys In Structural Applications 1.9.3.2. Aluminium6063 Alloy 1.9.3.3. Chemical Composition Of Aluminium6063 Alloy 1.9.3.4. Physical Properties 1.9.3.5. Mechanical Properties 1.10. Important Mechanical Properties Chapter 2- Literature Review 2.1. Literature Review Chapter 3- Methodology Of Test Performed 3.1. Methodology Of Project 3.2. Test Performed On Aluminium 6063 Alloy 3.2.1. Tensile Test 3.2.1.1. Tensile Test Specimen 3.2.2. Izod Impact Test 3.2.3. Charpy Impact Test 3.2.4. Rockwell Hardness Test Chapter 4- Results And Analysis 4.1. Test Performed 4.1.1. Tensile Test 4.1.2. Impact Test By Izod Method 4.1.3. Impact Test By Charpy Method 4.1.4. Rockwell Hardness Test 4.2. Microstructures Of Aluminium 6063 Alloy Chapter 5- Conclusion

12 13 14 15 16 17 17 17 18 20-23 21 24-29 25 26 26 26 27 28 28 30-44 31 31 37 39 42 44 45

5.1. Conclusion 5.2. Future Scope Of Aluminium 6063 Alloy References Appendix 1 Appendix 2

46 46 47 48 50

LIST OF FIGURES

S.No.
Fig 4.1 Fig 4.2 Fig 4.3 Fig 5.1 Fig 5.2 Fig 5.3

Title
Tensile Test Specimen Izod Test Specimen Charpy Test Specimen Microstructure After Quenching Microstructure After Normalizing Microstructure After Annealing

Page No.
32 38 40 44 44 44

LIST OF TABELS

S.No.
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10

Title
Tensile Test Table Before Heat Treatment Tensile Test Table After Normalizing Tensile Test Table After Quenching Tensile Test Table After Annealing Izod Impact Test Table Before Heat Treatment Izod Impact Test Table After Quenching Izod Impact Test Table After Normalizing Izod Impact Test Table After Annealing Charpy Impact Test Table Before Heat Treatment Charpy Impact Test Table After Quenching

Page No.
31 32 34 35 37 38 39 39 40 41

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4.11 4.12 4.13 4.14 4.15 4.16

Charpy Test Table After Normalizing Charpy Test Table After Annealing Rockwell Hardness Test Table Before Heat Treatment Rockwell Hardness Test Table After Quenching Rockwell Hardness Test Table After Normalizing Rockwell Hardness Test Table After Annealing

41 42 42 43 43 43

ABSTRACT
Heat treatment processes for aluminium are precision processes. Based on the objectives of this research, precipitate free zones in the aluminium alloy 6063 actually give bad effect to the mechanical properties of that alloy. The mechanical properties of the aluminium alloy should be altering properly to improve their behavior using precipitation hardening which one of the heat treatment types. Precipitation hardening is the most suitable heat treatment that should use to minimize the precipitate free zones in the microstructure of the aluminium alloy 6063. In the precipitation hardening process, the thermal and temperature condition is under control

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with high precision to ensure the transformation of the aluminium alloy structure is in good condition and supervision limit. The samples of the material are placed in the furnace to make a heat treating process and then quench it in the water for quenching medium. The material testing that had been applied is based on hardness, impact and microstructure analysis. The purpose of the hardness testing are to find out the hardness reading for all the samples that used to look the wear resistance effect that occur after make a heat treating process to the aluminium alloy 6063. From the impact test, the purposes are to know impact energy that absorbed to fracture the samples of the material and then make a comparison data between after and before heat treatment. Lastly, for microstructure analysis it is important to determine because to look the narrow evaluation of precipitate free zones in the microstructure of aluminium alloy after make a precipitation hardening processes. From the data and result that already determined, it shown the positive result based on objectives and scope of this project.

CHAPTER -1

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INTRODUCTION

1.1 INTRODUCTION OF HEAT TREATMENT

Heat treatment is a group of industrial and metal working processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering and quenching. It is noteworthy that while the term heat treatment applies only to processes where the heating and cooling are done for the specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding. Metallic materials consist of a microstructure of small crystals called "grains" or crystallites. The nature of the grains (i.e. grain size and composition) is one of the most

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effective factors that can determine the overall mechanical behavior of the metal. Heat treatment provides an efficient way to manipulate the properties of the metal by controlling rate of diffusion, and the rate of cooling within the microstructure. There are two mechanisms that may change an alloy's properties during heat treatment. The martensite transformation causes the crystals to deform intrinsically. The diffusion mechanism causes changes in the homogeneity of the alloy. The crystal structure consists of atoms that are grouped in a very specific arrangement, called a lattice. In most elements, this order will rearrange itself, depending on conditions like temperature and pressure. This rearrangement, called allotropy or polymorphism, may occur several times, at many different temperatures for a particular metal. In alloys, this rearrangement may cause an element that will not normally dissolve into the base metal to suddenly become soluble, while a reversal of the allotropy will make the elements either partially, or completely insolubles

1.1.1. STAGES OF HEAT TREATMENT AND ITS PURPOSES

The term heat treatment for aluminium alloys is frequently restricted to the specific operations employed to increase strength & hardness of the precipitation-hardenable wrought and cast alloys. Heat Treatment- the term heat treatment may be defined as an operation or a combination of operations, involving the heating and cooling of a metal or an alloy in the solid state for the purpose of obtaining certain desirable conditions or properties without change in chemical composition. These usually are referred to as the heat treatable alloys to distinguish them from those alloys in which no significant strengthening can be achieved by heating and cooling. Heat treating in its broadest sense refers to any of the heating and cooling operations are performed for the purpose of changing the mechanical properties, metallurgical structure, or the residual stress state of the metal product . Heat treatment applied to aluminium and its alloys are preheating or homogenizing to reduce chemical segregation of cast structures and to improve material workability. Annealing

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to soften strain hardened and heat treated alloy components to relieve stresses and to stabilize properties and dimensions. Precipitation (age-hardening) heat treatment to provide hardening by precipitation of constituents from solid solution. Solution heat treatment to improve mechanical properties by putting alloying elements into solution. Heat treatment is a collection through may processes such as Annealing, Stress relief, Quenching, Tempering, normalizing and ageing. All the different heat treatment process consists the following three stages-. 1- Heating of the material. 2- Hold the temperature for a time (soaking time). 3- Cooling usually to room temperature (Normalizing). However the temperature and time for the various processes is dependent on the material mechanism controlling the wanted effect. The purpose of heat treatment is to achieve one or more of the following object To increase the hardness of metals. To relieve the stresses set up in the material after hot or cold working. To improve Machinability. To soften the metal. To modify the structure of the material to improve its electrical and magnetic properties. To change the grain size. To increase the qualities of the metal to provide better resistance to heat, corrosion and wear. Improve ductility and toughness.

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Pure aluminum is too soft for most structural applications and therefore is usually alloyed with several elements to improve its corrosion resistance, inhibit grain growth and of course to increase the strength. The optimum strengthening of aluminum is achieved by alloying and heat treatments that promote the formation of small, hard precipitates which interfere with the motion of dislocations. Aluminum alloys that can be heat treated to form these precipitates are considered heat treatable alloys. Pure aluminum is not heat treatable because no such particles can form while many heat treatable aluminum alloys are not wieldable because welding would destroy the microstructure produced by careful heat treatment. Virtually all heat treatable aluminum alloys are strengthened by precipitation hardening. Precipitation hardening involves raising the temperature of the alloy into the single phase region so that all of the precipitates dissolve. The alloy is then rapidly quenched to form a supersaturated solid solution and to trap excess vacancies and dislocation loops which can later act as nucleation sites for precipitation. The precipitates can form slowly at room temperature (natural aging) and more quickly at slightly elevated temperatures, typically 100C to 200C (artificial aging). The degree of hardening obtained depends on the size, number and relative strength of the precipitates. These factors are determined by the composition of the alloy and by the tempering temperature and tempering time. Proper heat treating requires precise control over temperature, the amount of time that an alloy remains at a certain temperature, and in the cooling rates of the particular technique. With the exception of stress-relieving, tempering, and aging, most heat treatments begin by heating an alloy beyond the upper transformation (A3) temperature. The alloy will usually be held at this temperature long enough for the heat to completely penetrate the alloy, thereby bringing it into a complete solid solution. Since a smaller grain size usually enhances mechanical properties, such as toughness, shear strength and tensile strength, these metals are often heated to a temperature that is just above the upper critical temperature, in order to prevent the grains of solution from growing too large. For instance, when steel is heated above the upper critical temperature, small grains of austenite form. These grow larger as temperature is increased. When cooled very quickly, during a martensite transformation, the

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austenite grain size directly affects the martensitic grain size. Larger grains have large grainboundaries, which serve as weak spots in the structure. The grain size is usually controlled to reduce the probability of breakage. The diffusion transformation is very time dependent. Cooling a metal will usually suppress the precipitation to a much lower temperature. Austenite, for example, usually only exists above the upper critical temperature. However, if the austenite is cooled quickly enough, the transformation may be surpressed for hundreds of degrees below the lower critical temperature. Such austenite is highly unstable and, if given enough time, will precipitate into various microstructures of ferrite and cementite. The cooling rate can be used to control rate of grain growth or can even be used to produce partially martensitic microstructures. However, the martensite transformation is time-independent. If the alloy is cooled to the martensite transformation temperature before other microstructures can fully form, the transformation will usually occur at just under the speed of sound.

1.2. THE OBJECTS OF HEAT TREATING ALUMINIUM ALLOYS

Speaking very generally, there are two principal purposes in view when aluminium and its alloys are industrially heat treated. These are broadly:(i) Strengthening or hardening and (ii) Annealing or softening

There are other objects in subjecting aluminium and its alloys to heat treatments and these include the alteration of electrical or corrosion properties, the release of casting stresses and the admission of permanent growth in , for example, pistons; these latter objects are however of minor importance as compared with the two main objectives indicated above.

1.3. CLASSIFICATION OF HEAT TREATMENT

Various types of heat treatment processes may be classified as follows:-

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1. Tempering a) Austempering b) Mar tempering c) Temperature based i) Low temperature tempering ii) Medium temperature tempering iii) High temperature tempering 2. Annealing a) Process annealing c) Spheroids annealing 3. Normalizing 4. Hardening a) Case hardening (or carburizing) c) Induction hardening e) Cyaniding b) Flame hardening d) Age hardening e) Nitriding b) Full annealing d) Diffusion annealing

1.4 TEMPERING
Tempering is a heat treatment technique for metals, alloys and glass. In steels, tempering is done to "toughen" the metal by transforming brittle martensite or Bainite into a combination of ferrite and cementite or sometimes tempered martensite. Precipitation hardening alloys, like many grades of aluminum and super alloys are tempered to precipitate

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intermetallic particles which strengthen the metal. Tempering is accomplished by a controlled reheating of the work piece to a temperature below its lower critical temperature. The brittle martensite becomes tough and ductile after it is tempered. Carbon atoms were trapped in the austenite when it was rapidly cooled, typically by oil or water quenching, forming the martensite. The martensite becomes strong after being tempered because when reheated, the microstructure can rearrange and the carbon atoms can diffuse out of the distorted body-centered-tetragonal (BCT) structure. After the carbon diffuses, the result is nearly pure ferrite with body-centered structure. In metallurgy, there is always a trade-off between strength and ductility. This delicate balance highlights many of the subtleties inherent to the tempering process. Precise control of time and temperature during the tempering process are critical to achieve a metal with well balanced mechanical properties.

1.5. ANNEALING
Annealing, in metallurgy and materials science, is a heat treatment wherein a material is altered, causing changes in its properties such as strength and hardness. It is a process that produces conditions by heating to above the recrystallization temperature, maintaining a suitable temperature, and then cooling. Annealing is used for inducing ductility, soften material, relieve internal stresses, refine the structure by making it homogeneous, and improve cold working properties. In the cases of copper, steel, silver, and brass, this process is performed by substantially heating the material (generally until glowing) for a while and allowing it to cool. Unlike ferrous metalswhich must be cooled slowly to annealcopper, silver and brass can be cooled slowly in air or quickly by quenching in water. In this fashion the metal is softened and prepared for further work such as shaping, stamping, or forming.

1.5.1. OBJECTIVES OF ANNEALING

To soften the aluminium so that it may be easily machined or cold worked.

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To refine the grain size & structure to improve mechanical properties like strength & ductility.

To relieve internal stresses which may have been caused by hot & cold working or by unequal contraction in casting.

To alter electrical magnetic or other physical properties. To remove gases trapped in the metal during initial casting.

1.5.2. STAGES OF ANNEALING

There are three stages in the annealing process, with the first being the recovery phase, which results in softening of the metal through removal of crystal defects (the primary type of which is the linear defect called a dislocation) and the internal stresses which they cause. Recovery phase covers all annealing phenomena that occur before the appearance of new strain-free grains. The second phase is recrystallization, where new strain-free grains nucleate and grow to replace those deformed by internal stresses. If annealing is allowed to continue once recrystallization has been completed, grain growth will occur, in which the microstructure starts to coarsen and may cause the metal to have less than satisfactory mechanical properties.

1.6. NORMALIZING
Normalizing is a type of heat treatment applicable to ferrous metals only. It differs from annealing in that the metal is heated to a higher temperature and then removed from the furnace for air cooling. The purpose of normalizing is to remove the internal stresses induced by heat treating, welding, casting, forg-ing, forming, or machining. Stress, if not controlled, leads to metal failure; therefore, before hardening steel, you should normalize it first to ensure the maximum desired results. Usually, low-carbon steels do not require normalizing; however, if these steels are normalized, no harmful effects result. Castings are usually annealed, rather than normalized; however, some castings require the normalizing treatment.

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Table 2-2 shows the approximate soaking periods for normalizing steel. Note that the soaking time varies with the thickness of the metal. Normalized steels are harder and stronger than annealed steels. In the normalized condition, steel is much tougher than in any other structural condition. Parts subjected to impact and those that require maximum toughness with resistance to external stress are usually normalized. In normalizing, the mass of metal has an influence on the cooling rate and on the resulting structure. Thin pieces cool faster and are harder after normalizing than thick ones. In annealing (furnace cooling), the hardness of the two are about the same.

1.6.1. OBJECTIVES OF NORMALIZING

To refine the grain structure of the aluminum to improve the machaniabilty tensile strength & structure of weld. To remove strains caused by cold working processes like hammering rolling, bending etc which makes the metal brittle & unreliable. To remove dislocations caused in the internal structure of the aluminum due to hot working. To improve certain mechanical & electrical properties.

1.7. HARDENING
The hardening treatment for most steels consists of heating the steel to a set temperature and then cooling it rapidly by plunging it into oil, water, or brine. Most steels require rapid cooling (quenching) for hardening but a few can be air-cooled with the same results. Hardening increases the hardness and strength of the steel, but makes it less ductile. Generally, the harder the steel, the more brittle it becomes. To remove some of the brittleness, you should temper the steel after hardening. Many nonferrous metals can be hardened and their strength increased by controlled heating and rapid cooling. In this case, the process is called heat treatment, rather than hardening. To harden steel, you cool the metal

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rapidly after thoroughly soaking it at a temperature slightly above its upper critical point. The approximate soaking periods for hardening steel are listed in table 2-2. The addition of alloys to steel decreases the cooling rate required to produce hardness. A decrease in the cooling rate is an advantage, since it lessens the danger of cracking and warping. Pure iron, wrought iron, and extremely low-carbon steels have very little hardening properties and are difficult to harden by heat treatment. Cast iron has limited capabilities for hardening. When you cool cast iron rapidly, it forms white iron, which is hard and brittle. And when you cool it slowly, it forms gray iron, which is soft but brittle under impact. In plain carbon steel, the maximum hardness obtained by heat treatment depends almost entirely on the carbon content of the steel. To perform hardening process, Al-alloy is heated to a temperature above its critical range. It is held at this temperature for a considerable time and then allowed to cool by quenching in water, oil, brine solution.

1.7.1. OBJECTIVES OF HARDENING

To increase the hardness of the metal so that it can resist wear. To enable it to cut other metals i.e. to make it suitable for cutting tools.

Various factors responsible for hardness in aluminium alloy are the following: Quenching rate Work size

1.8. HEAT TREATMENT: CAPABILITIES AND LIMITATIONS

Heat treatments are an established, if obscure, method of disinfesting certain empty structures and equipment. Since the anticipated phase-out of methyl bromide fumigants, interest in this non-chemical pest management technique has been growing. Many of the advantages, disadvantages, considerations, observations, costs and results of using heat to

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disinfest empty food processing and storage structures are situational in reality. Like fumigation with methyl bromide, successful heat treatments depend upon trained personnel, careful preparation, employee cooperation, good weather, etc. Some possible advantages of a heat treatment include the following Perceived to be less dangerous than fumigation Fewer regulations than associated with fumigation Can monitor and adjust treatment easier than fumigation More effective than fumigation of a leaky structure More effective against pathogenic microorganisms

Some possible disadvantages of a heat treatment include the following Generally ineffective at penetrating commodities and debris Significantly more expensive than a methyl bromide fumigation Exposure period may be longer than for a methyl bromide fumigation Strong potential for damage to equipment and structure Less known about actual heat treatments than fumigations

1.9. INTRODUCTION OFALUMINIUM

Aluminium is a silvery white member of the boron group of chemical elements. It has the symbol Al and its atomic number is 13. It is not soluble in water under normal circumstances. Aluminium is the most abundant metal in the Earth's crust, and the third most abundant element, after oxygen and silicon. It makes up about 8% by weight of the Earth's solid surface. Aluminium is too reactive chemically to occur in nature as a free metal. Instead, it is found combined in over 270 different minerals. The chief source of aluminium is bauxite ore.

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Aluminium is remarkable for the metal's low density and for its ability to resist corrosion due to the phenomenon of passivation. Structural components made from aluminium and its alloys are vital to the aerospace industry and are very important in other areas of transportation and building. Its reactive nature makes it useful as a catalyst or additive in chemical mixtures, including ammonium nitrate explosives, to enhance blast power. Despite its prevalence in the environment, aluminium salts are not known to be used by any form of life. Also in keeping with the element's abundance, it is well tolerated by plants in soils (in which it is a major component), and to a lesser extent, by animals as a component of plant materials in the diet (which often contain traces of dust and soil). Soluble aluminium salts have some demonstrated toxicity to animals if delivered in quantity by unnatural routes, such as injection. Controversy still exists about aluminums possible longterm toxicity to humans from larger ingested amounts.

1.9.1. CHARACTERISTICS
Aluminium is a soft, durable, lightweight, ductile and malleable metal with appearance ranging from silvery to dull gray, depending on the surface roughness. Aluminium is nonmagnetic and no sparking. It is also insoluble in alcohol, though it can be soluble in water in certain forms. The yield strength of pure aluminium is 711 MPa, while aluminium alloys have yield strengths ranging from 200 MPa to 600 MPa. Aluminium has about one-third the density and stiffness of steel. It is easily machined, cast, drawn and extruded. Corrosion resistance can be excellent due to a thin surface layer of aluminium oxide that forms when the metal is exposed to air, effectively preventing further oxidation. The strongest aluminium alloys are less corrosion resistant due to galvanic reactions with alloyed copper. This corrosion resistance is also often greatly reduced when many aqueous salts are present, particularly in the presence of dissimilar metals. Aluminium atoms are arranged in a face-centered cubic (fcc) structure. Aluminium is one of the few metals that retain full silvery reflectance in finely powdered form, making it an important component of silver paints. Aluminium mirror finish has the highest reflectance of

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any metal in the 200400 nm (UV) and the 3,00010,000 nm (far IR) regions; in the 400 700 nm visible range it is slightly outperformed by tin and silver and in the 7003000 (near IR) by silver, gold, and copper. Aluminium is a good thermal and electrical conductor, having 62% the conductivity of copper. Aluminium is capable of being a superconductor, with a superconducting critical temperature of 1.2 Kelvins and a critical magnetic field of about 100 gauss (10 milliteslas).

1.9.2. APPLICATIONS
Aluminium is the most widely used non-ferrous metal. Global production of aluminium in 2005 was 31.9 million tonnes. It exceeded that of any other metal except iron (837.5 million tonnes). Forecast for 2012 is 4245 million tons, driven by rising Chinese output. Relatively pure aluminium is encountered only when corrosion resistance and/or workability is more important than strength or hardness. A thin layer of aluminium can be deposited onto a flat surface by physical vapour deposition or (very infrequently) chemical vapour deposition or other chemical means to form optical coatings and mirrors. When so deposited, a fresh, pure aluminium film serves as a good reflector (approximately 92%) of visible light and an excellent reflector (as much as 98%) of medium and far infrared radiation. Pure aluminium has a low tensile strength, but when combined with thermo-mechanical processing, aluminium alloys display a marked improvement in mechanical properties, especially when tempered. Aluminium alloys form vital components of aircraft and rockets as a result of their high strength-to-weight ratio. Aluminium readily forms alloys with many elements such as copper, zinc, magnesium, manganese and silicon (e.g., duralumin). Today, almost all bulk metal materials that are referred to loosely as "aluminium", are actually alloys. For example, the common aluminium foils and beverage cans are alloys of 92% to 99% aluminium. Some of the many uses for aluminium metal are in:

Transportation (automobiles, aircraft, trucks, railway cars, marine vessels, bicycles etc.) as sheet, tube, castings etc.

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Packaging (cans, foil, etc.) Construction (windows, doors, siding, building wire, etc.)

A wide range of household items, from cooking utensils to baseball bats, watches.

Street lighting poles, sailing ship masts, walking poles etc. Outer shells of consumer electronics, also cases for equipment e.g. photographic equipment.

Electrical transmission lines for power distribution

MKM steel and Alnico magnets Super purity aluminium (SPA, 99.980% to 99.999% Al), used in electronics and CDs. Heat sinks for electronic appliances such as transistors and CPUs. Substrate material of metal-core copper clad laminates used in high brightness LED lighting.

Powdered aluminium is used in paint, and in pyrotechnics such as solid rocket fuels and thermite.

Aluminium can be reacted with hydrochloric acid to form hydrogen gas. A variety of countries, including France, Italy, Poland, Finland, Romania, Israel, and the former Yugoslavia, have issued coins struck in aluminium or aluminium-copper alloys.[39]

Some guitar models sports aluminium diamond plates on the surface of the instruments, usually either chrome or black. Kramer Guitars and Travis Bean are both known for having produced guitars with necks made of aluminium, which gives the instrument a very distinct sound.

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1.9.3. ALUMINIUM ALLOYS

Aluminium alloys are alloys in which aluminium (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon, and zinc. There are two principal classifications, namely casting alloys and wrought alloys, both of which are further subdivided into the categories heat-treatable and non-heat-treatable. About 85% of aluminium is used for wrought products, for example rolled plate, foils and extrusions. Cast aluminium alloys yield cost effective products due to the low melting point, although they generally have lower tensile strengths than wrought alloys. The most important cast aluminium alloy system is Al-Si, where the high levels of silicon (4.0% to 13%) contribute to give good casting characteristics. Aluminium alloys are widely used in engineering structures and components where light weight or corrosion resistance is required. Alloys composed mostly of the two lightweight metals aluminium and magnesium have been very important in aerospace manufacturing since somewhat before 1940. Aluminium-magnesium alloys are both lighter than other aluminium alloys and much less flammable than alloys that contain a very high percentage of magnesium. Aluminium alloy surfaces will keep their apparent shine in a dry environment due to the formation of a clear, protective layer of aluminium oxide. In a wet environment, galvanic corrosion can occur when an aluminium alloy is placed in electrical contact with other metals with more negative corrosion potentials than aluminium. Aluminium alloy compositions are registered with The Aluminum Association. Many organizations publish more specific standards for the manufacture of aluminium alloy, including the Society of Automotive Engineers standards organization, specifically its aerospace standards subgroups, and ASTM International.

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1.9.3.1. ALUMINIUM ALLOYS IN STRUCTURAL APPLICATIONS

Aluminium alloys with a wide range of properties are used in engineering structures. Alloy systems are classified by a number system (ANSI) or by names indicating their main alloying constituents (DIN and ISO). The strength and durability of aluminium alloys vary widely, not only as a result of the components of the specific alloy, but also as a result of heat treatments and manufacturing processes. A lack of the knowledge of these aspects has from time to time led to improperly designed structures and gained aluminium a bad reputation. One important structural limitation of aluminium alloys is their fatigue strength. Unlike steels, aluminium alloys have no well-defined fatigue limit, meaning that fatigue failure eventually occurs, under even very small cyclic loadings. This implies that engineers must assess these loads and design for a fixed life rather than an infinite life. Another important property of aluminium alloys is their sensitivity to heat. Workshop procedures involving heating are complicated by the fact that aluminium, unlike steel, melts without first glowing red. Forming operations where a blow torch is used therefore require some expertise, since no visual signs reveal how close the material is to melting. Aluminium alloys, like all structural alloys, also are subject to internal stresses following heating operations such as welding and casting. The problem with aluminium alloys in this regard is their low melting point, which make them more susceptible to distortions from thermally induced stress relief. Controlled stress relief can be done during manufacturing by heattreating the parts in an oven, followed by gradual coolingin effect annealing the stresses. The low melting point of aluminium alloys has not precluded their use in rocketry; even for use in constructing combustion chambers where gases can reach 3500 K. The Agena upper stage engine used a regeneratively cooled aluminium design for some parts of the nozzle, including the thermally critical throat region.

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1.9.3.2. ALUMINIUM 6063 ALLOY

Al 6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. The standard controlling its composition is maintained by The Aluminum Association. It has generally good mechanical properties and is heat treatable and weld able. It is similar to the British aluminium alloy HE9. 6063 Aluminium alloy is mostly used in extruded shapes for architecture, particularly window frames, door frames, and roofs. It is typically produced with very smooth surfaces fit for anodizing.

1.9.3.3. CHEMICAL COMPOSITION OF ALUMINIUM 6063 ALLOY Table1.1-Chemical Composition Of Aluminium 6063 Alloy
Cu 0.10 Si 0.20 / 0.60 Fe 0.35 Mn 0.10 Mg 0.45 / 0.90 Zn 0.10 Cr 0.10 Ti 0.10 Al Balance

1.9.3.4. PHYSICAL PROPERTIES OF ALUMINIUM 6063 ALLOY

Table1.2-Physical Properties Of Aluminum 6063 Alloy

Property Density Melting point Modulus of elasticity Electrical resistivity Thermal conductivity Thermal expansion Value 2.70g/cm3 750oC 69.5GPa 0.35 x 10-6 ohm 200 W/mK 23.5 x 10-6 /K

1.9.3.5. MECHANICAL PROPERTIES

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Table1.3- Mechanical Properties

Temper Minimum proof stress 0.2% (MPa) Minimum tensile strength (MPa) Shear strength(MPa) Elongation (%) Hardness Vickers O 50 100 70 22 25 T4 60 130 110 21 50 T6 160 195 150 14 80

1.10. IMPORTANT MECHANICAL PROPERTIES

a) TENSILE STRENGTH:It is the ability of the material to resist the externally applied forces without breaking or yielding. Tensile strength measures the force required to pull something such as rope, wire, or a structural beam to the point where it breaks. The tensile strength of a material is the maximum amount of tensile stress that it can take before failure, for example breaking.

b) HARDNESS:Hardness is the measure of how resistant solid matter is to various kinds of permanent shape change when a force is applied. Macroscopic hardness is generally characterized by strong intermolecular bonds, however the behavior of solid materials under force is complex, therefore there are different measurements of hardness: scratch hardness, indentation hardness, and rebound hardness. Hardness is dependent on ductility, elasticity, plasticity, strain, strength, toughness, visco-elasticity, and viscosity. Common examples of hard matter are ceramics, concrete, certain metals, and super hard materials, which can be contrasted with soft matter

c) BRITTLENESS:A material is brittle if, when subjected to stress, it breaks without significant deformation (strain). Brittle materials absorb relatively little energy prior to fracture, even those of high strength. Breaking is often accompanied by a snapping sound. Brittle materials include most ceramics and glasses (which do not deform plastically) and some polymers, such

30

as PMMA and polystyrene. Many steels become brittle at low temperatures (see ductile-brittle transition temperature), depending on their composition and processing. When used in materials science, it is generally applied to materials that fail in tension rather than shear, or when there is little or no evidence of plastic deformation before failure. When a material has reached the limit of its strength, it usually has the option of either deformation or fracture. A naturally malleable metal can be made stronger by impeding the mechanisms of plastic deformation (reducing grain size, dispersion strengthening, work hardening, etc.), but if this is taken to an extreme, fracture becomes the more likely outcome, and the material can become brittle. Improving material toughness is therefore a balancing act.

d) DUCTILITY:The property of metal which permits it to be reduced in cross sectional area without fracture. In a tensile test, ductile metals show considerable elongation eventually failing by necking, with consequent rapid increase in local stresses. It is the property of the material enabling it to be drawn into wire with the application of a tensile force. A ductile material material must be both strong and plastic. The ductility is usually measured by the terms %age elongation and %age reduction in area. The ductile material commonly used in engineering practice ( in order of diminishing ductility) are mild steel , copper, aluminium, nickel, zinc, tin and lead.

31

CHAPTER - 2 LITERATURE REVIEW

32

2.1. LITERATURE REVIEW

Heat treatment processes for aluminium are precision processes. Based on the objectives of this research, precipitate free zones in the aluminium alloy 6063 actually give bad effect to the mechanical properties of that alloy. The mechanical properties of the aluminium alloy should be altering properly to improve their behavior using precipitation hardening which one of the heat treatment types. Precipitation hardening is the most suitable heat treatment that should use to minimize the precipitate free zones in the microstructure of the aluminium alloy 6063. In the precipitation hardening process, the thermal and temperature condition is under control with high precision to ensure the transformation of the aluminium alloy structure is in good condition and supervision limit. The samples of the material are placed in the furnace to make a heat treating process and then quench it in the water for quenching medium. The material testing that had been applied is based on hardness, impact and microstructure analysis. The purpose of the hardness testing are to find out the hardness reading for all the samples that used to look the wear resistance effect that occur after make a heat treating process to the aluminium alloy 6063. From the impact test, the purposes are to know impact energy that absorbed to fracture the samples of the material and then make a comparison data between after and before heat treatment. Lastly, for microstructure analysis it is important to determine because to look the narrow evaluation of precipitate free zones in the microstructure of aluminium alloy after make a precipitation hardening processes. From the data and result that already determined, it shown the positive result based on objectives and scope of this project.

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The literature review of existing heat treatments indicates that heat straightening with maximum temperature limited to 1200F is relatively similar to the process annealing heat treatment. Heat straightening with maximum temperature limited to 1400oF is similar to the normalizing annealing heat treatment. Both these heat treatments repair plastically deformed microstructure by the phenomenon known as recovery and recrystallization. Normalizing annealing is more efficient and faster than process annealing in repairing the plastically deformed microstructure by recrystallization. Heat treatment and repair of the material microstructure is incidental to the heat straightening repair process. The heat straightened beam can be further heat treated to complete the repair of the material microstructure (recrystallization etc.). The practical and economic feasibility of additional heat treatment using electrically powered and controlled radiant heaters was evaluated and found to be reasonable. The effects of heat treatment on the dynamic compressive properties and energy absorption characteristics of open cell aluminium 6063 alloy produced by infiltrating process were studied. various kinds of heat treatment were exploited such as quenching normalising and annealing. Tensile compressive and hardness test has been performed to define the properties of aluminium 6063 alloy. The results show that tha hardness of the alloy increases also it softens on quenching the grain structure also define by the tests .

The effects of solution-ageing treatment on the mechanical properties of aluminium 6063 products were studied by the method of orthogonal experiment. The mechanical properties at different treatment conditions were analyzed. The results show that the effects of heat treatment were obviously influenced by the original microstructure of the aluminium 60603. Higher temperature is favorable for the sufficient solution of alloy elements, but the grains will grow up when treated at a higher temperature or soaked for a longer time. There is a contradiction between the maximum tensile strength and elongation percentage. The surplus phases not melted in the substrate and the solution precipitated supersaturated elements are the main factors influencing the properties of the alloys.

34

To examine the effectiveness of the treatment, simulating experiments are conducted using a heat-treatable 6063 aluminum alloy, and the grain size, hardness property, and tensile properties are measured and compared with those of the conventionally heat-treated sheets. The results are summarized as follows: (1) resistance heating at a current density of about 100 A mm2 realizes heating the aluminum alloy sheet into the solution temperature range in 2 s, (2) complete achievement of rapid solution treatment by the resistance heating requires the condition that the precipitates exist finely in the matrix, (3) the new treatment decreases the grain size by approximately one-half but the mechanical properties are not remarkably improved. A systematic experimental investigation of the effect of heat-treatment technique on the mechanical properties of 6063 aluminum alloy was carried out. Particularly, an artificial neural network and a genetic algorithm were used to search for the optimum technique, adapted for 6063 aluminum alloy. The results indicated strongly that an artificial neural network combined with a genetic algorithm indeed offer a new effective means for the optimization of materials processing technique. A series of heat treatments were made on samples cut from bars of a 6063 heat treatable aluminum alloy that were solubilized for 4 h at 520 C, and were cooled down to room temperature by placing one of their ends into a shallow tank of water to produce a continuous thermal gradient along their length. Heating and cooling are carried simultaneously for carrying out different tests. Various test are being conducted on different equipments such as UTM machine is being used for testing compressive and tensile tests of aluminium 6063 alloy . for hardness test Rockwell hardness test is being conducted IZOD and Charpy tests are being conducted to find the impact strength of aluminium 6063 alloy. These tests are performed on different temperatures for carrying out Quenching, Normalising and Annealing processes and results are being calculated.

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CHAPTER - 3 METHODOLOGY AND TESTS PERFORMED

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3.1. METHODOLOGY OF PROJECT

1) Take the aluminium 6063 alloy 2) Now make specimen of required dimension for different tests like tensile test, Charpy test, and Izod test. 3) We will test its mechanical properties like hardness, brittleness, impact, tensile & compressive strength on respective machines such as Rockwell hardness m/c, impact testing m/c, Universal Testing Machine etc. 4) Now we start performing the heat treatment processes which are suitable for aluminium 6063 alloy one by one.

a)

ANNEALING: - Anneal at 525oC for 3 hours in muffle furnace. It is cooled inside the
furnace itself. Where parts have been solution heat-treated a maximum cooling rate of 20C per hour must be maintained until the temperature is reduced to 290C. Below this temperature, the rate of cooling is not important.

b)

NORMALIZING: - Normalized is at 525oC for 3 hrs and then it is taken out from
furnace and cooled in the atmospheric air.

37

c)

HARDENING: - Hardening is performed at 525oC for 3 hrs and then immediately

quenched in water. This is applicable to the heat treatable alloys and involves a heat treatment process whereby the alloying constituents are taken into solution and retained by rapid quenching. Subsequent heat treatment at tower temperatures i.e. ageing or natural ageing at room temperature allows for a controlled precipitation of the constituents thereby achieving increased hardness and strength. Time at temperature for solution treatment depends on the type of alloy and the furnace load. Sufficient time must be allowed to take the alloys into solution if optimum properties are to be obtained.

5) Now we will again measure all the mechanical properties which we had checked earlier. 6) Now compare the properties of aluminium 6063 alloy before & after heat treatment

3.2. TESTS PERFORMED ON ALUMINUM 6063 ALLOY

3.2.1. TENSILE TEST
Tensile testing, also known as tension testing, is a fundamental materials science test in which a sample is subjected to uniaxial tension until failure. The results from the test are commonly used to select a material for an application, for quality control, and to predict how a material will react under other types of forces. Properties that are directly measured via a tensile test are ultimate tensile strength, maximum elongation and reduction in area. From these measurements the following properties can also be determined: Young's modulus, Poisson's ratio, yield strength, and strain-hardening characteristics.

3.2.1.1. Tensile Test Specimen

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A tensile test specimen is a standardized sample cross-section. It has two shoulders and a gage section in between. The shoulders are large so they can be readily gripped, where as the gage section has a smaller cross-section so that the deformation and failure can occur in this area. The shoulders of the test specimen can be manufactured in various ways to mate to various grips in the testing machine (see the image below). Each system has advantages and disadvantages; for example, shoulders designed for serrated grips are easy and cheap to manufacture, but the alignment of the specimen is dependent on the skill of the technician. On the other hand, a pinned grip assures good alignment. Threaded shoulders and grips also assure good alignment, but the technician must know to thread each shoulder into the grip at least one diameter's length, otherwise the threads can strip before the specimen fractures. In large castings and forgings it is common to add extra material, which is designed to be removed from the casting so that test specimens can be made from it. These specimen not be exact representation of the whole work piece because the grain structure may be different throughout. In smaller work pieces or when critical parts of the casting must be tested, a work piece may be sacrificed to make the test specimens. For work pieces that are machined from bar stock, the test specimen can be made from the same piece as the bar stock.

3.2.2. IZOD IMPACT TEST:Izod impact strength testing is an ASTM standard method of determining impact strength. A notched sample is generally used to determine impact strength. The test is named after the English engineer Edwin Gilbert Izod (18761946), who described it in his 1903 address to the British Association, subsequently published in Engineering. The specimen is clamped into the pendulum impact test fixture with the notched side facing the striking edge of the pendulum. The pendulum is released and allowed to strike through the specimen. If breakage does not occur, a heavier hammer is used until failure

39

occurs. Since many materials (especially thermoplastics) exhibit lower impact strength at reduced temperatures, it is sometimes appropriate to test materials at temperatures that simulate the intended end use environment. Impact is a very important phenomenon in governing the life of a structure. In the case of aircraft, impact can take place by the bird hitting the plane while it is cruising, during take off and landing there is impact by the debris present on the runway An arm held at a specific height (constant potential energy) is released. The arm hits the sample and breaks it. From the energy absorbed by the sample, its impact strength is determined. The dimensions of a standard specimen for ASTM D256 are 4 x 12.7 x 3.2 mm (2.5" x 0.5" x 1/8"). The most common specimen thickness is 3.2 mm (0.125"), but the width can vary between 3.0 and 12.7 mm (0.118" and 0.500"). This test can also be used to determine the notch sensitivity.

3.2.3 CHARPY IMPACT TEST:The Charpy impact test, also known as the Charpy v-notch test, is a standardized high strain-rate test which determines the amount of energy absorbed by a material during fracture. This absorbed energy is a measure of a given material's toughness and acts as a tool to study temperature-dependent brittle-ductile transition. It is widely applied in industry, since it is easy to prepare and conduct and results can be obtained quickly and cheaply. But a major disadvantage is that all results are only comparative. The test was developed in 1905 by the French scientist Georges Charpy. It was pivotal in understanding the fracture problems of ships during the Second World War. Today it is used in many industries for testing building and construction materials used in the construction of pressure vessels, bridges and to see how storms will affect materials used in building.

40

The apparatus consists of a pendulum axe swinging at a notched sample of material. The energy transferred to the material can be inferred by comparing the difference in the height of the hammer before and after a big fracture. The notch in the sample affects the results of the impact test, thus it is necessary for the notch to be of regular dimensions and geometry. The size of the sample can also affect results, since the dimensions determine whether or not the material is in plane strain. This difference can greatly affect conclusions made. The "Standard methods for Notched Bar Impact Testing of Metallic Materials" can be found in ASTM E23, ISO 148-1 or EN 10045-1, where all the aspects of the test and equipment used are described in detail.

3.2.4. ROCKWELL HARDNESS TEST

The Rockwell scale is a hardness scale based on the indentation hardness of a material. The Rockwell test determines the hardness by measuring the depth of penetration of an indenter under a large load compared to the penetration made by a preload. There are different scales, which are denoted by a single letter, that use different loads or indenters. The result, which is a dimensionless number, is noted by HRX where X is the scale letter. When testing metals, indentation hardness correlates linearly with tensile strength. This important relation permits economically important nondestructive testing of bulk metal deliveries with lightweight, even portable equipment, such as hand-held Rockwell hardness testers

41

42

CHAPTER - 4 RESULTS AND ANALYSIS

4.1. TESTS PERFORMED

4.1.1. TENSILE TEST BEFORE HEAT TREATMENT:a- Original dimensions: Diameter of specimen (d1) = 10mm

Cross sectional area of specimen (A1)=

)2 mm2 = 78.53mm2

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Gauge length of specimen (l1) = 5.65

= 50.0 mm

b- Final dimensions: Diameter of specimen (d2) = mm

Cross sectional area of specimen (A2)=

)2 mm2

Gauge length of specimen (l2) = 5.65

Table No.4.1- Tensile Test Table Before Heat Treatment S.No Ultimate load (kN) strength= (MPa) 235.5 206.9 229.1 Extension (l2-l1) mm area = Ultimate % elongation = % reduction in

1 2 3

18.5 16.25 18.0

60-50=10 58-50=8 59-50=9

20 16 18

84.00 80.66 82.36

Mean diameter at breaking point = 4.2mm 1- Mean Ultimate strength = (235.5+206.6+229.1) / 3 = 223.8 MPa

2- Mean % elongation = (20+16+18) / 3 = 18 %

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3- Mean % reduction in area = (84+80.66+82.36) / 3 = 82.34 %

FFig 4.1 Tensile Test Specimen Before Heat Treatment

AFTER HEAT TREATMENT:i) TENSILE TEST AFTER NORMALIZING:-

Table No.4.2- Tensile Test Table After Normalizing S.No Ultimate load (kN) Extension (l2-l1) mm Ultimate strength= area = % elongation = % reduction in

1 2 3

8.5 9 9.2

64-50=14 63-50=13 64-50=14

(MPa) 108.2 114.6 117.15

28 26 28

82.36 81.5 82.36

Area =/4(D12)

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= /4(10)2 = 78.53 mm2

Ultimate strength =

1000

(i) Ultimate strength= (8.5 x1000) / 78.53 = 108.2 MPa (i) Ultimate strength= (9 x1000) / 78.53 = 114.6 MPa (iii) Ultimate strength= (9.2 x1000) / 78.53 = 117.15 MPa Mean ultimate strength = (108.2+114.6+117.15) / 3 = 113.31 MPa

Percentage elongation =

(i) % age elongation = [(64-50) / 50] x100 = 28% (ii) % age elongation = 26% (iii) % age elongation = 28% Mean percentage elongation = (28+26+28) / 3 = 27.33 %

Percentage reduction in area =

A1=78.53 mm2 (i) A2= /4 x (4.2)2 = 13.85 mm2 %age reduction= 82.36% (ii) A2= /4 x (4.3)2 = 14.52 mm2 %age reduction= 81.5%

46

(iii) A2= /4 x (4.2)2 = 13.85 mm2 %age reduction= 82.36% Mean reduction in area = (82.36+81.5+82.36) / 3= 82.07% ii) TENSILE TEST AFTER QUENCHING:-

Table No.4.3- Tensile Test Table After Quenching S.No Ultimate load (kN) Extension (l2-l1) mm Ultimate strength= area = % elongation = % reduction in

1 2 3

9.75 60-50=10 10 63-50=13 9.5 61-50=11 2 Area =/4(D1 ) = /4(10)2 = 78.5mm2

(MPa) 124.15 127.15 120.97

20 26 22

76.9 84.00 19.63

Ultimate strength =

1000

(i) Ultimate strength= (9.75 x1000) / 78.53 = 124.15 MPa (ii) Ultimate strength= (10 x1000) / 78.53 = 127.33 MPa (iii) Ultimate strength= (9.5 x1000) / 78.53 = 120.97 MPa Mean ultimate strength = (12.15 + 127.33 + 120.97) / 3 = 124.15 MPa

47

Percentage elongation =

(i) % age elongation = [(60-50) / 50]x100 = 20% (ii) % age elongation = [(63-50) / 50]x100 = 26% (iii) % age elongation = [(61-50) / 50]x100 = 22% Mean percentage elongation = (20+26+22) / 3 = 22.66 %

Percentage reduction in area =

A1=78.53 mm2 (i) A2= /4 x (4.8)2 = 18.095 mm2 %age reduction= [(78.53-18.0955) / 78.53] x100 = 76.9% (ii) A2= /4 x (4)2 = 12.56 mm2 %age reduction= 84.0% (iii) A2= /4 x (5)2 = 19.6325 mm2 %age reduction= 75.0% Mean reduction in area = (76.9+ 84+ 75) / 3= 78.63% iii) TENSILE TEST AFTER ANNEALING:-

Table No.4.4- Tensile Test Table After Annealing

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S.No

Ultimate load (kN)

Extension (l2-l1) mm

Ultimate strength=

% elongation =

% reduction in area =

1 2 3

6 68-50=18 6 66-50=16 6 68-50=18 2 Area =/4(D1 ) = /4(10)2 = x 25= 78.5 mm2

(MPa) 76.403 78.95 77.25

36 32 36

87.7 85.5 87.7

Ultimate strength =

1000

(i) Ultimate strength= (6 x1000) / 78.53 = 76.403 MPa (ii) Ultimate strength= (6 x1000) / 78.53 = 78.95 MPa (iii) Ultimate strength= (6 x1000) / 78.53 = 76.403 MPa Mean ultimate strength = (76.403+78.95+76.403) / 3 = 77.25 MPa

Percentage elongation =

(i) % age elongation = [(68-50) / 50]x100 = 36% (ii) % age elongation = 32% (iii) % age elongation = 36% Mean percentage elongation = (36+32+36) / 3 = 34.66 %

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Percentage reduction in area =

A1=78.53 mm2 (i) A2= /4 x (3.5)2 = 9.6 mm2 %age reduction= 87.7% (ii) A2= /4 x (3.8)2 = 11.34 mm2 %age reduction= 85.5% (iii) A2= /4 x (3.5)2 = 9.6 mm2 %age reduction= 87.7% Mean reduction in area = (87.7+85.5+87.7) / 3= 86.96%

4.1.2. IMPACT TEST BY IZOD METHOD:BEFORE HEAT TREATMENT

Experimental data Material of test= aluminium 6063 alloy Type of notch = V notch Dimension of test piece = (75 Depth of notch = 2mm Angle of notch = 45 Velocity of striking = 3.99 m/sec Table No.4.5-Izod Impact Test Table Before Heat Treatment S.No. Initial energy (E1) Residual energy (E2) Energy absorbed (E1) in mm

50

(joules) 1 2 3 168 168 168

(joules) 38 44 36

E2) (joules) 130 124 132

Mean value of impact strength = (R1+R2+R3) / 3 joules = (130+124+132) / 3 = 128.66 Joules

Fig.4.2 Izod impact test specimen

AFTER HEAT TREATMENT

i) IZOD IMPACT TEST AFTER QUENCHING:-

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Table No.4.6- Izod Impact Test Table After Quenching S.n o 1 2 3 Initial energy (E1) (joules) 168 168 168 Residual energy (E2) (joules) 34 36 40 Energy absorbed (E1E2) (joules) 134 132 128

Mean energy absorbed = (134+ 132+128) / 3 = 131.33 Joules

ii) IZOD IMPACT TEST AFTER NORMALIZING:-

Table No.4.7- Izod Impact Test Table After Normalizing S.n o 1 2 3 Initial energy (E1) (joules) 168 168 168 Residual energy (E2) (joules) 48 40 44 Energy absorbed (E1E2) (joules) 120 128 124

Mean energy absorbed = (120+128+124+) / 3 = 124 Joules

iii) IZOD IMPACT TEST AFTER ANNEALING:Table No.4.8- Izod Impact Test Table After Annealing

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S.n o 1 2 3

Initial energy (E1) (joules) 168 168 168

Residual energy (E2) (joules) 40 40 34

Energy absorbed (E1E2) (joules) 128 128 134

Mean energy absorbed = (128+128+134) / 3 = 130joules

4.1.3. IMPACT TEST BY CHARPY METHOD

BEFORE HEAT TREATMENT
Experimental data Material of test= aluminium 6063 alloy Type of notch = V notch Dimension of test piece = (55 Depth of notch = 2mm Angle of notch = 45 Velocity of striking = 5.35 m/sec Table No.4.9- Charpy Impact Test Table Before Heat Treatment S.No Initial energy (E1) (joules) 1 2 3 300 300 300 Residual energy (E2) (joules) 30 26 26 Energy absorbed (E1E2) (joules) 270 274 274 ) in mm

53

Mean value of impact strength = (R1+R2+R3) / 3 joules = 272.66 joules

Fig4.3-Charpy Test Specimen

AFTER HEAT TREATMENT

i) CHARPY IMPACT TEST AFTER QUENCHING:-

Table No.4.10- Charpy Impact Test Table After Quenching S.No Initial energy (E1) (joules) Residual energy (E2) (joules) Energy absorbed (E1E2)

54

1 2 3

300 300 300

86 90 94

(joules) 214 210 206

Mean value of impact strength = (R1+R2+R3) / 3 joules = (214+210+206)/3 =210 joules

ii) CHARPY IMPACT TEST AFTER NORMALIZING:-

Table.4.11- Charpy Test Table After Normalizing S.No Initial energy (E1) (joules) 1 2 3 300 300 300 Residual energy (E2) (joules) 82 94 90 Energy absorbed (E1E2) (joules) 218 206 210

Mean value of impact strength = (R1+R2+R3) / 3 joules = (218+206+210) / 3 =211.33joule iii) CHARPY IMPACT TEST AFTER ANNEALING :-

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Table.4.12- Charpy Test Table After Annealing S.No Initial energy (E1) (joules) 1 2 3 300 300 300 Residual energy (E2) (joules) 102 106 100 Energy absorbed (E1E2) (joules) 198 194 200

Mean value of impact strength = (R1+R2+R3) / 3 joules = (198+194+200) / 3 =197.33 joules

4.1.4. ROCKWELL HARDNESS TEST

BEFORE HEAT TREATMENT
Experimental DataMaterial of test specimen = aluminum 6063 alloy Hardness scale used = B scale (red) Minor load= 10 kgf Major load= 60 kgf Dia. Of steel ball indentor = 2.5mm Table No.4.13- Rockwell Hardness Table Before Heat Treatment

Test no. Hardness no.

1 40

2 44

3 42

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Mean Rockwell hardness no. = (40+44+42) / 3 = 42

AFTER HEAT TREATMENT

i)

ROCKWELL HARDNESS AFTER QUENCHING:Table No.4.14- Rockwell Hardness Table After Quenching

Test no. Hardness no.

1 62

2 60

3 66

Mean Rockwell hardness no. = (62+60+66) /3 = 62.66

ii)

ROCKWELL HARDNESS AFTER NORMALIZING:Table No.4.15- Rockwell Hardness Table After Normalizing

Test no. Hardness no.

1 55

2 57

3 52

Mean Rockwell hardness no. = (55+57+52) /3 = 54.66

iii)

ROCKWELL HARDNESS AFTER ANNEALING:-

Table No.4.16- Rockwell Hardness Table After Annealing Test no. Hardness no. 1 29 2 28 3 31

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Mean Rockwell hardness no. = (29+28+31) /3 = 29.33

4.2. MICROSTRUCTURES OF ALUMINUM 6063 ALLOY

i) AFTER QUENCHING

Fig.5.1- Microstructure After Quenching ii) AFTER NORMALIZING

Fig.5.2-Microstructure After Normalizing iii) AFTER ANNEALING

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Fig.5.3-Microstructure After Annealing

CHAPTER-5 CONCLUSION

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5.1. CONCLUSION
On the basis of our experimental data we come to following conclusions: i. ii. i. ii. iii. i. ii. iii. iv. During quenching process we observed that hardness increases ductility decreases During annealing process Softens the alloy Ductility improved Refines the grain structures During normalising process Refines the grain structure completely Ductility enhanced Maintain granular homogeneity Strength increases

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So it is very important to do the heat treatment of metal and its alloys because every operation in industries required different material properties (i.e., hardness, ductility, brittleness, strength etc) . These properties can be achieved by heat treatment processes for different operations.

5.2. FUTURE SCOPE OF ALUMINIUM 6063 ALLOY

i) T4- temper 6063 aluminium is finding applications in hydro formed tube for chassis. ii) Aluminium 6063 alloy is highly weld able using TIG welding iii) 6063 can be used in production of extrusions

REFERENCES
1) Abrasive wear behavior of different case depth gas carburized AL 6063l. M.I zcher, M.Tabur, Turkey University 2) Camel Cather M, Bayram Ali, sala Baushi Material science and engineering vol 407, oct2005 3) Hafiz Mahmoud Mat. Series and Engg, Vol 340. 15 Jan 2003, ) 4) Haque M.M, journals of mat. Processing technology, VOL IV, 1999: 5 ) Heat Treatment: Principles and Techniques-By T.V Rajan, C.P Sharma, Ashok Sharma 6) Physical Metallurgy- Vijendar Singh.

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7) Putatunda Sushil K Material science and Engineering Volume 315, September 2001

APPENDIX1 MACHINES USED IN THIS PROJECT

UNIVERSAL TESTING MACHINE
A universal testing machine also known as a material testing machine and can be used to test the tensile and compressive properties of materials. This type of machines are called universal testing machine because it can perform all the tests like compression, bending, tension etc to examine the material in all mechanical properties. These machines generally have two columns but single columns types are also available. Load cells and extensometers measure the key parameters of force and deformation which can also be presented in graphical mode in case of computer operated machines. These machines are widely used and would be found in almost all materials testing laboratory.

SALIENT FEATURES
Machines are available in mechanical & digital / computerized model. Its maximum capacity is 40 KN.

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This will enables you to see the Load vs Displacement curve, Maximum Load,

Maximum Displacement, U.T.S.-% Elongation.

Accuracy conforming to IS 1828 Gr.1 Simplified design for ease of operation and maintenance Safety provisions against over load/over travel Number of extra accessories available for different tests. Machine with auto load features Calibration in kgs available on request Middle beam has motorized up & down adjustments. Easy adjustment of straining rate Highly rigid loading frame

IZOD IMPACT TESTING MACHINE

The test method generally utilized in North America is ASTM D256. The result of the Izod test is reported in energy lost per unit of specimen thickness (such as ft-lb/in or J/cm) at the notch ('t' in graphic at right). Additionally, the results may be reported as energy lost per unit cross-sectional area at the notch (J/m or ft-lb/in). In Europe, ISO 180 methods are used and results reported based only on the cross-sectional area at the notch (J/m). Polymeric materials that are sensitive to the stress concentrations at the notch ('notchsensitive') will perform poorly in the notched Izod test. Engineers use this knowledge to avoid using such polymers in designs with create high stress concentrations such as sharp corners or cutouts. Unnotched specimens are also frequently tested via the Izod impact method to give a more complete understanding of impact resistance.

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APPENDIX 2 STANDARDS
SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)
SAE International (SAE) is an organization for mobility engineering professionals in the aerospace, automotive, and commercial vehicle industries. The Society is a standards development organization for the engineering of powered vehicles of all kinds, including cars, trucks, boats, aircraft, and others. SAE International is a global association that serves more than 120,000 engineers and professionals in the aerospace, automotive and commercial vehicle industries each year. The mission of SAE International is to enable voluntary consensus on standards development and life-long learning.

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The SAE Foundation raises funds to support and nurture enthusiasm for science and technology education in students in K-12 and through college, including A World in Motion and the Collegiate Design Series.

TECHNICAL STANDARDS
SAE International provides an impartial forum for companies, government agencies, educational institutions and consultants to agree on technical standards for the worldwide vehicle mobility industry. These standards play a key role in improving safety, reducing costs, increasing productivity, improving market position, providing market access, and advancing new technologies.

ASTM INTERNATIONAL (ASTM)

ASTM International (ASTM), originally known as the American Society for Testing and Materials, is an international standards organization that develops and publishes voluntary consensus technical standards for a wide range of materials, products, systems, and services. The organization's headquarters is in West Conshohocken, Pennsylvania, about 5 miles (8 km) northwest of Philadelphia. ASTM, founded in 1898, predates other standards organizations such as BSI (1901), DIN (1917) and AFNOR (1926), but differs from these in that it is not a national standards body, that role being taken in the USA by ANSI. However, ASTM has a dominant role among standards developers in the USA, and claims to be the world's largest developer of standards. Using a consensus process, ASTM supports thousands of volunteer technical committees, which draw their members from around the world and collectively develop and maintain more than 12,000 standards. ASTM International publishes the Annual Book of ASTM Standards each year in print, CD and online versions. The online version was available by subscription and cost was based upon usage. For 2008, the complete set of books or CDs cost almost US$9000 and included 81 volumes. For 2010, the complete set of books or CDs cost almost $9700 and included 82 volumes.

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The standards produced by ASTM International fall into six categories:

The Standard Specification, that defines the requirements to be satisfied by subject of the standard. The Standard Test Method, that defines the way a test is performed and the precision of the result. The result of the test may be used to assess compliance with a Standard Specification.

The Standard Practice, that defines a sequence of operations that, unlike a Standard Test Method, does not produce a result.

The Standard Guide, that provides an organized collection of information or series of options that does not recommend a specific course of action.

The Standard Classification, that provides an arrangement or division of materials, products, systems, or services into groups based on similar characteristics such as origin, composition, properties, or use.

The Terminology Standard, that provides agreed definitions of terms used in the other.