Beruflich Dokumente
Kultur Dokumente
Table of Contents
1 Aluminum Alloys: .......................................................................................................................... 3
1 Aluminum Alloys:
Aluminum the most second plentiful metallic element on earth became an economic competitor in
engineering applications as recently as the end of the 19th century. It was to become a metal for its
time. For the most important industrial development would, by demanding material characteristic
consistent with the unique qualities of aluminum and its alloys. Greatly benefits growth in the
production and use of new metal.
Namely
1. casting alloys
2. wrought alloys
Both of which are further subdivided into the categories heat-treatable and non-heat-treatable. About
85% of aluminum is used for wrought products, for example rolled plate, foils and extrusions. Cast
aluminum 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 aluminum alloy system
is Al–Si, where the high levels of silicon (4.0–13%) contribute to give good casting characteristics.
Aluminum alloys are widely used in engineering structures and components where light weight or
corrosion resistance is required.
alloys include some of the highest strength heat treatable aluminum alloys. The most common
applications for the 2xxx series alloys are aerospace, military vehicles and rocket fins.
This is full phase diagram of aluminum and copper but useful portion is only up to 10% of copper.
From 2-5.56% of copper is mostly used for heat treatment purposes. The theta (θ) phase is an
intermediate alloy phase whose com-position corresponds closely to the compound CuAl2. These
alloys may contain smaller amounts of silicon, iron, magnesium, manganese, chromium, and zinc.
These are moderate strength non-heat treatable materials that retain strength at elevated temperatures
and are seldom used for major structural applications.
The most common applications for the 3xxx series alloys are cooking utensils, radiators, air
conditioning condensers, evaporators, heat exchangers and associated piping systems. . The
maximum solubility of manganese in the solid solution is 1.82 at the eutectic temperature of 12160F.
Because of the limited solubility, manganese is not used as a major alloying element in any casting
alloys and is used in only a few wrought alloys.
The aluminum-rich portion of the aluminum silicon alloy system is shown. The maximum solubility
of silicon in α solid solution is 1.65 percent at the eutectic temperature of 1071 oF. Although the
solvus line shows lower solubility at lower temperatures, these alloys are generally not heat treatable.
The 5xxx series alloy used in the form of plate and the 6xxx are often joined to the plate in some
extruded form. Some of the common applications for the 6xxx series alloys are handrails, drive
shafts, automotive frame sections, bicycle frames, tubular lawn furniture, scaffolding, stiffeners and
braces used on trucks, boats and many other structural fabrications.
Commercial wrought alloys contain zinc, magnesium, and copper with smaller additions of
manganese and chromium. The zinc substantially increases strength and permits precipitation
hardening. Some of these alloys can be susceptible to stress corrosion cracking and for this reason
are not usually fusion welded. Other alloys within this series are often fusion welded with excellent
results. Some of the common applications of the 7xxx series alloys are aerospace, armored vehicles,
baseball bats and bicycle frames.
Summary:
There are many aluminum alloys used in industry today - over 400 wrought alloys and over
200 casting allloys are currently registered with the Aluminum Association. Certainly one of
the most important considerations encountered during the welding of aluminum is the
identification of the aluminum base alloy type to be welded. If the base material type of the
component to be welded is not available through a reliable source, it can be difficult to select
a suitable welding procedure. There are some general guidelines as to the most probable type
of aluminum used in different applications, such as those mentioned above. However, it is
very important to be aware that incorrect assumptions as to the chemistry of an aluminum
alloy can result in very serious effects on the weld performance. It is strongly recommended
that positive identification of the type of aluminum is made and that welding procedures be
developed and tested in order to verify weld performance.
similarly classified into non-heat-treatable and heat-treatable types. The major difference is that the
casting alloys used in the greatest volumes contains alloying additions of silicon far in excess of that
found (or used) in most wrought alloys. Aluminum casting alloys must contain, in addition to
strengthening elements, sufficient amounts of eutectic forming elements (usually silicon) in order to
have adequate fluidity to feed the shrinkage that occurs in all but the simplest castings.
Designations in the form xxx.1 and xxx.2 include the composition of specific alloys in remelt ingot
form suitable for foundry use. Designations in the form xxx.0 in all cases define composition limits
applicable to castings. Further variations in specified compositions are denoted by prefix letters used
primarily to define differences in impurity limits. Accordingly, one of the most common gravity cast
alloys, 356, has variations A356, B356, and C356; each of these alloys has identical major alloy
contents but has decreasing specification limits applicable to impurities, especially iron content.
In designations of the 1xx.x type, the second and third digits indicate minimum aluminum content
(99.00% or greater); these digits are the same as the two to the right of the decimal point in the
minimum aluminum percentage expressed to the nearest 0.01%. The fourth digit in 1xx.x
designations, which is to the right of the decimal point, indicates product form: 0 denotes castings
(such as electric motor rotors), and 1 denotes ingot.
In 2xx.x through 8xx.x designations for aluminum alloys, the second and third digits have no
numerical significance but only identify the various alloys in the group. The digit to the right of the
decimal point indicates product form: 0 denotes castings, 1 denotes standard ingot, and 2 denotes
ingot having composition ranges narrower than but within those of standard ingot. Alloy
modifications, as previously mentioned, are identified by a capital letter preceding the numerical
designation.
A355:
An aluminum alloy with 0.02% copper added for greatly improved strength over the more common
A356 material. This alloy yields highly consistent castings that are crack resistant, easy to repair, and
have excellent tensile elongation properties.
A356:
Aluminum alloys are characterized by very good mechanical properties and low porosity with a
globular microstructure which is fine and uniform. The mechanical properties can be further
improved through heat treatments such as T5 and T6. These alloys are used for casting general-
purpose die castings. The common alloys used are 356-T6 for cast wheels.
A360.0:
Is specified for die cast parts that require good corrosion resistance Special alloys for special
applications are available, but their use usually entails significant cost premiums. .
A390:
This alloy is hypereutectic aluminum-silicon alloy. The optimum structure of it must consist of fine,
uniformly distributed primary Si crystals in a eutectic matrix. This alloy does not require heat
treatment. The low coefficient of thermal expansion, high hardness and good wear resistance of these
alloys make them suitable for internal combustion engines, pistons and cylinder blocks.
514:
This alloy has a relatively poor fluidity and a high degree of directional solidification shrinkage.
High pressure die casting is the primary method of forming this alloy. This combination of material
properties makes 514 less casting friendly. As a result careful attention to casting geometry is
essential. Because of its poor fluidity, fine detail and thin sections are difficult and radii must be
large Because of shrinkage, feeding the casting requires large risers proper design. High ductility and
excellent corrosion resistance is the main advantage of this alloy. It is commonly found boat
propellers where impact toughness is required.
References
Properties and Selection: Nonferrous Alloys and Special-Purpose Materials was published in 1990 as Volume 2
of the10 Edition Metals Handbook.
Heat Treating was published in 1991 as Volume 4 of the ASM Handbook.
Introduction to physical metallurgy Sidney H. Avner.
Heat treatment principal and techniques by C.P Sharma T.V Rajan and Ashok Sharma