Aluminum Alloys
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Aluminum
Bauxite
Pure Aluminum
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Aluminum Alloys
Precipitation Strengthening : Creates fine dispersion of precipitated particles in the metal and hinder dislocation movement. Basic steps : Solution heat treatment: Alloy sample heated to a temperature between solvus and solidus and soaked at that temperature. Quenching: Sample then quenched to room temperature in water. Aging: Solutionized and quenched sample is then aged to form finely dispersed particles.
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Decomposition Products Created by Aging
Super saturated solid solution is in unstable condition. Alloy tends to seek a lower energy state by decomposing into metastable or equilibrium phase. Supersaturated solid solution as highest energy state. Equilibrium precipitate has lowest energy state.
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Example - Al 4% Cu Alloy
Al -4% Cu is solutionized at about 5150C Alloy is rapidly cooled in water. Alloy is artificially aged in 130 1900C Structures formed : GP1 Zone: At lower aging temperature, copper atom is segregated in supersaturated solid solution. GP2 Zone: Tetragonal structure, 10-100 nm diameter. Phase: Nucleates heterogeneously on dislocation. Phase: Equilibrium phase, incoherent (CuAl2).
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General Properties of Aluminum
Low density, corrosion resistance. High alloy strength (about 690 MPa) Nontoxic and good electrical properties. Production: Aluminum hydroxide is precipitated from aluminum solution. Aluminum hydroxide is thickened and calcined to Al2O3 which is dissolve in cryolite and electrolyzed. Metallic aluminum sinks to bottom and is tapped out.
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Wrought Aluminum Alloys
Primary Fabrication: Usually semiconsciously cast by direct chill method. Scalping: inch metal is removed from hot rolled surface for good finishing. Ingots are homogenized and rolled. Classification: According to major alloying elements. Four digits: First digit major group of alloying elements. Second digit: Impurity limits. Last 2 digits: Identify aluminum alloy.
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Non Heat Treatable Aluminum Alloys
1xxx alloys : 99% Al + Fe + Si + 0.12% Cu Tensile strength = 90 MPa Used for sheet metals 3xxx alloys : Manganese is principle alloying element. Al 3003 = Al 1100 + 1.25% Mn Tensile strength = 110 MPa General purpose alloy 5xxx alloys: Al + up to 5% Mg Al5052 = Al + 25%Mg + 0.2% Cr Tensile strength = 193 MPa Used in bus, truck and marine sheet metals.
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Heat Treatable Aluminum Alloys
2xxx alloys : Al + Cu + Mg Al2024 = Al + 4.5% Cu + 1.5% Mg +0.6%Mn Strength = 442 MPa Used for aircraft structures. 6xxx alloys: Al + Mg + Si Al6061 = Al + 1% Mg + 0.6%Si + 0.3% Cu + 0.2% Cr Strength = 290 MPa Used for general purpose structure. 7xxx alloys: A + Zn + Mg + Cu Al7075 = Al + 5.6% Zn + 2.5% Mg + 1.6% Cu + 0.25% Cr Strength = 504 MPa Used for aircraft structures.
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Aluminum Casting
Sand Casting: Simple and used for small quantities and complex jobs. Permanent mold casting: Molten metal is poured into permanent metal mold. Finer grain structure and strength due to fast cooling. Less shrinkage and porosity. More shrinkage and simple parts only. Die casting: Molten metal forced into molds under pressure. Almost finished parts, automatic. Good tolerance and surface finish. Fine grain structure.
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Some applications of Al
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Aluminum Casting Alloy Composites
Composition of casting alloys differs greatly from wrought alloys Casting properties and mechanical properties are of primary interest. Denoted as 4 digits with a period between last two digits.
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Aluminum Lithium (Al-Li) Alloys
Developed primarily as direct replacement for existing aluminum alloys to reduce the weight of aircraft and aerospace structures. Loe density materials to reduce weight and reduce components size that leads to low stiffness and reduced fatigue life. Typical components : structural members in air frame, aerospace vehicle skin, liquid oxygen and hydrogen fuel tanks in spacecraft.
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Lithium
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Su 27
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Compositions of Aluminum lithium alloys
Alloys 2090 2091 8090 Weldalite 049
Cu 2.7 2.1 1.3 5.4
Li 2.2 2.0 2.45 1.3
Zr 0.12 0.1 0.12 0.14
Others
0.95 Mg 0.4 Ag 0.4 Mg
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Metallurgy and properties
Maximum solubility of Li in Aluminum is 4.2 % Lithium is the lightest metallic element with solid density of 0.534 g/m3 BCC crystal structure with melting temperature of 181 0 C Each 1 % of Li reduces the density of Al Li alloys by 3 % but increases the stiffness by 5 % Addition of Zirconium control the grain microstructure during age hardening
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Mechanical properties of typical near peak aged Al Li alloys
Alloys
Density (G/cm3)
Ductility (El%)
Elastic Modulus (GPa)
76
Trmsile Strength (MPa)
500
Longitudin al KIC (MPa
Melting Temperatu res (0 C)
) 580 660
2090
2.59
3-6
44
2091
2.58
75
550
130
560 - 670
8090
2.55
4-5
77
480
75
600 655
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Advantages of Al - Li
Alloy 2090 replacement for 7075 T6 8 % lower density and 10 % higher stiffness Used in heavy aircraft structures Superior corrosion resistance than 7075 Alloy 2091 replacement for 2024 T3 8 % lower density and 7 5 higher modulus superior damage tolerance. Alloy 8090 replacement for Al alloy of 2014 and 2024. 10 % lower density and 11 % higher modulus Good mechanical properties at lower temperatures (cryogenic) Weldalite 049 weldable Al Li alloys that can be welded replacing 2219 and 2014. Density 2.7 g/m 3 and 5 % higher modulus.
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Scraped Aluminum
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