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E AS107 Aluminium Tan Joon Kiat

Introduction to Engineering Materials and Aeromaterials (Singapore University of Social

Sciences)

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EAS 107 – Introduction to Engineering Materials and Aeromaterials

Lab Report Unit 2: Heat Treatment of Aluminium

Name: TAN JOON KIAT

PI number: Q1870884
Course lecturer: Mr Bang Toong Kiang
Group B

I declare that this is my own words.

The word count is 1328.

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Table of Contents
1. Abstract.................................................................................................................................2
2. Introduction..........................................................................................................................3
2.1 Precipitation Hardening (Age hardening)....................................................................3
2.2 Stages of age hardening..................................................................................................4
3. Experimental Procedure......................................................................................................5
3.1 Objective..........................................................................................................................5
3.2 Specimen Background....................................................................................................5
3.3 Heat treatment Procedures............................................................................................5
3.4 Test Equipment...............................................................................................................7
Rockwell Hardness Test...................................................................................................7
Tensile Test........................................................................................................................7
Metallographic Examination............................................................................................7
4. Experiment Results..............................................................................................................8
4.1 Calculations and formulas.............................................................................................8
4.2 Test data for Al-Cu aluminium alloy (Solution treated, natural ageing)..................9
4.3 Test data for Al-Cu aluminium alloy (Precipitation hardening post solution
treatment)............................................................................................................................11
4.4 Fracture (Macro) Analysis...........................................................................................13
5. Discussion............................................................................................................................15
6. Conclusion...........................................................................................................................16

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1. Abstract
In this experiment, we are to understand the effect of solution treatment and artificial ageing
on the properties of aluminium copper (Al-Cu) alloy. 22 samples of Al-4%Cu alloys (with
4.4% copper content) will be subjected to non-protective solution heat treatment at different
sets of fixed temperatures followed by age hardening at different times. These samples will
then be tested for its hardness level (HRF) by using Rockwell hardness tester. Lastly, the
samples will undergo tensile testing (destructive test) to measure its tensile strength.
Additionally, an image analyser will be used to study the fracture characteristic of the
samples. With these data acquired, we can compare the hardness and tensile strength of each
samples to understand the effects of aging temperatures and time on hardness and tensile
strength of Al-Cu, thus, revealing the ideal mechanical properties by identifying the optimum
heat treatment condition.

2. Introduction
2.1 Precipitation Hardening (Age hardening)
Precipitation hardening, also known as age hardening is a heat treatment process which
increases the yield strength of alloy by introducing nano-sized precipitate during heat
treatment. The precipitate creates distortion to the crystal lattice (Fig 2.1) resulting in motion
of dislocation being blocked.

Figure 2.1.1: Distortion of crystal lattices (Coherent precipitate)

Age hardening does not cause any deformation to the parts and is widely used in aerospace
where fatigue performance and good strength are required. (Eg. fuselage structure, turbine
blades, valve stems, gears and plunger)

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For age hardening, the alloy must have the following:

1) Form a single phase upon heating above the solvus line.

2) Matrix is soft and ductile while precipitate is hard and brittle.

3) Must be quenchable and a coherent precipitate must form.

2.2 Stages of age hardening

1. Solution treatment
The alloy is heated above its solvus temperature and held until a
homogeneous solid solution (α) is produce. This will dissolve phase
precipitate (θ), creating a single-phase solution. Thus, Al-4%Cu is solution
treated between 500°C to 548°C (Between solvus & eutectic temperatures)
2. Quenching
After solution treatment, the alloy (α) is rapidly cooled. θ does not form as
there is insufficient time. This structure becomes supersaturated (αss) and is a
metastable structure which contain excessive Cu.
3. Ageing
The sample is heated again and hold at temperature below solvus. The Cu
diffuse to nucleation site and precipitate grow, thus α + Ø structure is
produced.

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Figure 2.2.1: Al-4%Cu Phase Diagram

3. Experimental Procedure
3.1 Objective
To investigate the effect of aging temperature on the properties of Al-Cu alloy. Carry out
appropriate tests to investigate and changes in the microstructure and mechanical properties.

The objectives of Lab Unit 2 are as the followings:

1. To perform the heat treatment process for Al-Cu alloy.

2. To perform basic metallographic techniques and mechanical testing

Experiment to be performed on the followings:

 Alloy content of the Al-Cu Alloy

 Solution Treatment
 Aging
 Compare resultant properties
 Type of fracture

3.2 Specimen Background

My group B will be working on set 1 where the samples was heated to 520°C for 25mins and
150°C for 15/30/45/60mins, subsequently heated to 150°C for 15, 30, 45 and 60 mins.

The sample had been machined as shown in Figure 3.2.1.

Fig 3.2.1: Al-4%Cu sample

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3.3 Heat treatment Procedures

The age hardening heat treatment of aluminium consists of three stages. First stage is solution
treatment and the second stage are quenching and the third stage is aging.

The solution treatment and aging procedure for the samples are shown in table 3.3.1.

Set number No. of Solution Treatment Aging

Sample
s
Original 1 No Treatment No aging

Group A: 1 10 Heated to 520°C for 15mins,  2pieces natural aging.

water quenched.  8 pieces heated to 200°C
Heated to 200°C for 15/30/45/60mins, for 15/30/45/60 followed
water quenched. by air cooled.

Group B: 1 10 Heated to 520°C for 25 mins,  2 pieces natural aging.

water quenched.  8 pieces heated to 150°C
Heated to 150°C for 15/30/45/60mins, for 15/30/45/60mins
water quenched. followed by air cooled.

Group A: 2 10 Heated to 520°C for 35mins,  2 pieces natural aging.

water quenched.  8pieces heated to 300°C
Heated to 300°C for 15/30/45/60mins, for 15/30/45/60mins
water quenched. followed by air cooled.

Group B: 2 10 Heated to 520°C for 45mins,  2 pieces natural aging.

water quenched.  8 pieces heated to 250°C
Heated to 250°C for 15/30/45/60mins, for 15/30/45/60mins
water quenched. followed by air cooled.

Table 3.3.1

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3.4 Test Equipment

After aging, the samples will undergo two mechanical tests and Metallographic Examination.

Rockwell Hardness Test

Fig 3.4.1: wiZhard Hardness Test Machine

Tensile Test

Fig 3.4.2: Hounsfield extensometer, model H 20 K-W

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Metallographic Examination

Fig 3.4.3: Image Analyzer

4. Experiment Results
4.1 Calculations and formulas

Using the below sample as an example (Refer to appendix for attached graph and table),

%El - %RA -
Ultimate Young's
Yield Elongation Reduction
Hardness Tensile Modulus
Ageing Time Stress in Area
Sample Mean Strength of
Temperature (min) бY (Lu - Lo / (do2-df2/
(HRF) U.T.S бT Elasticity
(MPa) 5d) x 100 do2) x 100
(MPa) E (GPa)
(%) (%)
PH1 (Set 1) 150°C 45 94.6 417.62 264.83 8.77 17.28 19.0

Calculating Young’s modulus (E):

F (σ) 31 00
Stress Force
σ(stress) = = 2
= π (5)2 = 157.88 N/mm2
Original cross−section Area ( π D ) ( )
4 4

Change∈length 0.4 5
ϵ(strain) = = = 0.018 (dimensionless unit)
5 x original dia . 5 (5)

σ ( stress) 157.88 N /mm2

Young’s Modulus = = = 8771.11 MPa ≈ 8.77 GPa
ϵ (strain ) 0.018

Calculating Ultimate Tensile Strength (бT):

F 8200
Max Force
U.T.S = = π D = π ( 5 )2 ≈ 417.62 MPa
2
Cross−section area ( ) ( )
4 4

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Calculating Yield stress (бY):

F ( yield ) 5200
Yield Force
Yield stress = = πD 2
= π (5)2 ≈ 264.83 MPa
Cross−section Area ( ) ( )
4 4

Calculating Percentage Elongation (%El):

After tensilelength−Before Tensile length

Percentage Elongation = x 100% =
5 x Original Diameter ( ASTM E 8 M std)
4 1.82−37.5
x 100 %
5(5)

≈ 17.28 %

Calculating Percentage Reduction in Area (%RA):

Original Cross−section Area−Necking Area

Reduction Area (%) = x 100 % ≈ 19.0%
original Cross−section Area

4.2 Test data for Al-Cu aluminium alloy (Solution treated, natural ageing)
Al-Cu Solution Treated at 520°C

%RA -
Ultimate Young's %El -
Yield Reduction
Solution Hardness Tensile Modulus Elongation
Time Stress in Area
Sample treatment Mean Strength of (Lu - Lo /
(min) бY (do2-df2/d
Temperature (HRF) U.T.S бT Elasticity 5d) x 100
(MPa) o2) x 100
(MPa) E (GPa) (%)
(%)

Original
(Group B) N.A N.A 96.8 468.55 244.46 8.49 22.72 18.9%

PH1 (Set 1) 15 94.6 absent absent absent 28.44 18.9%

PH (Set 1) 150°C 30 93.9 428.83 264.83 8.15 23.72 18.9%
PH1 (Set 1) 45 94.6 417.62 264.83 8.77 17.28 19.0%
PH1 (Set 1) 60 95.0 453.27 300.48 10.82 20.96 18.9%
Table 4.2.1: Data for solution treated Al-Cu at different times

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Al-Cu Hardness Test (HRF)

97
96.5
96
95.5
Mean HRF

95
96.8
94.5
94
95
93.5 94.6
93.9
93
92.5
92
Original (Grp. B) 150°C @ 15mins 150°C @ 30mins 150°C @ 45mins 150°C @ 60mins

Solution treatment at 520°C & 150°C for different duration

Bar graph 4.2.2: Comparison of hardness (HRF) VS Time

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Al-Cu Ultimate Tensile Strength (U.T.S)

470

460

450

440
Mean MPa

468.55
430
453.27
420
428.83
410 417.62
400

390
Original (Grp. B) 150°C @ 15mins 150°C @ 30mins 150°C @ 45mins 150°C @ 60mins

Solution treatment at 520°C & 150°C for different duration

Bar graph 4.2.3: Comparison of ultimate tensile strength (U.T.S) across samples

4.3 Test data for Al-Cu aluminium alloy

(Precipitation hardening post solution treatment)
Al-Cu Solution treatment @ 520°C for 15minutes followed by Precipitation hardening
%El - %RA -
Ultimate Young's
Yield Elongation Reduction
Ageing Hardness Tensile Modulus
Sample Time Stress in Area
Temperatur Mean Strength of
(Group A) (min) бY (Lu - Lo / (do2-df2/
e (HRF) U.T.S бT Elasticity
(MPa) 5d) x 100 do2) x
(MPa) E (GPa)
(%) 100 (%)
PH (Set 1) 15 96.7 463.46 290.30 7.28 22.28 18.9
PH (Set 1) 30 94.0 448.18 264.30 8.81 22.08 18.9
200°C
PH (Set 1) 45 94.9 432.90 254.65 9.55 22.44 18.8
PH (Set 1) 60 94.6 453.27 305.58 10.61 22.24 18.9
Al-Cu Solution treatment @ 520°C for 25 minutes followed by Precipitation hardening
%El - %RA -
Ultimate Young's
Yield Elongation Reduction
Ageing Hardness Tensile Modulus
Sample Time Stress in Area
Temperatur Mean Strength of
(Group B) (min) бY (Lu - Lo / (do2-df2/
e (HRF) U.T.S бT Elasticity
(MPa) 5d) x 100 do2) x
(MPa) E (GPa)
(%) 100 (%)
PH (Set 1) 30 93.9 428.83 264.83 8.15 23.72 18.9
PH (Set 1) 150°C 45 94.6 417.62 264.83 8.77 17.28 19.0
PH (Set 1) 60 95.0 453.27 300.48 10.82 20.96 18.9

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Al-Cu Solution treatment @ 520°C for 35 minutes followed by Precipitation hardening

Ultimate Young's %El - %RA -
Yield
Ageing Hardness Tensile Modulus Elongation Reduction
Sample Time Stress in Area
Temperatur Mean Strength of
(Group A) (min) бY
e (HRF) U.T.S бT Elasticity (Lu - Lo / (do2-df2/
(MPa) 5d) x 100 do2) x
(MPa) E (GPa)
(%) 100 (%)
PH (Set 2) 15 94.5 463.46 295.39 10.61 13.36 19.0
PH (Set 2) 30 85.0 381.97 254.65 10.44 12.28 19.0
300°C
PH (Set 2) 45 88.5 407.44 285.21 9.00 11.32 19.0
PH (Set 2) 60 78.0 389.61 381.97 9.78 12.76 19.0
Al-Cu Solution treatment @ 520°C for 45 minutes followed by Precipitation hardening
Ultimate Young's %El - %RA -
Yield
Ageing Hardness Tensile Modulus Elongation Reduction
Sample Time Stress in Area
Temperatur Mean Strength of
(Group B) (min) бY
e (HRF) U.T.S бT Elasticity (Lu - Lo / (do2-df2/
(MPa) 5d) x 100 do2) x
(MPa) E (GPa)
(%) 100 (%)
PH (Set 2) 15 103.0 519.48 397.25 8.37 15.36 18.9
PH (Set 2) 30 100.4 478.74 399.80 9.09 16.64 18.9
250°C
PH (Set 2) 45 95.5 439.52 341.23 9.55 12.88 19.1
PH (Set 2) 60 92.0 478.74 356.51 8.49 12.68 19.1

Hardness (HRF)
105

100

95
Mean HRF

90

85

80

75
Natural Ageing 15mins 30mins 45min 60mins

HRF across samples at 150°C , 200°C , 250°C , 300°C ageing temperatures

150°C 200°C 250°C 300°C

Line graph 4.3.1: Comparison of hardness (HRF) across Age hardened samples

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Ultimate Tensile Strength (U.T.S)

550

500

450
бT (Mpa)

400

350

300
Natural Ageing 15mins 30mins 45mins 60mins

U.T.S across samples at 150°C , 200°C , 250°C , 300°C ageing temperatures

150°C 200°C 250°C 300°C

Line graph 4.3.2: Comparison of tensile strength (U.T.S) across Age hardened samples

4.4 Fracture (Macro) Analysis

Below are images of fracture analysis showing ductile fractures retrieved from optical
microscope image analyzer.

Sample image Treatment %Brittleness

Solution treatment at 520°C 8.1%

for 25 minutes

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Age at 150°C for 15 41.4%

minutes

Table 4.4.1: Comparison of ductile fracture surfaces

Sample image Treatment %Brittleness

Age at 150°C for 30 7.7%

minutes

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Age at 150°C for 45 19.6%

minutes

Age at 150°C for 60 23.4%

minutes

Table 4.4.2: Comparison of ductile fracture surfaces

5. Discussion

Comparing Solution treatment sample resultant properties

With reference of Table 4.2.1, we can see that there is a dropped in the mean hardness of
natural aging sample when compared against the original sample. While there is a dropped
in the mean hardness, the yield stress increases. This could be due to the sample becoming
more ductile after natural aging and thus the increased in yield stress.

Comparing aging treatment sample resultant properties

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With reference of Line graph 4.3.1 & 4.3.2, we can see that sample that is artificially aged at
150ºC for 15mins yielded the best hardness and ultimate tensile strength. While line
graph Line graph 4.3.2 shows that there is a spiked in ultimate tensile strength for sample
aged at 250ºC for 60min. There is a possibility that there might be some mistake during the
age hardening process or erroneous data collection for that sample. From the graph, we can
also see that the tensile strength starts decreasing after 45min. This could be due to
overaging.

Type of fracture

After observing and analysing the physical sample and the metallographic images, we can see
that ductile fracture is prominent. All physical sample showed sign of necking. This necking
phenomenon is also known as plastic deformation and is normally found in ductile fracture.
The large brittleness area for sample aged at 150°C for 15 minutes could be due to mistake in
the age hardening process.

6. Conclusion
From this experiment, it may be concluded that the hardness increases with increasing aging
time up to a certain limit which depends on the alloy composition and aging temperature.
Theoretically, alloy that undergoes lower aging temperature and left to aged naturally will
have higher strength and is not susceptible to overaging. In this lab, we are unable to achieve
full results as due to constraint time and absentees. Alloy that undergoes higher aging
temperature and left to aged artificially will achieve peak strength faster (lower peak strength
compared to lower aging temperature) but is susceptible to overaging. From research done by
other institute, the ideal temperature to aged will be 150ºC for around 50h.

To conclude, by controlling the temperature and time, we can control the precipitation of the
θ phase and achieve the desired tensile strength.

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7. References
 Askeland D R & Wright W J. 2014. The science and engineering of materials.
(Seventh ed.) Cengage Learning

 Science Direct (2013). Effect of solution treatment and artificial ageing on

microstructure and mechanical properties of aluminium alloys. Retrieved 31March,
2016 retrieved from
http://www.ysxbcn.com/down/2013/03_en/09-p0631.pdf

 “MSE 2090: Introduction to Materials Science Chapter 8, Failure” Retrieved from

http://people.virginia.edu/~lz2n/mse209/Chapter8.pdf

 Group A lab data (Excel)

 Group B lab data (Excel)

 Individual Tensile graph for calculations

 Fracture (Macro) Analysis Images

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