POLITECNICO DI MILANO

 
 
MATERIALS FOR ENERGY
A.Y. 2019/2020

 
ASSIGNMENT REPORT

CASE-2
 

Prof. GARIBOLDI ELISABETTA

MOHANRAJ SHANMUGAM – 914760

a) Why Al-0.5Si-0.5Mg can be used for electrical conductors?

In practical, some applications needs both high conductivity as well as high mechanical
strength. For such cases (Al-0.5Si-0.5Mg) can be used because these AA6xxx alloys features low
impurity and low alloying element concentrations. These kind of alloys entirely depend on the
age-hardening and also permits well known β- precipitation sequence to generate higher
mechanical strength and to reduce the factors the impact conductivity by depleting the solutes into
the precipitates.

b) Which are the strengthening mechanisms used to optimize strength and electrical conductivity
in this case?

The annealing of as cast material increases the strength of the material as well as the electrical
conductivity of the material. According to the study, the increase in conductivity is due to the
formation of β- precipitation sequence which also decreases the solute concentration of the Mg and
Si. This precipitates hinder the movement of dislocations leading to increase in the strength of the
material.

c) Explain the innovative/beneficial parts of the process proposed by the authors?

The authors have modified the sequence of the process to obtain the high strength conductors. The
proposed sequence is as follows.

TRC  AGE HARDENING  COLD ROLLING  BACK- ANNEALING (OPTIONAL)

The author has clearly stated that in order to obtain maximum strength age-hardening, annealing and
heavy cold rolling should be applied on the other hand to get ultimate electrical conductivity an
optional back annealing can be employed.

d) What changes in the alloy microstructures could be introduced by the casting process
adopted?
Regarding the microstructure, once the alloy is subjected to TRC process the homogeneous
recrystallized grain structures become elongated upon cold working that in turn contributes to
higher strengths.

The above figures gives the clear comparison of the conventionally processed (a) and modified
TRC process results (b). It is clear from the figure (b) that when a considerable amount of stress is
applied to the homogeneous grain structures it gets deformed and becomes elongated.
 In the case of modified TRC the centreline segregation is predominantly visible that
processed conventionally as it is clear from the below figure. This line is formed due to the Al-Fe-
Si- constituent phases.

e) Why they could help in the economy of the process in view of the specific needs of the product
(electrical conductor)?

It is clear from the present study that batch annealing gives homogeneous strength and
conductivity along the coil and independent of the temperature profile which may vary along the
width and diameter. This modified TRC production does not require any special processing facilities
rather than which used facilities that is already available in production sites. SHT mainly focuses on
strengthening mechanism. Considering only electrical conductivity point of view SHT can be
avoided which requires in-line quenching, annealing, large furnaces, long soaking times, low in-line
speed which obviously needs huge capital and energy investment thus making the conventional
process uneconomical. Modified TRC process does not require these above mentioned facilities thus
cutting down those cost and becoming more economical and industrially more feasible.

f) The authors mention a drawback of the process. Which one?

According to present study, it is clear that the author has focussed selection of alloy only in
accordance with the conductivity. As we all know aluminium and its alloys has the maximum
conductivity next to copper. So the strength level of alloys is recorded low. But in general the
strength to conductivity ratio is improved compared to conventionally processed material.