“Heaven’s Light Is Our Guide”

Rajshahi University of Engineering &

Technology, rajshahi

Department of mechanical Engineering

Course no: ME-3200

Course name:
Case study on Mechanical Engineering

Submitted by:
Md. Shahriar Islam (1602062)
Abdullah Al Masud (1602090)
Submitted to:
Dr. Md. Nurul Islam
Professor
Department of Mechanical Engineering, RUET
 “Study on different aluminum alloys”

Abstract:
Aluminum is the most broadly utilized nonferrous metal because of its numerous
desirable physicals, chemical, and metallurgical properties. Aluminum shows a
adjust of all compounds but for a couple of high temperature vaporous species
where aluminum may be uniform or divisible. Different materials are mixed with
aluminum to improve the properties of the pure aluminum, is called aluminum
alloy in which aluminum is the predominant metal. Alloys are made to induce
superior properties than what the nature has given to the mankind. By combining
small amount of different materials, some better characteristics are created than
pure aluminum. The regular alloying factors are copper, magnesium,
manganese, silicon, tin and zinc.

Introduction:
Aluminum is placed at group-13 and period-3 in the most modern periodic table
based on its electronic configuration. Among many metals, aluminum has been
designated as very soft, non- magnetic and ductile metal having 2470°C and
660°C as boiling and melting points respectively. In ancient time, the use of steel
was mentionable. But, at present the use of aluminum is growing day by day.
The reason behind this is, aluminum weights Much less than steel and shows
better corrosive resistance property. Besides, the malleability and elastic
property of aluminum is much higher than steel. For this reason, aluminum is
more preferable than steel in many mechanical systems which has resulted in
increased production of aluminum metal. Many countries like China, United
states, Australia, Saudi Arabia produce abundant amounts of aluminum due to
its vast application. The light weight and high mechanical and thermal properties
have employed aluminum in alloying applications. Two major types of
aluminum alloys are: 1. Wrought alloy 2. Cast alloy. In both types, there are
some alloys which are heat treatable and others are non-heat treatable. In this
paper, almost all wrought alloys (heat and non-heat treatable) have been
discussed along with their preparation method, composition, mechanical
properties and costings. From the cast alloys, one alloy (8xx.x series) has been
included.
Pure aluminum lacks higher expansible strength due to which it is alloyed adding
elements like copper, manganese, magnesium etc. in order to apply it in different
fields. In alloyed aluminum the percentage of aluminum is approximately 85%
and other elements comprises of 15%. Merging of other elements results in
strength improvement, workability, better electrical conductivity, higher
corrosive resistance in comparison to pure aluminum. Along with these
aluminum alloys supposed to be light weight and show high tensile strength. For
these reasons, alloying field has become the most prominent application field of
aluminum.
1 Aluminum-Lithium Alloy:
Aluminum-lithium alloy (Al-Li) is combined with aluminum and lithium, often
in addition to copper and zirconium. Since lithium has low density, for this
reason, these alloys have also lower density than aluminum. Includes up to
2.45% with commercial Al-Li mixed lithium mass. 3% density is reduced and
6% Young’s modulus is increased because of the inclusion of lithium in each
percentage of weight [1]. Additions of lithium give higher fatigue crack
development resistance. The main advantage of aluminum-lithium alloys is
corrosion resistance stress.
Aluminum-lithium alloy can be prepared by extraction process, sealing method,
atmospheric melting method. Lithium is highly chemical active substance so that
sealing method and atmospheric melting method are too costly and need more
instruments arrangements. Sometimes in those methods, the portion of lithium
can’t be controlled. Extraction method is the most effective and has a lower
production cost. In this method, the amount of lithium can be controlled which
are added to molted aluminum. Pure lithium is ejected into a container filled
aluminum. Extraction process can be performed both in open atmosphere and
closed atmosphere. Some arrangements need to be set to prevent the oxidization
of lithium.
Table 1: Compositions of aluminum lithium alloy [2]
Si Fe Cu Mg Mn Cr Zn Ti Li Zr Al
0.10 0.12 2.4-3.0 0.05 0.25 0.05 0.1 0.15 1.9-2.6 0.08- 0.15 Rem.
0.05 0.07 2.4-3.0 0.4 0.3 ... 0.7 0.1 1.4-1.8 0.05-0.12 Rem.
In the composition of aluminum-lithium alloys, copper is used as a third material
which can increase the strength without sacrificing higher ductility and also raise
prof stress, for that reason excessive ductility values are not so important on the
other hand, magnesium content increases the strength of the object. Copper also
involves formation of T2(Al3CuLi3) precipitates which is the major reason for
increasing toughness. For the addition of Zinc, the corrosion resistance property
will be improved. The addition of zirconium is improved the hardness value.
Along with this, Zirconium forms (Al3Zr) dispersoids whose main purpose is to
control recrystallization.

Aluminum-lithium alloy has 510 MPa ultimate tensile stress and 427 MPa
tensile yield strength [3]. It shows hardness 162 BHN [4]. Its Young modulus is
68 GPa [5]. The density of solid aluminum lithium alloy at 250C is 2.58 gm/cm3
[4]. Lithium addition in aluminum reduces the thermal conductivity and the
value is 0.22 Cal/cms.0C and more addition of lithium decrease the thermal
conductivity constantly [6]. Aluminum lithium alloy has the specific heat of
961.1 JK-1Kg-1 [7].

Different aluminum-lithium alloys are used in different parts of aircraft. The

main property that needs the material of aircraft is reducing the weight as much
as possible. This goal is fulfilled by adding lithium in aluminum that can reduce
more than 8% density which property of material reduces the wight of material.
But some disadvantages are faced in Al-Li alloys like a tendency for highly
anisotropic mechanical properties, short-transverse of ductility becomes low and
loss of the toughness which owing to have the thermal instability. To solve this
problem, a third material is added to reduce ductility as discussed above.

2 Duralumin:
Duralumin is mainly composed of aluminum, copper and magnesium. Along
with this, other alloying elements like manganese, silicon, iron etc. are added to
obtain the preferred mechanical properties. Though the electrical and thermal
conductivity of duralumin is poor, its tensile strength is higher than aluminum
and light in weight. The reason behind this is, adding high content of magnesium
results in increasing Young modulus by 17% and ultimate strength by 9% in
comparison with adding low content of magnesium [8].
The most common preparation method of duralumin is casting. At first, the
molted materials (Al, Mg, Cu, Si etc.) are placed in a wooden box which must
have runner, riser, ingates and screw. The molted materials are kept into the box
until they are solid and stable. It takes 1 hour to become completely stable and
then the casting of duralumin is completed. After casting some mechanical
processes are required to get proper shape and smooth surface for different
purposes.
Table 2: Composition of duralumin alloy [9].
Cu Mg Mn Si Fe Ti Cr Zn Al
4.51 1.62 0.6 0.55 0.4 0.06 0.13 0.15 Rem.

Corrosion resistance can be increased by metallurgical bonding of surface layer

of aluminum. Merging of silicon results in reducing thermal expansion of
coefficient along with increasing wear resistance. Besides, addition of hardening
elements like magnesium, silver enhances resistance of duralumin T6 heat
treatment and this treatment is uniform in a solid solution. Other additive
elements like manganese, iron and titanium improves the micro structure and
mechanical behaviors of the alloy. Further improvements of duralumin are
possible by reducing amount of iron and silicon in the content and adding
Zirconium as additional alloying element. Zirconium has a positive impact on
the properties of duralumin and it increases fracture toughness.
Duralumin has 450 MPa tensile yield stress and 720 MPa ultimate tensile stress
[10]. It shows 110 BHN hardness [8]. Its young’s modulus is 62GPa. Thermal
conductivity of duralumin is 1.52 W/m/K [11]. Melting temperature of
duralumin varies from 4820C to 6000C [12]. Duralumin has 875 J/k/kg specific
heat and density of 2.787 gm/cm3.

The main applications of duralumin alloys are bulkheads, aircraft skin, wing ribs,
auto mobile industries and engine components which are used as wires plates
and bars. Duralumin is used in sheet product because of the addition of copper
which improves the strength quality of the materials. Duralumin is also utilized
in heavy forgings other suspension segments. It is also used in light weight guns.
3. Aluminum-magnesium alloy:
Aluminum-magnesium alloys are described by means of relatively excellent cast
ability and are exclusive by using outstanding corrosion resistance due to
excessive magnesium components. Magnesium also increases the strength via
solid solution and also takes part at the improvement of the strain hardening
capacity. It can be said that aluminum-magnesium alloys are considered as the
maximum strength nonheated-treatable among all aluminum alloys. Following
table shows the compositions of most commonly used two aluminum-
magnesium alloys.
Table 3: Composition of aluminum-magnesium alloy [13].
Mg Si Fe Cu Al
2.86 0.07 0.07 0.01 Rem.
5.55 0.08 0.07 0.01 Rem.

Aluminum-magnesium (5xxx series) alloy is a non-heat treatable wrought

aluminum alloy. The most common and easy method of aluminum-magnesium
alloy preparation is the electrodeposition method. In early time, direct deposition
method was used. But at present deposition is done through electroplating. It is
easy to operate the process and the process is good enough to make nano alloys.

In the composition of Al-Mg alloy, silicon is added to improve the tensile

strength as well as takes place to improve the conductivity. Very little portion of
copper is added to increase the strength without significant loss of corrosion
resistance. Addition of iron in Al-Mg alloy increases ultimate tensile strength
while the amount of iron is very low [14].
But the inclusion of magnesium more than 4.7% sometimes diminishes the
strength of the alloy, this problem occurs due to the arrangement of
comparatively fragile Al3Mg2 intermetallic element.
Aluminum- magnesium alloy shows approximately 50220Mpa Young's
modulus, 58Mpa yield strength, 195Mpa ultimate tensile strength and 14.2%
elongation [15]. Besides, the corrosion rate of this alloy is 0.056mm/year.
However, this alloy has a hardness of approximately 65 BHN [16]. Specific heat
of Al-Mg alloy at 300k temperature is 120 W/m.k while the portion of
magnesium in the alloy is 6% [17]. Density of aluminum magnesium alloy at
250c is 2.602 gm/cm3 [18]. The melting point of Al-Mg alloy is at the range of
5740C to 6800C and thermal conductivity is 900 J/Kg/K [19].
Al-Mg alloys are the most suitable alloy for substituting in shipbuilding. Due to
high formability, excellent corrosion inhabitation and high strength; aluminum-
magnesium alloys are used in car body sheets [20].

4. Aluminum-Scandium alloy:
Aluminum-scandium alloy is the combination of aluminum and scandium where
the amount of scandium is very low. Very little amount of scandium mixed in
aluminum shows higher yield stress and tensile stress than pure aluminum.
Aluminum-scandium alloys have a really particular substructure which
essentially impacts the hardening and softening procedure happening during
annealing this is because of the existence of the Al3Sc accelerates, the aluminum-
scandium alloys hold their distorted microstructures in any event, when annealed
at exceptionally high temperatures [21].
Aluminum- scandium alloy can be prepared by various methods. But, to obtain
larger recovery rate of scandium aluminothermic reaction with molten salt
process is followed. The first step of the process is the acquisition of special
molten salt. The compounds like KCl, NaCl, ScF3, Na3AlF6 is selected. Then
Sc2O3 is taken. The amount of Na3AlF6, KCl and NaCl are kept fixed and that
amount must be sufficient to operate the chemical reaction in the salt. Then the
charge of ScF3 and NaF is varied. For this reason, the molten salt is achieved
and it is combined to melted aluminum to formulate the main aluminum -
scandium alloy [22].
Table 4: Composition of aluminum-scandium alloy [23]
Mg Zn Cr Mn Sc Cu Ni Si Fe Al
5.9 0.17 0.002 0.13 0.2 0.08 0.003 0.38 0.34 Rem.
5.97 0.012 0.002 0.11 0.4 0.07 0.002 0.33 0.31 Rem.

The addition of Mg improves the strength as well as reduces the wight; on the
other hand, Sc and Zr are added to create a stable solution Al3Sc(Zr) which cause
the improvement of the strength of the alloy. The dislocation densities and
hardness of aluminum alloys expand significantly with the addition of Zn. Little
increment of Fe in the alloy creates an important development in yield strength.
Liquid temperature is decreased and solidification time is increased with the
expanding of silicon [24]. Although the impact of manganese on hardness is
destitute but the expansion of manganese in aluminum alloy undergoes to the
arrangement of precipitates that have an impact on the resistivity behavior
significantly.
Scandium is added to aluminum for the development of weldability and
corrosion inhibition. However, Al-Sc alloy shows approximately 381MPa Yield
strength, 467MPa tensile strength, 0.038mm/year corrosion rate and
10.5%elongation [25]. Besides, this alloy has Vickers micro hardness of 200 Hv
at 300k annealing temperature [26]. Addition of scandium increase the
recrystallization temperature above 6000C [25].
Due to the reduction of weight, increasing the strength, aluminum-scandium
alloy has many practical uses. As mentioned before, the portion of scandium in
the alloy is very small. The bicycle frames which are made of Al-Sc alloy shows
12% eight reductions, improvement of 50% yield strength and improves 24%
fatigue life. Al-Sc alloys are also utilized as sheet and plate for aviation
applications. Other applications of Al-Sc alloys are bumpers, wheels, canisters
of air bag and frames pistons.
5. Aluminum-silicon alloy:
The addition of silicon to aluminum increase the wear resistance, weight ratio;
on the other hand, decreases coefficient of thermal expansion and density [27].
By maintaining the temperature under the highest solubility level to avoid partial
melting and overheating consequences, addition of silicon to aluminum creates
a huge enhancement in impact resistance and ductility.
Aluminum-silicon alloy belongs to the 4xxx series of aluminum alloy which is
mainly used in preparing molded parts. Al-Si alloy is prepared in an induction
furnace whose temperature range is 700° to 800°C. At first, a specific amount of
silicon approximately 75 to 90% of required amount is mixed with aluminum
charge. At this time, silicon is taken as particles and dissolution in aluminum
occurs because of fusion of amount which doesn't make any delay in furnace
productivity. Then the melted charge is taken for analysis and extra silicon is
added to get it to the final stage. The density difference between molten
aluminum and silicon particle is very low which enables silicon to show a
tendency to float in alloy surface
Following table shows the composition of an aluminum-silicon alloy.
Table 5: Composition of Al-Si alloy [28].
Si Fe Mg Mn Ti Cu Al
7.46 0.326 0.33 0.047 0.04 0.07 Rem.

In the compositions of aluminum-silicon alloy, the involvement of iron is to

improve the strength but higher amount of iron can damage other mechanical
properties, for neutralization a little portion of manganese is included to the
alloy. By the addition of melt magnesium in the range of 0.3 to 0.5, the tensile
strength is improved. Addition of copper improves the strength of the alloy but
the portion must be below 2% because over 2% copper can affect bad impact
overall mechanical property because of porosity formations [29].
The value of Young Modulus and Poisson ratio of aluminum-silicon alloy is
74000 MPa and 0.33 respectively [30]. Besides, this alloy has approximately 200
MPa Yield strength, 400MPa ultimate tensile strength and 12-17% elongation
[31]. Hardness value of this alloy is approximately 108 BHN [32]. The density
of aluminum-silicon alloy is 2.65 gm/cm3 and its melting point is about 600-
760° C [33]. This alloy has 920J/Kg/k of specific heat, 69.7×10 -6 m2/sec of
thermal diffusivity and 173.8 W/m/k thermal conductivity [34].
Because of fulfilling environmental demand, the uses of Al-Si alloys are
increased in aerospace industry and automobile sector. Al-Sc alloys are used in
cylindrical car blocks. These alloys are also used in the engines application
where the temperature is too much high.

7. Comparative analysis:
As describe before, the main reasons of the addition of different alloying element
to aluminum are reduction of weight and ductility of the material and improve
the strength. Besides, improving these properties of the materials, main alloying
elements are also taken part of the development of the mechanical properties like
ultimate tensile strength, yield strength, Young’s modulus, hardness number,
corrosion resistance, elongation etc. Addition of these main alloying elements
with some transition alloying elements can maintain a good quality having great
mechanical and chemical property. In this part a comparative analysis based on
yield strength and hardness number is presented.
450
400
Yield Strength (MPa) 350
300
250
200
150
100
50
0
Al-Li Al-Sc Duralumin Al-Mg Al-Si

Figure 1: Yield strength of different aluminum alloy

In this figure, comparison of yield strength of different aluminum alloy is
accomplished. This comparison shows that Aluminum lithium alloy, aluminum
scandium alloy, duralumin and aluminum zinc alloy have the satisfied yield
strength because, it can be said that strong material has a higher yield strength.
200
Hardness (BHN)

150

100

50

0
Al-Li Al-Sc Duralumin Al-Mg Al-Si

Figure 2: Hardness of different aluminum alloy

In this figure, comparison of hardness of different aluminum alloy is
accomplished. This comparison shows that aluminum lithium alloy, aluminum
scandium alloy, duralumin and aluminum zinc alloy have better hardness
number because higher hardness number has the higher resistance of indentation.
Aluminum alloys have various applications. So that, in different types of
applications, the selected alloys need to improve several properties. For that
reason, aluminum alloys take a very important part in our current world.
6. Tentative Costing:
Costing is a major criterion for alloy selection and applying the alloy in a specific
field. Higher costing and difficulties on preparing of an alloy forces a material
or mechanical engineer to take decision about selection of alloy. Because, high
costing of an alloy increases the price of the product (made from alloy) which
increases overall cost of the process. So, it can be said that, price affects the alloy
selection and overall cost of the manufacturing factory. The following figure
shows tentative material cost of different aluminum alloys:
323.85
320

240
Price, €

160

80
40.045 38 33.37 35.67

0
Al-Li Al-Sc Duralumin Al-Mg Al-Si

Figure 3: Tentative cost of aluminum alloys

The possible price of the alloys has been calculated based on the price of
different alloying elements. At first, price of various charge of the elements has
been taken from Sigma Aldrich (an online site). Then, the price of main alloying
element (100gm) has been calculated based on the alloy composition. However,
the column chart shows that, Al-Sc is the most valued alloy as scandium is too
much expensive. This high costing of Al-Sc alloy limits its application field in
spite of having better mechanical properties. Besides, the price of Al-Li,
Duralumin, Al-Si and Al- Zn is comparatively low. As a result, these alloys are
mostly used in aerospace, marine and military sectors. Though Al-Sn, Al-Mn
and Al-Mg possesses comparatively low mechanical properties but their lowest
production cost enables them to apply in automobile, marine and piping sectors.

8. Aluminum alloy consumption in different sectors:

Every day the demand of aluminum and its alloys are increasing as aluminum is
the most eco-friendly, cost effective and recycled industrial material. For this
reason, the employment of aluminum alloy in different application field is
increasing to great extent. The properties offered by aluminum and its alloy
enable any aluminum-based products to show high durability and cost efficiency
which are the major reason of its vast applications. The following figure shows
the consumption amount of aluminum and its alloy in different sector.
Electrical Others…
engineering Transport
13% 27%

Consumers
Foil and
goods
packaging
5%
16%

Machinary and
equidments
Constructions 9%
25%
Figure3: Aluminum alloy consumption in different sectors

9. Conclusion:
The composition analysis shows that the main alloying elements of aluminum
are Li, Cu, Sc, Mg, and Si. These elements are added to improve the chemical
and mechanical properties in order to use in different field. The analysis also
represents that making a small change in the alloying element and little addition
of transition elements like Zr, Cr, Ti etc. helps to develop new microstructure of
the alloy with new improving mechanical characteristics. In the comparison of
yield strength and hardness number, aluminum lithium alloy, aluminum
scandium alloy and aluminum zinc have the satisfied values. Besides, aluminum
magnesium alloy has also great mechanical properties and important sort of
applications. On the other hand, comparing to the tentative costing of aluminum
alloys, the material cost of Al-Li, Duralumin and Al-Si are comparatively low.
However, the application analysis illustrates that aerospace field is the most
prominent use of aluminum alloy. Besides, aluminum alloy has also other fields
of applications.
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