Aluminium & Aluminium Alloys

(Modification of Al-Si Alloys)

Introduction and Overview
Aluminum has a density of only 2.7 g/cm3, approximately one-third as much as
steel (7.83 g/cm3). One cubic foot of steel weighs about 490 lb; a cubic foot of
aluminum, only about 170 lb. Its Melting Point is 658°C & Boiling Point is
2057°C.Its Tensile Strength varies from 95 to 157 MN/m2.

An aluminium alloy is a chemical composition where other elements are added to

pure aluminium in order to enhance its properties ,primarily to increase its
strength. These other elements include iron, silicon, copper, magnesium,
manganese and zinc at levels that combined may make up as much as 15 percent of
the alloy by weight. Alloying requires the thorough mixing of aluminum with these
other elements while the aluminum is in molten – liquid – form.

Alloy Categories
It is convenient to divide aluminum alloys into two major categories: wrought
compositions and cast compositions. A further differentiation for each category is
based on the primary mechanism of property development. Many alloys respond to
thermal treatment based on phase solubilities. These treatments include solution
heat treatment, quenching, and precipitation, or age, hardening. For either casting
or wrought alloys ,such alloys are described as heat treatable. A large number of
other wrought compositions rely instead on work hardening through mechanical
reduction, usually in combination with various annealing procedures for property
development. These alloys are referred to as work hardening. Some casting alloys
are essentially not heat treatable and are used only in as-cast or in thermally
modified conditions unrelated to solution or precipitation effects.

Cast & Wrought Alloy nomenclatures have been developed. The Aluminum
Association system is most widely recognized in the United States. Their alloy
identification system employs different nomenclatures for wrought and cast alloys,
but divides alloys into families for simplification. For wrought alloys a four-digit
system is used to produce a list of wrought composition families as follows:
 1. •1 xxx: Controlled unalloyed (pure) composition, used primarily in the electrical and
chemical industries

2. •2 xxx: Alloys in which copper is the principal alloying element, although other elements,
notably magnesium, may be specified. 2xxxseries alloys are widely used in aircraft
where their high strength (yield strengths as high as 455 MPa, or 66 ksi) is valued.

3. •3 xxx: Alloys in which manganese is the principal alloying element, used as general
purpose alloys for architectural applications and various products

4. •4 xxx: Alloys in which silicon is the principal alloying element, used in welding rods and
brazing sheet

5. •5 xxx: Alloys in which magnesium is the principal alloying element, used in boat hulls,
gangplanks, and other products exposed to marine environments

6. •6 xxx: Alloys in which magnesium and silicon are the principal alloying elements,
commonly used for architectural extrusions and automotive components

7. •7 xxx: Alloys in which zinc is the principal alloying element (although other elements,
such as copper, magnesium, chromium,& zirconium, may be specified), used in aircraft
structural components and other high-strength applications. The 7xxxseries are the
strongest aluminum alloys, with yield strengths ≥500 MPa (≥73 ksi) possible.

8. •8 xxx :Alloys characterizing miscellaneous compositions. The 8xxxseries alloys may

contain appreciable amounts of tin, lithium,&/or iron.

9. •9 xxx: Reserved for future use.

4xx.x Series.
Alloys of the 4xx.xgroup, based on the binary aluminum silicon system and
containing from 5 to 12% Si, find many applications where combinations of
moderate strength and high ductility and impact resistance are required.

4000 series Aluminium alloy nominal composition (% weight)

Alloy Al contents Alloying element

4007 96.3 Si 1.4 Fe 0.7 Mn 1.2 Ni 0.3 Cr 0.1

4015 96.8 Si 2.0 Mn 1.0 Mg 0 .2

4047 85.5 Si 12.0 Fe 0.8 Cu 0.3 Zn 0.2 Mn 0.15 Mg 0.1

Effects of Specific Alloying Elements and Impurities

On Properties Of Silumin After Modification Of Al-Si
Aluminium Alloy
The mechanical, physical, and chemical properties of aluminum silicon alloys depend upon
composition and microstructure. The addition of selected elements to pure aluminum
greatly enhances its properties and usefulness. Because of this, most applications for
aluminum utilize alloys having one or more elemental additions. The major alloying
additions used with aluminum silicon are copper, manganese, magnesium,nickle,iron and
zinc. The total amount of these elements can constitute up to 10% of the alloy composition
(all percentages given in weight percent). Impurity elements are also present, but their total
percentage is usually less than 0.15% in aluminum silicon
alloys.
The important alloying elements and impurities are listed here as a concise review of major
effects. Some of the effects, particularly with respect to impurities, are not well documented
and are specific to particular alloys or conditions.

 Change in Properties & Mechanical Behaviour may include effects

of precipitation hardening (age hardening), solid solution
hardening, dispersion strengthening, grain refining, modifying
intermetallic phases, suppression of grain growth at elevated
temperatures (e.g. during annealing), wear resistance and
other tribological properties.
● Silicon, Si (up to 17%)
 Improves cast ability of aluminum alloys due to a better fluidity and
lower shrinkage of molten aluminum-silicon alloys.
 Increases strength of the alloys.
 Improves resistance to abrasive wear.
 Silicon in a combination with magnesium allows to strengthen the alloys by
precipitation hardening heat treatment (Wrought aluminum-magnesium-silicon
alloys (6xxx), Cast aluminum alloy 356.0).

● Copper, Cu (up to 6.5%)

 Increases tensile strength, fatigue strength and hardness of the alloys due
to the effect of solid solution hardening.
 Allows to strengthen the alloys by precipitation hardening heat treatment
(Wrought aluminum-copper alloys (2xxx), Cast aluminum alloy 201.0).
 Decreases the ductility of the alloys.
 Decreases corrosion resistance.

● Magnesium, Mg (up to 10%)

 Strengthens and hardens the alloys by solid solution hardening mechanism
without considerable decrease of ductility (Wrought aluminum-magnesium
alloys (5xxx), Cast aluminum alloy 518.0.
 In a combination with silicon or zinc allows to strengthen the alloys by
precipitation hardening heat treatment (Wrought aluminum-magnesium-silicon
alloys (6xxx), Wrought aluminum-zinc-magnesium alloys (7xxx), Cast
aluminum alloy 356.0, Cast aluminum alloy 713.0)

● Manganese, Mn (up to 1.5%)

 Strengthens and hardens the alloys (Wrought aluminum-manganese alloys
(3xxx)) by solid solution hardening and dispersion hardening mechanisms.
 Improves low cycle fatigue resistance.
 Increases corrosion resistance.
 Improves ductility of aluminum alloys containing iron and silicon due to
modification of Al5FeSi intermetallic inclusions from platelet to cubic form
Al15(MnFe)3Si2.
● Zinc, Zn (up to 8%)
 In a combination with magnesium or magnesium-copper allows to
strengthen the alloys by precipitation hardening heat treatment (Wrought
aluminum-zinc-magnesium alloys (7xxx), Cast aluminum alloy 713.0).
 Increases susceptibility of the alloys to Stress corrosion cracking.

● Chromium, Cr (up to 0.3%)

 Suppresses the grain growth at elevated temperatures (e.g. during heat
treatment).
 Improves ductility and toughness of aluminum alloys containing iron and
silicon due to modification of Al 5FeSi intermetallic inclusions from platelet to
cubic form (similar to the effect of manganese).
 Reduces susceptibility of the alloys to Stress corrosion cracking.

● Nickel, Ni (up to 2%)

 Increases hardness and strength of aluminum-copper (Wrought aluminum-
copper alloys (2xxx) and aluminum-silicon (Wrought aluminum-silicon alloy
4032) at elevated temperatures.
 Reduces the Coefficient of Thermal Expansion.

● Lithium, Li (up to 2.6%)

 Increases strength by the precipitation hardening heat treatment.
 Increases Modulus of Elasticity.
 Reduces density.

● Titanium, Ti (up to 0.35%)

 Refines primary aluminum grains (grains formed during the Solidification)
due to formation of fine nuclei Al 3Ti. Titanium is commonly added to aluminum
alloys together with boron due to their synergistic grain refining effect.

● Boron, B (up to 0.03%)

 Boron in a combination with titanium refines primary aluminum grains
(grains formed during the Solidification) due to formation of fine nuclei TiB2.
● Zirconium,Zr & Vanadium,V (up to 0.2%)
 Inhibit recovery and recrystallization
 Increase the recrystallization temperature.

● Iron, Fe (up to 1.1%)

 Increases strength due to formation of Al-Fe intermetallics.
 Decreases ductility. I most aluminum alloys Iron is undesirable impurity.

● Sodium, Na (up to 0.015%); Antimony,

Sb (up to 0.5%); Calcium, Ca (up to
0.015%), Strontium, Sr (up to 0.05%)
 Increase ductility of hypoeutectic and eutectic aluminum-silicon alloys
(Wrought aluminum-silicon alloys (4xxx), Cast aluminum alloy 443.0) by a
modification of the silicon phase from coarse platelet like particles to fine
fibrous structure.

● Tin, Sn (up to 40%)

 Reduces coefficient of friction of aluminum alloys (Aluminum based bearing
materials).
 Increases compatibility of the aluminum bearing alloy.
 Improves conformability.
 Improves embedability.

● Problems & Challenges-?????

Although modification is an established technology, its mechanism of operation is
still not fully understood. Recent research has shown that three different eutectic
solidification mechanisms can operate in Al-Si foundry alloys. The operation of
each mechanism can be controlled by altering chemical composition and casting
conditions.
However, has its own set of disadvantages : (i) High cost compared
with Steels;
(ii) Low Fracture Toughness in High strength conditions i.e
Low Fatigue Strength i.e Fatigue Failure
(iii) Limited Performance At Elevated Temperature.
Because of a low melting point metal, therefore microstructural stability (and
consequently creep) is an important issue even for near ambient temperature.

Because Of Lower Fatigue Strength Fatigue Failure will occur

which normally initiate at stress concentrations, structural
discontinuities & also
Fatigue corrosion mechanism, and the combination of both
effects (stress and corrosion) constitutes stress corrosion
cracking (SCC).
Therefore work has to be done on to Increase Fatigue Strength.
Coalesce([First Name]+" "+[Last Name],[Last Name],[First Name],[Email],
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Coalesce([First Name],[Last Name],[Email],[Company]) Is Not Null

"Business"
[End Time]>[Start Time]

0
Coalesce([First Name]+" "+[Last Name],[Last Name],[First Name],[Email],
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0

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0

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Coalesce([First Name]+" "+[Last Name],[Last Name],[First Name],[Email],
[Company])

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"Business"
[End Time]>[Start Time]

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"Good"

0
0

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[End Time]>[Start Time]
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Coalesce([First Name],[Last Name],[Email],[Company]) Is Not Null

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[Subtotal]+[Tax]

No
[End Date]>[Start Date]
Coalesce([First Name]+" "+[Last Name],[Last Name],[First Name],[Email],
[Company])
Coalesce([Last Name]+" "+[First Name],[Last Name],[First Name],[Email],
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Coalesce([First Name],[Last Name],[Email],[Company]) Is Not Null

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0
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=Today()
[Delivery Date]>=Today()
No

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Coalesce([First Name]+" "+[Last Name],[Last Name],[First Name],[Email],
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Coalesce([First Name],[Last Name],[Email],[Company]) Is Not Null

"Full-time"
[Unit Price]*[Quantity]*(1-[Discount])
0

"None"
=Today()

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0

0
[End Time]>[Start Time]
[End Date]>=[Start Date]

"Not Submitted"
=Today()

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[Subtotal]+[Tax]+[Shipping]
0

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[Original Contract Sum]+[Change Orders]

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([Completed Previously]+[Completed This Period])-(([Completed Previously]+
[Completed This Period])*0.05)+[Tax]

(([Completed Previously]+[Completed This Period])-(([Completed Previously]+

[Completed This Period])*0.05)+[Tax])-[Previous Payments]

0
0

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Today()
"1 - New"

"1 - Critical"

=Today()
Make sure the Status and Resolution fields are in sync

[Status]="3 - Resolved"

[Resolution] Is Null

If the Status is Resolved but the Resolution is not specified,

raise an error to prevent the data from being saved

You must select a resolution.

[Status]="4 - Closed"

[Resolution] Is Null
 If the Status is Closed but the Resolution is not specified, raise
an error to prevent the data from being saved

An issue must be resolved before it can be closed.

[Resolution] Is Not Null

If the Status is not Resolved and not Closed but a Resolution

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Resolution

Null

Make sure the Status and Resolution fields are in sync

[Status]="3 - Resolved"

[Resolution] Is Null

If the Status is Resolved but the Resolution is not specified,

raise an error to prevent the data from being saved

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[Status]="4 - Closed"

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[Resolution] Is Not Null

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0

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0

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IIf([Returned Date] Is Null,"Checked Out","Returned")

Today()
IIf([Returned Date] Is Null,"Checked Out","Returned")

Today()
IIf([Returned Date] Is Null,"Loaned","Returned")

Today()
[End Time]>[Start Time]
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0
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1

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"Open"
0

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[End Date]>=[Start Date]

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Not Update([Changed Date])

Changed Date

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0

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0
=Today()

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[Quantity]*[Unit Price]

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"New"
Concat([Budget Year]," - ",[Budget Quarter])
DateDiff(MONTH,[Start Date],[End Date])*[Rental Rate]

[End Date]>=[Start Date]

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2
0
[End Time]>[Start Time]
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0

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"On Track"
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"Business"
IIf([Status] In ("Completed","Deferred"),No,Yes)

[Percent Complete] Between 0 And 1

"2 - Medium"

"Not Started"

This data macro makes sure the Status is set correctly if the Percent
Complete is updated or it makes sure the Percent Complete is set correctly
if the Status is updated.
Percent Complete: 0=0%, 1=100%

[Percent Complete]=0

Percent Complete is default - check Status

[Status]="Completed"

If Status is changed to Completed set Percent Complete to

100%

Percent Complete

[Percent Complete]=1

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[Status]

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 [Status]="Completed" Or [Status]="Not Started"

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Status

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This data macro makes sure the Status is set correctly if the Percent
Complete is updated or it makes sure the Percent Complete is set correctly
if the Status is updated.
Percent Complete: 0=0%, 1=100%

Update([Percent Complete])
[Percent Complete]=1

If Percent Complete is changed to 100% and Status is not set

to Completed, set Status to Completed

[Status]<>"Completed"

Status

"Completed"

[Percent Complete]=0
If Percent Complete is changed to 0% and Status is
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[Status]="Completed"

Status

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If Percent Complete is between 0% and 100% and the Status is

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Status

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[Status]="Completed"

If Status is changed to Completed and Percent Complete is not

100%, set Percent Complete to 100%

[Percent Complete]<>1
Percent Complete

[Status]="Not Started"

If Status is changed to Not Started and Percent Complete is

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[Percent Complete]<>0

Percent Complete

0
[Percent Complete]=1

If Status is changed to something other than Completed and

the Percent Complete is 100%, set Percent Complete to 0%

Percent Complete

0
IIf([Status] In ("Completed","Deferred"),No,Yes)

[Percent Complete] Between 0 And 1

"2 - Medium"

"Not Started"
This data macro makes sure the Status is set correctly if the Percent
Complete is updated or it makes sure the Percent Complete is set correctly
if the Status is updated.
Percent Complete: 0=0%, 1=100%

Update([Percent Complete])

[Percent Complete]=1

If Percent Complete is changed to 100% and Status is not set

to Completed, set Status to Completed

[Status]<>"Completed"

Status

"Completed"
[Percent Complete]=0

If Percent Complete is changed to 0% and Status is

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[Status]="Completed"

Status

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[Status]="Completed" Or [Status]="Not Started"

If Percent Complete is between 0% and 100% and the Status is
either Completed or Not Started, set Status to In Progress

Status

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[Status]="Completed"

If Status is changed to Completed and Percent Complete is not

100%, set Percent Complete to 100%
[Percent Complete]<>1

Percent Complete

[Status]="Not Started"

If Status is changed to Not Started and Percent Complete is

not 0%, set Percent Complete to 0%

[Percent Complete]<>0
Percent Complete

[Percent Complete]=1

If Status is changed to something other than Completed and

the Percent Complete is 100%, set Percent Complete to 0%

Percent Complete

0
Coalesce([First Name]+" "+[Last Name],[Last Name],[First Name],[Email],
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Coalesce([First Name]+" "+[Last Name],[Last Name],[First Name],[Email],
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Coalesce([First Name],[Last Name],[Email],[Company]) Is Not Null

"Business"
0
=Today()
[Sunday]+[Monday]+[Tuesday]+[Wednesday]+[Thursday]+[Friday]+[Saturday]

([Sunday]+[Monday]+[Tuesday]+[Wednesday]+[Thursday]+[Friday]+
[Saturday])*[Pay Rate]

0
0

0
0
0
DateDiff(DAY,[Start Date],[End Date])

[End Date]>=[Start Date]

"Pleasure"
Coalesce([First Name]+" "+[Last Name],[Last Name],[First Name],[Email],
[Company])

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Coalesce([First Name],[Last Name],[Email],[Company]) Is Not Null

"Business"
Today()

"Best Way"
0