Introduction about Aluminum 7075

Aluminum 7075 is a high-strength alloy commonly used in the aerospace and defense
industries due to its excellent mechanical properties and corrosion resistance. This
alloy contains zinc, copper, and magnesium, which contribute to its strength and
durability. The unique combination of these elements results in an alloy that is
lightweight yet incredibly strong, making it a popular choice for critical applications
where reliability and performance are paramount. In this research, we will explore the
properties and characteristics of aluminum 7075, including its composition,
manufacturing process, and applications, Aluminum 7075 is a high-strength alloy
commonly used in the aerospace and defense industries due to its excellent
mechanical properties and corrosion resistance. This alloy contains zinc, copper, and
magnesium, which contribute to its strength and durability. The unique combination of
these elements results in an alloy that is lightweight yet incredibly strong, making it a
popular choice for critical applications where reliability and performance are paramount.
In this research, we will explore the properties and characteristics of aluminum 7075,
including its composition, manufacturing process, and applications. We will also
investigate its advantages and limitations, as well as its potential for further
development and improvement.

I will mention some application about aluminum 7075 alloy.

1- Forming.
Aluminum 7075 is a high-strength aluminum alloy that is commonly used in forming
applications due to its excellent strength and toughness. The alloy has good formability,
which means it can be easily shaped into a variety of forms, including sheets, plates,
and bars. Here, we will explore the pros and cons of forming aluminum 7075

Pros:

 High strength: Aluminum 7075 is one of the highest strength aluminum alloys
available, making it ideal for forming applications where high strength is required.
 Lightweight: Aluminum 7075 has a low density, making it ideal for applications
where weight reduction is critical. This is particularly important in aerospace and
defense applications.
 Corrosion resistance: Aluminum 7075 is highly resistant to corrosion, making it a
good choice for applications where exposure to the elements is a concern.
 Good formability: Aluminum 7075 has good formability, which means it can be
easily shaped into a variety of forms, including sheets, plates, and bars. This

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 makes it a good choice for applications such as aircraft wing skins, fuselage
frames, and other structural components.

Cons:

 Expensive: Aluminum 7075 can be expensive compared to other aluminum

alloys, which can make it difficult to use in some applications.
 Difficult to weld: Aluminum 7075 is difficult to weld, which can limit its use in
certain applications. This is because the alloy has a tendency to crack during
welding, which can lead to failure in high-stress applications.
 Stress corrosion cracking: Aluminum 7075 is prone to stress corrosion cracking,
which can lead to failure in high-stress applications. This is particularly important
to consider when using the alloy in marine or other corrosive environments.
 Limited availability: Aluminum 7075 may not be readily available in certain sizes
or shapes, which can limit its use in certain applications.

2- Machining
Aluminum 7075 is a challenging alloy to machine due to its high strength and
toughness. It has a tendency to generate a significant amount of heat during
machining, which can lead to tool wear and poor surface finish. To overcome these
challenges, specialized cutting tools and machining techniques are required, such
as high-speed machining and use of coolants to reduce heat buildup. Additionally,
aluminum 7075 should be machined at slower speeds than softer aluminum alloys
to prevent damage to the workpiece and cutting tools. Despite its challenges,
aluminum 7075 is a popular choice for machining applications in aerospace,
defense, and high-performance industries due to its strength, durability, and
corrosion resistance.

Pros:

 High strength: Aluminum 7075 has a high strength-to-weight ratio, making it ideal
for applications where strength is important, such as aerospace and automotive
industries.
 Machinability: Aluminum 7075 is considered a difficult-to-machine material, but
with the right tools and techniques, it can be machined effectively.
 Corrosion resistance: Aluminum 7075 has good corrosion resistance, making it
suitable for applications where exposure to moisture or corrosive environments is
a concern.
 Heat treatable: Aluminum 7075 can be heat treated to increase its strength,
making it a versatile material for a wide range of applications.
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 Cons:

 Work hardening: Aluminum 7075 can work harden during machining, which can
lead to tool wear and reduced machining efficiency.
 Chip formation: The formation of long, stringy chips during machining can cause
problems such as clogging the cutting tool and affecting surface finish.
 Surface finish: Achieving a good surface finish can be challenging when
machining aluminum 7075 due to its tendency to form burrs and rough surfaces.
 Tool wear: Machining aluminum 7075 can cause rapid tool wear, which can
increase machining costs and reduce efficiency.

3- Additive manufacturing
Additive manufacturing, also known as 3D printing, is a promising technology for
producing complex components made from aluminum 7075 alloy. Additive
manufacturing techniques such as powder bed fusion and directed energy
deposition enable the production of parts with intricate geometries that would be
difficult or impossible to achieve using traditional manufacturing methods. The
ability to print aluminum 7075 allows for the creation of lightweight yet strong
components for a wide range of applications, including aerospace, defense, and
automotive industries.

Pros:

 Design freedom: Additive manufacturing allows for complex geometries that

cannot be achieved with traditional manufacturing methods. This can be
especially useful for aerospace and defense applications where lightweight, high-
strength parts are required.
 Material efficiency: Additive manufacturing allows for material to be used more
efficiently, reducing waste and saving costs.
 Reduced lead time: Additive manufacturing can significantly reduce lead times
for production of parts compared to traditional manufacturing methods.
 Cost-effective for small production runs: Additive manufacturing can be a cost-
effective solution for producing small runs of parts, as there is no need for
expensive tooling.

Cons:

 Limited size: Additive manufacturing machines have a limited build size, so larger
parts may need to be produced in multiple sections and assembled afterwards.

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  Surface finish: Parts produced using additive manufacturing may require
additional finishing operations to achieve the desired surface finish.
 Material properties: Parts produced using additive manufacturing may have
different properties than those produced using traditional methods, including
reduced strength and ductility.
 Cost: While additive manufacturing can be cost-effective for small production
runs, it can be more expensive for larger runs due to the cost of the equipment
and materials.

Additive manufacturing fusion cons.

 Cracking: Due to its high strength, aluminum 7075 is more prone to cracking than
softer aluminum alloys. This can be especially true during machining, where
excessive heat buildup can cause thermal cracking. Proper machining
techniques, tool selection, and coolant use can help reduce the risk of cracking.
 Porosity: Aluminum 7075 has a tendency to develop porosity, or tiny voids or air
pockets, during casting or additive manufacturing processes. Porosity can
weaken the material and reduce its mechanical properties. Proper processing
and quality control can help minimize porosity.
 Residual stress: As mentioned earlier, fusion-based additive manufacturing
methods, such as powder bed fusion and directed energy deposition, can result
in residual stress in the final product. This can be especially problematic for
aluminum 7075, which is more prone to stress cracking. Post-processing steps
such as heat treatment or stress relief annealing can help alleviate residual
stress.

Fusion cons fixed with additive manufacturing solid state

Solid-state additive manufacturing techniques, such as binder jetting and sheet
lamination, can be used to repair cracking, porosity, and residual stress in additive
manufacturing fusion.

 solid-state methods can be used to add material layer by layer to fill in the crack
and restore the part's integrity. This can be done without the need for excessive
heat, which can further damage the part.
 Porosity can also be addressed using solid-state methods. By adding material
layer by layer, solid-state techniques can help fill in voids and air pockets and
improve the overall strength and mechanical properties of the part.
 Residual stress can be alleviated using solid-state methods such as sheet
lamination, which can create parts with reduced internal stress compared to other
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additive manufacturing techniques. This can be especially important for high-
performance materials like aluminum 7075, which are more prone to stress
cracking

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