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Aluminium and Its alloys

Presentation · April 2022

DOI: 10.13140/RG.2.2.33040.07685

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 Aluminum
➢Aluminum, the second most plentiful metallic element on earth, became an economic
competitor in engineering applications.

➢Aluminum has a density of only 2.7 g/cm3, approximately one-third as much as steel
(7.83 g/cm3).

➢Aluminum typically displays excellent electrical and thermal conductivity.

➢Aluminum is nonferromagnetic, a property of importance in the electrical and

electronics industries.

➢Some aluminum alloys exceed structural steel in strength. However, pure aluminum
and certain aluminum alloys are noted for extremely low strength and hardness.
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Aluminum

2
 Aluminum Alloys

Wrought Al-Alloys Cast Al-alloys

Wrought aluminum alloys are used in

the shaping processes: rolling, forging, This term is used in as-cast parts
extrusion, etc.

Heat-treatable alloys Non-Heat-treatable alloys Heat-treatable alloys Non-Heat-treatable alloys

3
 Aluminum Alloys Designation
Wrought Al-Alloys Cast Al-alloys

• 1xxx pure aluminum Al~99% • 1xx.x pure aluminum Al~99%

• 2xxx Al-Cu • 2xx.x Al-Cu
• 3xxx Al-Mn • 3xx.x Al-Si with add Cu and/or Mg
• 4xxx Al-Si • 4xx.x Al-Si
• 5xxx Al-Mg • 5xx.x Al-Mg
• 6xxx Al-(Mg, Si) (6061) • 6xx.x unused series
• 7xxx Al-Zn • 7xx.x Al-Zn
• 8xxx used major alloying elements such • 8xx.x Al-Tin
as iron or tin. • 9xx.x other elements
4
 Wrought Al-Alloys
Effect of alloying elements

❖Copper (Cu) 2xxx series.

❖Manganese (Mn) 3xxx series.

❖Silicon (Si) 4xxx series.

❖Magnesium (Mg) 5xxx series.

❖Magnesium Plus Silicon (Mg+Si) 6xxx series.

❖Zinc (Zn) 7xxx series.

❖Other Alloying elements

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 Pure Aluminum (1xxx series)

❖relatively low strength.

❖high ductility.
❖high electrical conductivity.
❖resistance to all types of corrosive environment.
❖High formability.

Formability is the ability of a metal to undergo plastic deformation without

being damaged.
the ability of sheet metal to be formed into a desired shape without cracking

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 Metal Forming Processes

Sheet Metal Forming

Bulk
deformation
Bulk Deformation Processes
❖Bulk Deformation is the metal forming operation
1. Forging 2. Rolling
where a significant change in shape occurs via
plastic deformation in metallic parts. Usually, the
initial shapes of the material can be cylindrical
bars, billets, rectangular billets, slabs, etc. In this
process, we plastically deform these structures in
cold or warm/hot conditions to get the desired
shape. The bulk deformation process is important
3. Extrusion 4. Wire and bar drawing
in manufacturing complicated shapes having good
mechanical properties. The plastic deformation of
the workpiece is large, making a considerable
change in shape and cross-section.

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 Metal Forming Processes

Bulk
deformation
Sheet Metal Forming

❖Sheet Metal Forming is a metal forming Sheet Metal Forming Processes

operation in which the geometry of a piece of 1. Bending 2. Deep Drawing
sheet undergoes modification upon the addition of
a force. Furthermore, the applied force has to be
larger than the yield strength of the metal. It
causes the metal to undergo plastic deformation.
Using this method, we can either bend or stretch a
metal sheet into the desired shape.
❖This method does not make any significant 3. Shearing 4. etc.
change in thickness and surface characteristics of
the sheet.
❖Workpiece – a sheet or a part fabricated from a
sheet
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 Al-Cu alloys (2xxx series)
❖Copper provides relatively high strength because it provides solution strengthening and the
ability to precipitation harden.
❖Many commercial aluminum alloys contain copper from 1 to 10%.

❖resistance to atmospheric corrosion is not as good as that of pure aluminum.

❖2xxx alloys may be susceptible to stress-corrosion cracking (SCC). Precipitation hardening
improves resistance to SCC but reduces ductility and toughness 9
 Al-Mn alloys (3xxx series)
❖Manganese provides only modest strength increase even when strain hardened but
relatively high formability and ductility.

❖very high resistance to corrosion in

almost all environments.

❖ Commercial aluminum-manganese

alloys contain up to 1.2% manganese.

❖manganese is commonly employed as

a supplementary alloying element in

the other series to enhance strength.

10
 Al-Si alloys (4xxx series)
❖There are two types of silicon-bearing aluminum alloys:
1) silicon alone. which are not very strong but provide excellent flow and finishing
characteristics.
2) include copper and/or magnesium as well as silicon and so gain strength by
solution heat treatment and aging.

❖The 4xxx alloys are not highly resistant to

atmospheric corrosion.

❖The 4xxx alloys are readily welded.

❖the mostly widely used weld filler alloys

( their high fluidity).

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 Al-Magnesium (Mg) 5xxx series
❖Magnesium additions to aluminum provide
the highest strength non-heat-treatable alloys.
❖high toughness, so can be used in critical
applications where superior toughness is vital .
❖ the 5xxx alloys also have excellent
resistance to atmospheric and seawater corrosion.

❖alloys with more than 3% Mg are not recommended for service in which significant exposure
to high temperature may be encountered because some sensitization to stress-corrosion
cracking (SCC) may develop
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 Al-Magnesium Plus Silicon (Mg+Si) 6xxx series

❖With both magnesium and silicon present, aluminum forms a quasi-binary section with
the Mg2Si phase of the magnesium-silicon system, which in turn provides excellent
precipitation-hardening capability.

❖This results in modestly higher strengths than possible with non-heat-treatable alloys,
combined with generally excellent corrosion resistance..

❖ Alloys of the 6xxx type are among the easiest of aluminum alloys to extrude.

❖As with the 2xxx series, some natural aging begins immediately after solution heat
treatment, so forming operations should be scheduled soon after the material is quenched..

13
 Al-Zinc (Zn) 7xxx series
❖Zinc-bearing aluminum alloys, especially when combined with copper and magnesium, provide
the highest strengths of any commercial series.

❖These alloys possess relatively poorer atmospheric corrosion resistance compared with other
aluminum alloys.

❖less tough and more susceptible to

stress-corrosion cracking SCC.

❖As with the 2xxx and 6xxx series, 7xxx alloys

naturally age following heat treatment, so scheduling

of any intended forming operations is essential.

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 Cast Al alloys (Russian Standard, GOST 1583–93)
Chemical and phase composition of industrial casting Al alloys according to Russian standard
Phase composition of
№ system Si,% Mg, % Cu,% Zn,% Strengthening phases1) TE, 0C
eutectics

1 Al–Si 4,5–13 – – – (Al)+(Si) – 577

(Al)+(Si)+
2 Al–Si–Mg 6–11 0,1–0,6 – – ', '' 555
Mg2Si ()
3 Al–Si–Cu 7–13 – 1,5–5 – (Al)+(Si)+Al2Cu () ', '' 525
(Al)+(Si)+Al2Cu+ ', '', ', '',
4 Al–Si–Cu–Mg 4–23 0,2–1,1 0,5–8 – 505
Al5Cu2Mg8Si6(Q) S (Al2CuMg)
Al–Si–Cu–Mg- (Al)+(Si)+Al2Cu+ ', '', ', '',
5 6–10 0,1–0,5 0,3–1,5 5–12 505
Zn Al5Cu2Mg8Si6(Q) S (Al2CuMg)

6 Al–Cu – – 3,5–11 – (Al)+Al2Cu ', '' 548

7 Al–Mg – 2,5–12 – – (Al)+Al8Mg5 – 450

(Al)+MgZn2 ()+
8 Al–Mg–Zn – 0,5–2,4 – 2,5–6,5 ,',T' 475
Al3Mg2Zn (T)
(Al)+M+T
9 Al–Zn–Mg–Cu – 1,5–2,5 0,4–1,5 5–8 ,' 470–475
(Al,Cu,Mg, Zn)

1) formed during aging after hardening 15

 Prepared by : Sayed Amer

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