{"title":"Introduction to Aluminum","authors":"A. Sverdlin","doi":"10.1201/9781351045636-140000421","DOIUrl":"https://doi.org/10.1201/9781351045636-140000421","url":null,"abstract":"Aluminum is the most heavily consumed non-ferrous metal in the world with an annual consumption of approximately 24 million tons of which it is estimate that 75% of this total amount is primary aluminum (aluminum extracted from ore). This article provides an overview of aluminum ores and their composition, reduction of aluminum, production of commercial quality aluminum, extraction, refinement and the production of ultrapure aluminum.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"8 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133449961","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Microstructure and Properties of Friction Stir Welded Aluminum Alloys","authors":"I. Kalemba, S. Dymek","doi":"10.1201/9781351045636-140000425","DOIUrl":"https://doi.org/10.1201/9781351045636-140000425","url":null,"abstract":"Aluminium alloy 7136 belongs to the Al–Zn–Mg–Cu group of aluminium alloys strengthened by precipitation. These alloys offer very good properties, i.e. high strength combined with good corrosion resistance, which makes them suitable for aerospace applications. The limited range of applications of these alloys is due to problems associated with their welding. The Al–Zn–Mg–Cu alloys are classified as non-weldable. The aim of this study was to determine the quality and properties of friction stir welded (FSW) joints of alloy 7136-T76. This article presents the results of a detailed study into the microstructure and mechanical properties of FSW welds. The paper demonstrates that the FSW method is suitable for joining Al–Zn–Mg–Cu alloys. The FSW joints are of good quality and high mechanical properties. Tests of joints created at various tool rotation speeds have shown that joints of suitable quality, in terms of microstructure and properties, can be obtained for a relatively wide range of process parameters. The tool rotation speeds applied during the welding process did not have a significant influence on the quality of the welds.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"33 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133218718","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Porosity in Aluminum Alloy Castings","authors":"L. Kuchariková, E. Tillová, J. Belan, M. Uhríčik","doi":"10.1201/9781351045636-140000291","DOIUrl":"https://doi.org/10.1201/9781351045636-140000291","url":null,"abstract":"The inclusions and impurities (such as oxides, carbide, defect, and so on) are formed mostly during the casting process. These inclusions and impurities reduce material properties because an increase in porosity has a tendency to form failure and corrosion of aluminum alloys. The effect of porosity on the fatigue life of AlSi9Cu3 cast alloy was studied, examining the effect of porosity size, distribution, and morphology on the fatigue behavior changes, using image analysis software. A comparison of the fatigue properties was made between material casted into a metallic mold and the material casted into a sand mold under the same conditions of gravity die casting. The fatigue properties were studied on equipment Vibrophores Amsler 50–250 HFP 5100 for material casted into a metallic mold and on Rotoflex for materials casted into a sand molds. The results show that porosity has the greatest detrimental effect on fatigue life. It was found that fatigue life decreases with increasing size of the pores surface. The experimental material casted into the metallic mold had about 98.78% smaller porosity size in comparison to the material casted into the sand mold; therefore, it showed better fatigue and mechanical properties.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"24 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116776744","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Hot Stamping of Complex-Shaped High-Strength Aluminum Components","authors":"Liliang Wang, Jun Liu, Jianguo Lin","doi":"10.1201/9781351045636-140000228","DOIUrl":"https://doi.org/10.1201/9781351045636-140000228","url":null,"abstract":"Aluminum alloy components are important contribution to lightweight transportations for improving energy efficiency. However, formability of aluminum alloys at room temperature often hinders their further applications in the automotive, rail, or aerospace industries. The solution heat treatment, forming, and in-die quenching (HFQ®) process is an advanced forming technology that performs both forming and heat treatment simultaneously in a single operation. Since its inception, a significant amount of research has been made on the process to develop it further and to assess the feasibility of using it to form components with increasingly complicated geometries, from a growing variety of alloys. This entry summarizes the HFQ® research work, with the emphasis on the development, modeling, and applications of the technology for stamping complex-shaped high-strength aluminum panel components.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"7 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116804482","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Electron Beam Welding of Aluminum Alloys","authors":"M. Sobih, Zuhair Elseddig","doi":"10.1201/9781351045636-140000300","DOIUrl":"https://doi.org/10.1201/9781351045636-140000300","url":null,"abstract":"Aluminum alloys are the subject of increasing interest in the automotive industry, as well as the aircraft industry, aiming to reduce the weight of components and also allowing a profit in term of energy saving. In assembly process, riveting has been widely used in the aircraft industry, whereas welding seems to be available in the car industry in the case of aluminum alloys. Nevertheless, conventional fusion welding can generate defects, such as gas porosity, oxide inclusions, solidification cracking (hot tearing), reduced strength in both the weld, and heat-affected zone (HAZ), which could limit its development. Electron beam welding (EBW) has unique advantages over other traditional fusion welding methods due to high energy density, deep penetration, large depth-to-width ratio, and small HAZ. EBW has been developed for many years and is being increasingly implemented in various industrial applications. In many cases, it has proven to be an efficient method for joining difficult to weld materials. One of the major problems associated with the EBW is how to select a proper combination of the process parameters because improper selection of these parameters causes defects in the weld joint, which could seriously influence the weld mechanical properties. This work introduces an overview of the EBW process, its parameters, process simulation, process optimization, and finally characterization of the electron beam weld joint of 2219 aluminum alloy.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"30 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125973376","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Microstructure and Microhardness of AlZnMnMg Alloy During Heat Treatment","authors":"S. Valdez-Rodríguez, B. Campillo, J. Islas","doi":"10.1201/9781351045636-140000189","DOIUrl":"https://doi.org/10.1201/9781351045636-140000189","url":null,"abstract":"In this work, the structural changes induced by the chemical nature of alloyed elements and aged treatment showed a beneficial connection with hardness and electrochemical degradation performance. Al-based alloys were investigated by means of the Vickers hardness test, in order to determine the effect of aging treatment on the hardness; X-ray diffraction and scanning electron microscopy were used to identify the phase transformation by the casting and ageing treatment; finally, a short-term electrochemical test to know the electrochemical performance. The results show that the formation of the (MgZn)49Al32 phase occurs under two conditions: when the magnesium content is more than 5.49% in as-cast condition, and the thermal treatment carried out at 450°C for 5 h. In addition, the hardness and electrochemical performance have been influenced by the presence and quantity of the (MgZn)49Al32 phase. The addition of magnesium alloy modifies the microstructure, increases the content of the (MgZn)49Al32 phase, and provides a localized corrosion, which leads to the breakdown of the oxide film (γ-Al2O3) formed on the Al alloy surface.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130417061","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
L. Casteletti, A. L. Neto, D. T. D. Macedo, L. Cruvinel, G. Totten
{"title":"Stellite Superalloy Powder Deposition on 7075 Aluminum Alloy","authors":"L. Casteletti, A. L. Neto, D. T. D. Macedo, L. Cruvinel, G. Totten","doi":"10.1201/9781351045636-140000303","DOIUrl":"https://doi.org/10.1201/9781351045636-140000303","url":null,"abstract":"Several types of powders can be deposited on metal alloys for property improvement using thermal spray processes. Aircraft grade 7075 aluminum alloy possesses good mechanical properties but poor wear and corrosion resistance. Thermal spray coatings can improve the poor wear performance of 7075 so that it is suitable for use in severe conditions by depositing a hard, wear-resisting layer over the base material. This can be done by a simple production process while maintaining the base material properties. Among the available coatings, cobalt-base superalloys, such as Stellites, provides excellent protection against corrosion and wear. However, the treatment must not deteriorate the substrate hardness. In the High Velocity Oxygen Fuel (HVOF) thermal spray process, the short resident time of the powder in the flame results in a relatively small temperature increase, which in turn results in a lower substrate temperature during the coating deposition. In the present work, HVOF thermal spray process was used to coat 7075-T3 aluminum alloy samples with Stellite 6 superalloy. This treatment resulted in layers of high hardness and improved wear performance while keeping the base material properties unchanged.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"75 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127388475","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"High-Speed Computer Tomography: Pressure Die Casting","authors":"Christian Heikel, E. Ambos","doi":"10.1201/9781351045636-140000261","DOIUrl":"https://doi.org/10.1201/9781351045636-140000261","url":null,"abstract":"For many years, molders have been trying to figure out the influence of diverse factors on the quality of die castings during molding. In 2010, the rapid computer tomograph became available for the first time. This system is derived from medical technology and offers new testing methods. The measures, which have been in progress for the past 5 years, were focused to point out the correlation between the major influences of pore expression in pressure die castings. These results are suggestive of the future technological and constructive work. Through continuous improvements in testing methods, the technology finally succeeded to work out major influences on pore expressions in pressure die castings. With these new findings, it is possible, and even proven by example, that through the right choice of process parameters strength-influencing pores can be reduced. In case of not preventing the formation of pores, they could be moved out of the areas, which are strength vulnerable. This is an appropriate concept to reduce the weight of components and therefore the implementation of lightweight constructions in the automotive industry.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128824327","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Calcium-Containing Aluminum Alloys","authors":"T. Akopyan, N. Belov, E. Naumova","doi":"10.1201/9781351045636-140000264","DOIUrl":"https://doi.org/10.1201/9781351045636-140000264","url":null,"abstract":"The phase composition and microstructure of ternary alloys, Al–Ca–X (where X = (Silicon) Si, (Magnesium) Mg, (Zinc) Zn, (Copper) Cu, (Nickel) Ni, (Iron) Fe, (Manganese) Mn, and (Scandium) Sc), developed based on Ca-containing eutectics have been studied. In most systems, ternary compounds are detected. It is found that the structure of Ca-containing eutectics is much finer than that of Al–Si alloys. Such alloys have a good combination of technological properties during casting and deforming. Because of the high volume fraction of Ca-containing particles (up to 33 vol.%), they may be considered as promising “natural composites.” The strength properties of Al–Ca–X alloys may be significantly enhanced by adding Sc and Zr, forming L12 nanoparticles. Alloys of the system Al–Zn–Mg–Ca can reach hardnesses higher than 200 HB, which gives reason to expect good strength properties. With the example of the Al–9%Zn–3.5%Mg–3%Ca model experimental alloy based on the (Al) + (Al,Zn)4Ca eutectic, the possibility, in principle, of manufacturing rolled sheets has been demonstrated.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":"80 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129180923","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Design of Forming Processes: Sheet Metal Forming","authors":"T. Wanheim","doi":"10.1201/9781351045636-140000402","DOIUrl":"https://doi.org/10.1201/9781351045636-140000402","url":null,"abstract":"This article addresses sheet metal deformations processes and are classified as secondary processing methodologies. Sheet metal forming processes are further classified as processes with: compressive stresses, tensile stresses, compressive and tensile stresses, bending, and shear. Additional discussion on sheet metal processing includes: process metallurgy and microstructure, process design, processing parameters, prevention of failures, formability and testing, and modeling.","PeriodicalId":348912,"journal":{"name":"Encyclopedia of Aluminum and Its Alloys","volume":" 9","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"120834205","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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