Aluminium and aluminium alloy

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Production of Aluminium France 1855: Austria 1888: Germany : • H. Sainte-Claire Deville first reduced aluminium chloride with sodium. • Karl Josef Bayer first patented the Bayer process (digesting crushed bauxite in strong sodium hydroxide solution at temperatures upto 240 o C. • Hall-Héroult introduced Hall-Héroult process by dissolving the alumina in molten cryolite (Na 3 AlF 6 ) United states 1976: • Alcoa commenced a chloride-based smelting process using alumina combined with chloride. Suranaree University of Technology Tapany Udomphol May-Aug 2007
Extraction of aluminium Aluminium can be extracted from bauxite, Kaolinite or nepheline. Bauxite: 30-50% Alumina (Al 2 O 3 ) 3-13% Silica (SiO 2 ) 10-18% Titanium oxide (TiO 2 ) Balanced water (H 2 O) Kaolinite 30-32% Alumina (Al 2 O 3 ) Balanced Silica (SiO 2 ) and water (H 2 O) Nepheline 30% Alumina (Al 2 O 3 ) 40% Silica (SiO 2 ) 20% Na 2 O + K 2 O Note: extraction processes of aluminium require high electricity consumption. suitable for countries where cheap electricity is supplied. Suranaree University of Technology Tapany Udomphol May-Aug 2007
Page 1 and 2: Lecture 2 Aluminium and its alloys
Page 3 and 4: Introduction- Why aluminium alloys?
Page 5: Applications for aluminium alloys C
Page 9 and 10: Bayer process Second step • The n
Page 11 and 12: Schematic diagram of Bayer process
Page 13 and 14: Hall-Héroult process • Aluminium
Page 15 and 16: Mechanism of electrolytic reaction
Page 17 and 18: Physical metallurgy of aluminium FC
Page 19 and 20: Phase diagrams of aluminium with va
Page 21 and 22: Heat treatments in aluminium alloys
Page 23 and 24: 1) The GP zone •The GP zones are
Page 25 and 26: Precipitate free zones (PFZ) at gra
Page 27 and 28: Hardening mechanisms • Hardening
Page 29 and 30: Relationship between strength and p
Page 31 and 32: Corrosion in aluminium alloys Surfa
Page 33 and 34: Contact with dissimilar metals •
Page 35 and 36: Surface pitting and exfoliation cor
Page 37 and 38: Mechanical behaviour of aluminium a
Page 39 and 40: 4) Grain size and shape • Alumini
Page 41 and 42: Toughness • Toughness is resistan
Page 43 and 44: Metallurgical factors influencing f
Page 45 and 46: Metallurgical features influencing
Page 47 and 48: Creep • Creep fracture (at high t
Page 49 and 50: Continuous casting process • The
Page 51 and 52: Control of metallurgical structure
Page 53 and 54: Homogenisation of DC ingots Homogen
Page 55 and 56: Thermal treatment Thermal treatment
Page 57 and 58:
Quenching 2) Hot or boiling water q
Page 59 and 60:
Thermo-mechanical processing Thermo
Page 61 and 62:
Alloy identification systems Temper
Page 63 and 64:
Work-hardening of aluminium and its
Page 65 and 66:
Work-hardening characteristics Duri
Page 67 and 68:
Designations of wrought aluminium a
Page 69 and 70:
Super-purity and commercial-purity
Page 71 and 72:
Al-Mg alloys (5xxx series) • Mg (
Page 73 and 74:
Miscellaneous alloys (8xxx series)
Page 75 and 76:
Al-Cu alloys (2xxx series) • Prec
Page 77 and 78:
Al-Mg-Si alloys (6xxx series) • M
Page 79 and 80:
Al-Mg-Si alloys (6xxx series) Mg +
Page 81 and 82:
Example: Age-hardening in Al-Cu all
Page 83 and 84:
Effects of time and temperature of
Page 85 and 86:
Cast aluminium alloys Properties re
Page 87 and 88:
British System • Designation of c
Page 89 and 90:
Alloys based on the Al-Si system Th
Page 91 and 92:
Modification of microstructure •
Page 93 and 94:
Example: Modification with Na • M
Page 95 and 96:
Over modification • Over modifica
Page 97 and 98:
Al-Cu alloy • Strength and hardne
Page 99 and 100:
Al-Zn-Mg alloys • Binary Al-Zn al
Page 101 and 102:
Sand casting • Versatile - comple
Page 103 and 104:
Semi-solid processing (Thixo-castin
Page 105 and 106:
Squeeze casting • The process inv
Page 107 and 108:
Cosworth Process • The Cosworth P
Page 109 and 110:
Comparison of mechanical properties
Page 111 and 112:
References • P. Thevoz, M. Gauman
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Aluminium and aluminium alloy

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