Handbook of Aluminum: Volume 2: Alloy Production and Materials Manufacturing

735 Pages·2003·11.74 MB·English

by  George E. Totten

of Aluminum
Volume 2
Alloy Production and Materials
Manufacturing
edited by
George E. Totten
6. E. Tutten & Associates, Inc.
Seattle, Washington, U.S.A
D. Scott MacKenzie
Houghton International Incorporated
Valley Forge, Pennsylvania, U.S.A.
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Preface
ThissecondvolumeofHandbookofAluminumaddressesthephysicalmetallurgyand
processing technologies of aluminum and its alloys in a thorough and deliberate
manner. Volume 1 covers a wide range of topics including pure aluminum and its
properties, an extensive discussion of the physical metallurgy of aluminum and its
alloys, and processes such as rolling, forging, casting, welding, quenching, super-
plastic forming, and others.
There are 18 chapters in volume 2 and some of the topics discussed include:
(cid:1) Production of aluminum alloys including extractive metallurgy, smelting,
master alloy creation, and recycling
(cid:1) Analytical methods used to characterize aluminum alloys
(cid:1) Work hardening, recovery, recrystallization, and grain growth
(cid:1) Modeling of microstructure evolution
(cid:1) Microstructure-texture-property relationships
(cid:1) Property prediction using quench factor analysis
(cid:1) Mechanical properties and alloy chemistry
(cid:1) Aluminum alloy corrosion
(cid:1) Surface chemistry of adhesion processes
(cid:1) Surface modification including nitriding
(cid:1) Friction stir welding
(cid:1) Aluminum intermetallics and metal matrix composites
(cid:1) Environmental effects and toxicity of aluminum production processes
iii
iv Preface
Theinformationinthesechapters,inadditiontothatinVolume1,providesthe
reader with an extensive and rigorous reference to nearly all aspects of the produc-
tion,physicalmetallurgy,andprocessingtechnologiesencounteredinthealuminum
alloy industry.
We are indebted for the tremendous effort and patience shown by all of our
contributors. We are especially indebted to Alice Totten and Patricia MacKenzie
for their unending patience and assistance throughout the preparation of this text.
We also acknowledge Houghton International for their support, without which this
book would not have been possible.
George E. Totten
D. Scott MacKenzie
Contents
Preface iii
Contributors vii
1. Extractive Metallurgy of Aluminum 1
Fathi Habashi
2. Smelting of Aluminum 47
Michael M. Gasik and Michael I. Gasik
3. Creation of Master Alloys for Aluminum 81
Michael M. Gasik and Vladislav I. Mazur
4. Recycling of Aluminum 115
Jorge Alberto Soares Teno´rio and Denise Crocce Romano Espinosa
5. Analytical Techniques for Aluminum 155
Alexis Deschamps
6. Work Hardening, Recovery, Recrystallization, and Grain Growth 193
Angelo Fernando Padilha and Ronald Lesley Plaut
7. Modeling of Microstructural Evolution During
Processing of Aluminum Alloys 221
Bala Radhakrishnan, Gorti Sarma, and Chris H. J. Davies
v
vi Contents
8. Texture-Property Relationships in Aluminum Alloys:
Simulations and Experiments 277
Dierk Raabe
9. Property Prediction 319
James T. Staley and Robert E. Sanders, Jr.
10. Mechanical Properties 343
D. Scott MacKenzie
11. Corrosion of Aluminum and Its Alloys 421
T. David Burleigh
12. Surface Chemistry of Adhesion to Aluminum 465
Margaret M. Hyland
13. Surface Modification 483
Kiyoshi Funatani, Masayuki Yoshida,
and Yoshiki Tsunekawa
14. Aluminum Nitriding 565
Heinz-Joachim Spies and Bert Reinhold
15. Friction Stir Welding of Aluminum Alloys 579
Anthony P. Reynolds
16. Aluminum Intermetallics 603
Georg Frommeyer and Sven Knippscheer
17. Aluminum-Based Metal Matrix Composites 631
Georg Frommeyer and Sven Knippscheer
18. Environmental and Toxicological Effects 671
Gilbert F. Bourcier
Appendixes
1. Alloy Equivalents 701
2. Aluminum Specifications 704
3. Wrought and Cast Aluminum Chemical Specifications 713
4. Typical Properties of Wrought and Cast Aluminum Alloys 716
Index 719
Contributors
Gilbert F. Bourcier, B.S. Old Dominion Engineering Services Company,
Midlothian, Virginia, U.S.A.
T. David Burleigh, Ph.D. New Mexico Tech, Socorro, New Mexico, U.S.A.
Chris H. J. Davies, Ph.D. Monash University, Victoria, Australia
Alexis Deschamps, M.Eng., Ph.D. Institut National Polytechnique de Grenoble,
Domaine Universitaire, Saint Martin d’He`res, France
DeniseCrocceRomanoEspinosa,Ph.D. UniversityofSa˜oPaulo,Sa˜oPaulo,Brazil
Georg Frommeyer, Dr.-Ing. Max-Planck-Institut fu¨r Eisenforschung GmbH,
Du¨sseldorf, Germany
Kiyoshi Funatani, Ph.D. IMST Institute, Nagoya, Aichi, Japan
Michael I. Gasik, D.Sci.Tech. National Metallurgical Academy of Ukraine,
Dnipropetrovsk, Ukraine
Michael M. Gasik, D.Sc., D.Tech.Sci. Helsinki University of Technology, Espoo,
Finland
Fathi Habashi, Dr.Tech. Laval University, Quebec City, Canada
vii
viii Contributors
Margaret M. Hyland, Ph.D. University of Auckland, Auckland, New Zealand
Sven Knippscheer, Dipl.-Ing. Max-Planck-Institut fu¨r Eisenforschung GmbH,
Du¨sseldorf, Germany
Vladislav I. Mazur, D.Sci.Tech. National Metallurgical Academy of Ukraine,
Dnipropetrovsk, Ukraine
D. Scott MacKenzie, Ph.D. Houghton International Incorporated, Valley Forge,
Pennsylvania, U.S.A.
Angelo Fernando Padilha, Dr.-Ing. University of Sa˜o Paulo, Sa˜o Paulo, Brazil
Ronald Lesley Plaut, Ph.D. University of Sa˜o Paulo, Sa˜o Paulo, Brazil
Dierk Raabe, Dr.-Ing. Max Planck Institut for Iron Research, Du¨sseldorf,
Germany
Bala Radhakrishnan, Ph.D. Oak Ridge National Laboratory, Oak Ridge,
Tennessee, U.S.A.
Bert Reinhold, Dipl.-Phys. ALD Vacuum Technologies AG, Hanau, Germany
Anthony P. Reynolds, Ph.D. University of South Carolina, Columbia, South
Carolina, U.S.A.
Robert E. Sanders, Jr., Ph.D. Aluminum Corporation of America, Alcoa Center,
Pennsylvania, U.S.A.
Gorti Sarma, Ph.D. Oak Ridge National Laboratory, Oak Ridge, Tennessee,
U.S.A.
Heinz-Joachim Spies, Dr.-Ing.habil. Freiberg University of Mining and Technol-
ogy, Freiberg, Germany
James T. Staley, Ph.D. Consultant, Durham, North Carolina, U.S.A.
Jorge Alberto Soares Teno´rio, Ph.D. University of Sa˜o Paulo, Sa˜o Paulo, Brazil
Yoshiki Tsunekawa, Ph.D. Toyota Technological Institute, Nagoya, Aichi, Japan
Masayuki Yoshida Nihon Parkerizing Company Ltd., Hiratsuka, Kanagawa,
Japan
1
Extractive Metallurgy of Aluminum
FATHI HABASHI
Laval University, Quebec City, Canada
1 HISTORY
Since Humphry Davy announced in 1808 his belief that the plentiful compound
alumina was theearth (oxide)of anundiscovered metal, scientistshad been making
efforts to obtain this new metal. Davy never made any aluminum himself; but in
1825, the Danish scientist Hans Christian Oersted (177771851) published his
successful experiment in producing a tiny sample of the metal in the laboratory by
reducingaluminumchloridewithpotassiumamalgam.Potassiumwasisolatedafew
years earlier by Davy.
Two years later, Friedrich Wo¨hler (180071882) in Germany produced tiny
globulesofaluminumbythesamemethod,andwasabletodemonstratethemetal’s
lightweight and malleability. Henri Sainte7Claire Deville (Fig. 1) in France in 1854
showed that cheaper sodium could also be used, and the first commercial plant
producing small quantities of aluminum was begun in 1855. Since potassium and
sodium were produced electrolytically, the process was expensive.
In 1886, following the development of large-scale equipment for generating
electrical power, Paul He´roult (Fig. 2a) inFrance, and Charles Hall (Fig. 2b) in the
United States, independently developed a process for the direct electrolytic
decomposition of Al O . They discovered that when an electric current is passed
2 3
through molten cryolite containing dissolved Al O at 98071000(cid:1)C, molten alumi-
2 3
numisdepositedatthecathodeandcarbondioxideisliberatedatthecarbonanode.
This discovery, coupled with the process developed by Karl Josef Bayer (Fig. 3)
in 1888 for the production of alumina, resulted in the modern process for the
production of aluminum.
1