Fundamentals of Aluminium Metallurgy: Production, Processing and Applications

854 Pages·2010·24.56 MB·English

by  Roger Lumley

1
2
Fundamentals of aluminium metallurgy
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
20
1
2
3
4
5
6
7
8
9
30
1
2
3
4
5
6
7
8
9
40
1
2
43X
i
© Woodhead Publishing Limited, 2011
1 Related titles:
2
3 Titanium alloys: modelling of microstructure, properties and applications
4 (ISBN 978-1-84569-375-6)
5 Computer-based modelling of material properties and microstructure is a fast-growing area
of research and the use of titanium is also growing rapidly in many applications. The book
6
links the modelling of microstructure and properties to titanium. The first part of the book
7
reviews experimental techniques for modelling the microstructure and properties of
8
titanium. A second group of chapters looks in depth at the physical models and a third group
9 examines neural network models. The final section covers surface engineering products.
10
1 Friction stir welding: from basics to applications
2 (ISBN 978-1-84569-450-0)
3 Friction stir welding (FSW) is a solid-state welding process that is gaining wide
acceptance in industry, especially the shipbuilding, aerospace, mass transportation and
4
automotive industries. FSW is particularly suited to those industries that use aluminium
5
and its alloys. This authoritative book provides a comprehensive review of the subject
6
of friction stir welding and covers topics such as process basics, equipment, modelling,
7
inspection and quality control and applications.
8
9 Hydrometallurgy: principles and applications
20 (ISBN 978-1-84569-407-4)
1 The book is concerned with the theoretical principles of hydrometallurgical processes
2 and engineering aspects. The hydrometallurgical processes of production of copper
are discussed and leaching of chalcopyrite as the main sulphide mineral of copper
3
processed in industry is used as an example. The book is suitable as a university
4
textbook for students of metallurgy.
5
6 Details of these and other Woodhead Publishing books can be obtained by:
7
• visiting our web site at www.woodheadpublishing.com
8
• contacting Customer Services (e-mail: [email protected]; fax:
9
[phone]; tel.: [phone] ext. 130; address: Woodhead
30 Publishing Limited, Abington Hall, Granta Park, Great Abington, Cambridge
1 CB21 6AH, UK)
2
If you would like to receive information on forthcoming titles, please send your
3
address details to: Francis Dodds (address, tel. and fax as above; e-mail: francis.
4 [email protected]). Please confirm which subject areas you are
5 interested in.
6
7
8
9
40
1
2
43X
ii
© Woodhead Publishing Limited, 2011
1
2
Fundamentals of 3
4
5
6
aluminium metallurgy
7
8
9
Production, processing and applications 10
1
2
3
4
Edited by 5
6
Roger Lumley
7
8
9
20
1
2
3
4
5
6
7
8
9
30
1
2
3
4
5
6
7
8
9
40
1
2
43X
iii
© Woodhead Publishing Limited, 2011
1 Published by Woodhead Publishing Limited, Abington Hall, Granta Park, Great
2 Abington, Cambridge CB21 6AH, UK
www.woodheadpublishing.com
3
4 Woodhead Publishing, 525 South 4th Street #241, Philadelphia, PA 19147, USA
5
6 Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28 Ansari Road,
Daryaganj, New Delhi – 110002, India
7
www.woodheadpublishingindia.com
8
9 First published 2011, Woodhead Publishing Limited
10 © Woodhead Publishing Limited, 2011
The authors have asserted their moral rights.
1
2 This book contains information obtained from authentic and highly regarded sources.
3 Reprinted material is quoted with permission, and sources are indicated. Reasonable
4 efforts have been made to publish reliable data and information, but the authors and the
publisher cannot assume responsibility for the validity of all materials. Neither the
5
authors nor the publisher, nor anyone else associated with this publication, shall be liable
6 for any loss, damage or liability directly or indirectly caused or alleged to be caused by
7 this book.
8 Neither this book nor any part may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopying, microfilming and recording, or
9
by any information storage or retrieval system, without permission in writing from
20 Woodhead Publishing Limited.
1 The consent of Woodhead Publishing Limited does not extend to copying for general
2 distribution, for promotion, for creating new works, or for resale. Specific permission
must be obtained in writing from Woodhead Publishing Limited for such copying.
3
4 Trademark notice: Product or corporate names may be trademarks or registered
5 trademarks, and are used only for identification and explanation, without intent to
6 infringe.
7
British Library Cataloguing in Publication Data
8 A catalogue record for this book is available from the British Library.
9
30 ISBN 978-1-84569-654-2 (print)
ISBN 978-0-85709-025-6 (online)
1
2 The publisher’s policy is to use permanent paper from mills that operate a sustainable
3 forestry policy, and which has been manufactured from pulp which is processed using
4 acid-free and elemental chlorine-free practices. Furthermore, the publisher ensures that
the text paper and cover board used have met acceptable environmental accreditation
5
standards.
6
7 Typeset by RefineCatch Limited, Bungay, Suffolk, UK
8 Printed by TJI Digital, Padstow, Cornwall, UK
9
40
1
2
43X
iv
© Woodhead Publishing Limited, 2011
1
2
Contents
3
4
5
6
7
8
9
10
1
2
Contributor contact details xiii
3
4
1 Introduction to aluminium metallurgy 1
5
R.N. LumLey, CSIRO Light Metals Flagship, Australia
6
1.1 Aluminium as an engineering material 1
7
1.2 The development of aluminium alloys 2
8
1.3 Cast aluminium alloys 5
9
1.4 Wrought aluminium alloys 7
20
1.5 Production of aluminium 8
1
1.6 Uses of aluminium 8
2
1.7 Conclusion 17
3
1.8 References 18
4
5
Part I Production and casting of aluminium and its alloys 21 6
7
2 Production of alumina 23 8
J. metSON, The University of Auckland, New Zealand 9
2.1 Introduction to the aluminium oxides 23 30
2.2 Al minerals – mining and processing 24 1
2.3 Alumina production processes 27 2
2.4 The Bayer alumina refinery 30 3
2.5 Alumina microstructure 38
4
2.6 Impurities 40
5
2.7 Production of speciality aluminas 42
6
2.8 Alumina production trends 43
7
2.9 Acknowledgements 44
8
2.10 References 44
9
40
3 Production of primary aluminium 49
1
H. KvaNde, Qatar University, Qatar
2
3.1 Introduction 49
43X
3.2 Raw materials used in the aluminium production process 51
v
© Woodhead Publishing Limited, 2011
vi Contents
1 3.3 Energy efficiency in the utilisation of carbon anodes 52
2 3.4 The carbon anodes 52
3 3.5 Electrolyte materials 54
4 3.6 The cathode and cathode materials 56
5 3.7 Current efficiency 57
6 3.8 Cell amperage increase 60
7 3.9 Cell lines 61
3.10 Health, environment and safety (HES) 63
8
3.11 Inert anodes 65
9
3.12 The past, present and future of primary aluminium production 67
10
3.13 Acknowledgements 69
1
3.14 References 69
2
3
4 Production of secondary aluminium 70
4
G. WaLLaCe, Sims Aluminium Pty Limited, Australia
5
4.1 History of secondary aluminium 70
6
4.2 Sources of raw materials 73
7
4.3 Processing 78
8
4.4 Cost drivers 81
9
4.5 Future trends 81
20
4.6 Further reading 82
1
4.7 Reference 82
2
3
5 Ingot casting and casthouse metallurgy of aluminium
4 and its alloys 83
5 J.F. GRaNdFIeLd, Grandfield Technology Pty Ltd, Australia
6
5.1 Direct chill casting 83
7 5.2 Heat flow and solidification 86
8 5.3 Macrosegregation 97
9 5.4 Typical surface defects 98
30 5.5 Gas pressurised extrusion billet casting 105
1 5.6 Rolling slab technology 107
2 5.7 Special variants of DC casting 108
3 5.8 DC casting safety 108
4 5.9 Chain conveyor casting 108
5 5.10 Melt treatment 110
6 5.11 Conclusion 123
7 5.12 Notes 124
8 5.13 References 124
9
6 Casting of aluminium alloys 141
40
1 S. OtaRaWaNNa, National Metal and Materials Technology
Center (MTEC), Thailand and a.K. daHLe, The University of
2
Queensland, Australia
43X
6.1 Introduction 141
© Woodhead Publishing Limited, 2011
Contents vii
6.2 Aluminium casting alloys 141 1
6.3 Microstructure control in aluminium foundry alloys 142 2
6.4 Filling the casting 143 3
6.5 Feeding and porosity 144 4
6.6 Casting processes 144 5
6.7 Summary 153 6
6.8 References 153 7
8
7 Quality issues in aluminum castings 155
9
G.K. SIGWORtH, GKS Engineering Services, USA
10
7.1 Introduction 155
1
7.2 Standard molds 156
2
7.3 Effect of solidification time 162
3
7.4 Theoretical basis for the quality index 164
4
7.5 Effect of inclusions and porosity on quality 167
7.6 Fatigue failure 169 5
7.7 Sources of casting defects 174 6
7.8 Effect of metal treatment and transfer on quality 177 7
7.9 Possible improvements in fatigue life 180 8
7.10 Conclusion 182 9
7.11 References 182 20
1
8 Case studies in aluminium casting alloys 185
2
J.a. tayLOR and d.H. StJOHN, CaSt CRC, The University
3
of Queensland, Australia and m.a. eaStON, CaSt CRC, Monash
4
University, Australia
5
8.1 Introduction 185
6
8.2 The effect of the alloy specification range on
7
microstructure and properties 186
8
8.3 An impurity that reduces castability and increases
9
casting defects 190
8.4 The effect of grain refinement on defect formation 195 30
8.5 The effect of excess titanium on foundry alloys 202 1
8.6 Selecting the right master alloy for grain refinement in 2
terms of effectiveness and cost optimisation 207 3
8.7 Selecting the right master alloy for eutectic modification 4
in terms of effectiveness and cost optimisation 208 5
8.8 Summary 214 6
8.9 References 214 7
8
9 High pressure die casting of aluminium and its alloys 217
9
m.t. muRRay, M Murray & Associates Pty Ltd, Australia
40
9.1 History of high pressure die casting 217
1
9.2 The die casting process 221
2
9.3 Aluminium alloys used in die casting 232
43X
9.4 Defects in die casting 235
© Woodhead Publishing Limited, 2011
viii Contents
1 9.5 Conclusion 257
2 9.6 References 259
3
4 10 Progress on the heat treatment of high pressure
5 die castings 262
6 R.N. LumLey, CSIRO Light Metals Flagship, Australia
7 10.1 Introduction 262
8 10.2 Role of alloying elements during solution treatment 271
9 10.3 Role of alloying elements during age hardening 279
10 10.4 Application to industrially produced parts and commercial
heat treatment facilities 291
1
10.5 Implications for redesign of high pressure die castings 299
2
10.6 Conclusion 300
3
10.7 Notes 302
4
10.8 References 302
5
6
7 Part II Metallurgical properties of aluminium and its alloys 305
8
9 11 Work hardening in aluminium alloys 307
20 W.J. POOLe and J.d. embuRy, The University of British Columbia,
1 Canada and d.J. LLOyd, Novelis Global Technology Centre, Canada
2 11.1 Introduction 307
3 11.2 Fundamentals of work hardening 308
4 11.3 Models of work hardening 312
5 11.4 Applications of work hardening models to industrial alloys 325
11.5 Commercial aspects of work hardening 332
6
11.6 Conclusion and future trends 338
7
11.7 Acknowledgements 339
8
11.8 Notes 339
9
11.9 References 339
30
1
12 Precipitation and solute clustering in aluminium:
2
advanced characterisation techniques 345
3
G. SHa, R.K.W. maRCeau and S.P. RINGeR, The University
4
of Sydney, Australia
5
12.1 Introduction 345
6
12.2 Al-Cu based alloys 347
7
12.3 Al-Cu-Mg based alloys 349
8
12.4 Al-Mg-Si based alloys 354
9
12.5 Al-Zn-Mg-(Cu) based alloys 356
40 12.6 Precipitation in Al alloys under severe plastic deformation 359
1 12.7 Conclusion 361
2 12.8 Acknowledgements 362
43X 12.9 References 362
© Woodhead Publishing Limited, 2011
Contents ix
13 Solute partitioning to enhance mechanical properties 1
of aged aluminium alloys 367 2
I.J. POLmeaR, Monash University, Australia 3
13.1 Introduction 367 4
13.2 Solute partitioning through compositional change 368 5
13.3 Studies of underaged alloys 371 6
13.4 Secondary precipitation 379 7
13.5 Conclusion 381 8
13.6 Acknowledgments 382 9
13.7 References 383 10
1
14 Vacancies in aluminium and solute-vacancy
2
interactions in aluminium alloys 386
3
a. SOmOza, Universidad Nacional del Centro de la Provincia
4
de Buenos Aires and Comisión de Investigaciones Científicas
5
de la Provincia de Buenos Aires, Argentina and a. duPaSquIeR,
Politecnico di Milano, Italy 6
7
14.1 Introduction 386
14.2 Experimental studies of vacancies and solute-vacancy 8
interactions 388 9
14.3 Modelling 408 20
14.4 Conclusion 415 1
14.5 Acknowledgements 416 2
14.6 References 416 3
4
15 Modeling the kinetics of precipitation processes 5
in aluminium alloys 422
6
C.R. HutCHINSON, Monash University, Australia 7
15.1 Introduction 422 8
15.2 Physical processes controlling precipitation 425
9
15.3 Current approaches to modeling precipitation kinetics 426
30
15.4 Coupling precipitation and plastic deformation 458
1
15.5 Future trends and perspectives 461
2
15.6 References 462
3
4
16 Ultrafine-grained aluminium alloys: processes,
5
structural features and properties 468
6
y. eStRIN, Monash University and CSIRO Process Science and
Engineering, Australia and m. muRaSHKIN and R. vaLIev, Ufa 7
State Aviation Technical University, Russia 8
16.1 Introduction 468 9
16.2 Severe plastic deformation techniques used in processing 40
of Al alloys 469 1
16.3 Producing ultrafine-grained aluminium alloys by means 2
of SPD techniques 473 43X
© Woodhead Publishing Limited, 2011