1. TAFE NSW -Technical and Further Education Commission www.highered.tafensw.edu.au ENMAT101A Engineering Materials and Processes Associate Degree of Applied Engineering (Renewable Energy Technologies) Lecture 17 – Aluminium and its alloys

2. TAFE NSW -Technical and Further Education Commission Aluminium and its alloys EMMAT101A Engineering Materials and Processes Reference TextSection Higgins RA & Bolton, 2010. Materials for Engineers and Technicians, 5th ed, Butterworth Heinemann Ch 17 Additional ReadingsSection

3. TAFE NSW -Technical and Further Education Commission Aluminium and its alloys EMMAT101A Engineering Materials and Processes Note: This lecture closely follows text (Higgins Ch17)

4. TAFE NSW -Technical and Further Education Commission Aluminium (Higgins 17.1) EMMAT101A Engineering Materials and Processes READ HIGGINS 17.1 Aluminium is very reactive – strongly electropositive and readily combines with all the non-metal (electronegative) ions. So it wasn’t produced until 1825 (Oersted) when it was more expensive than gold. Not any more! Aluminium Wikipedia

5. TAFE NSW -Technical and Further Education Commission Uses of aluminium EMMAT101A Engineering Materials and Processes http://www.alu-support.com/newsdisp.php?ID=129 READ HIGGINS 17.1 Demand for Aluminium was driven by aircraft. Today it is widely spread though most industries. Lightweight Durable Easy to form, extrude, diecast Good finishes High strength to weight

6. TAFE NSW -Technical and Further Education Commission Worldwide Aluminium Production EMMAT101A Engineering Materials and Processes Worldwide Aluminium production Aluminium needs electricity. It is actually easier to ship the ore to the electrical energy source rather than bring the electricity to the ore.

7. TAFE NSW -Technical and Further Education Commission The extraction of aluminium (Higgins 17.2) EMMAT101A Engineering Materials and Processes READ HIGGINS 17.2 The modern electrolytic process turns bauxite (Al2O3) into aluminium metal. Unlike a blast furnace that removes oxygen (reduction) with coke, aluminium requires electricity to do this: All 91 megajoules of the stuff per kg! So aluminium product suits countries with ample hydroelectricity. (e.g. Norway) http://en.wikipedia.org/wiki/File:AluminumSlab.JPG

8. TAFE NSW -Technical and Further Education Commission The extraction of aluminium (VIDEO) EMMAT101A Engineering Materials and Processes VIDEO The making of aluminium [videorecording] Advanced version. Russell, Geoff. 1993. Video Education Australia. DVD (30 min.) Explains the process of smelting aluminium using the smelter at Portland smelter in Victoria as an example. Detailed analysis of refining and smelting of aluminium. Covers production, economic, environmental issues. Excellent quality. DVD 669.722/RUSS669.722/RUSS

9. TAFE NSW -Technical and Further Education Commission Properties of aluminium (Higgins 17.3) EMMAT101A Engineering Materials and Processes READ HIGGINS 17.3 Conductivity (electrical and thermal) Corrosion resistance Ductility for forming, extrudion Low MP for diecasting Highly machinable Lightweight Good finishes - anodising High strength to weight Lots of alloys and heat treatments http://www.teknologiateollisuus.fi

10. TAFE NSW -Technical and Further Education Commission Aluminium alloys (Higgins 17.4) EMMAT101A Engineering Materials and Processes READ HIGGINS 17.4 4 main classes of aluminium alloys WroughtCast Non-heat Treatable Heat Treatable Traps to watch out for… 1. A common mistake is to call aluminium components “alloy” simply because it starts with “al”. Brass and even steel is “alloy” 2. In USA, Aluminium is called Aluminum. Same stuff, different name.

11. TAFE NSW -Technical and Further Education Commission Aluminium alloys (Higgins 17.4) EMMAT101A Engineering Materials and Processes READ HIGGINS 17.4 17.4.1 Wrought alloys 17.4.2 Cast alloys READ HIGGINS 17.5 17.5 Wrought alloys which are not heat-treated 17.6 Cast alloys which are not heat-treated

12. TAFE NSW -Technical and Further Education Commission Some common aluminium alloys EMMAT101A Engineering Materials and Processes http://www.globalmetals.com.au

13. TAFE NSW -Technical and Further Education Commission Aluminum alloys EMMAT101A Engineering Materials and Processes They are normally identified by a four figure system which originated in the USA and is now universally accepted (with variations – usually extra digits). Note: Higgins is based on British Standards (BS) from which most Australian standards are based. Where it is written 1473: 5083 It simply means BS 1473 and grade 5083 (e.g. table 17.1)

14. TAFE NSW -Technical and Further Education Commission EMMAT101A Engineering Materials and Processes Higgins

15. TAFE NSW -Technical and Further Education Commission EMMAT101A Engineering Materials and Processes Higgins Figure 17.2 The aluminium-silicon thermal equilibrium diagram. The effects of 'modification' on both the position of the eutectic point and the structure are also shown. READ HIGGINS

16. TAFE NSW -Technical and Further Education Commission EMMAT101A Engineering Materials and Processes Higgins

17. TAFE NSW -Technical and Further Education Commission EMMAT101A Engineering Materials and Processes Higgins (i) 12 per cent silicon in aluminium - unmodified, as cast. Since this alloy contains more than the eutectic amount (11.6 per cent) of silicon (see Figure 17.2), primary silicon (angular crystals) are present. The eutectic is coarse and brittle and consists of 'needles' of silicon in a matrix of a solid solution because the layers of a in the eutectic have fused together to form a continuous mass (the amount of silicon being only 11.6 per cent of the eutectic so that the layers of a would be roughly ten times the thickness of those in silicon),

18. TAFE NSW -Technical and Further Education Commission EMMAT101A Engineering Materials and Processes Higgins (ii) The same alloy as (i) but modified by the addition of 0.01 per cent sodium. This has the effect of displacing the eutectic point to 14 per cent silicon so that the structure now consists of primary crystals of a (light) in a background of extremely fine-grained eutectic (dark). The alloy is now stronger and tougher,

19. TAFE NSW -Technical and Further Education Commission EMMAT101A Engineering Materials and Processes Higgins (iii) A duralumin- type alloy in the 'as extruded' condition (unetched). The particles consist mainly of CuAl2 (see Figure 17.4) elongated in the direction of extrusion. Most of this CuAl2 would be absorbed during subsequent solution treatment.

20. TAFE NSW -Technical and Further Education Commission Wrought alloys which are heat-treated (Higgins 17.7) EMMAT101A Engineering Materials and Processes Figure 17.4 Structural changes which take place during the heat- treatment of a duralumin- type of alloy. Higgins

21. TAFE NSW -Technical and Further Education Commission Wrought alloys which are heat-treated (Higgins 17.7) EMMAT101A Engineering Materials and Processes Figure 17.5 The effects of time and temperature of precipitation treatment on the strength of duralumin. Higgins

22. TAFE NSW -Technical and Further Education Commission Wrought alloys which are heat-treated (Higgins 17.7) EMMAT101A Engineering Materials and Processes CAREFULLY READ 17.7.1 Heat-treatment Age Hardening

23. TAFE NSW -Technical and Further Education Commission EMMAT101A Engineering Materials and Processes

24. TAFE NSW -Technical and Further Education Commission EMMAT101A Engineering Materials and Processes

25. TAFE NSW -Technical and Further Education Commission Cast alloys which are heat-treated (Higgins 17.8) EMMAT101A Engineering Materials and Processes

26. TAFE NSW -Technical and Further Education Commission

27. EMMAT101A Engineering Materials and Processes Online Resources. Aluminium Non Ferrous Metals

28. TAFE NSW -Technical and Further Education Commission GLOSSARY Bauxite Electrolysis Precipitation hardening Age hardening Wrought Cast Anodising Oxide layer As quenched Alumina EMMAT101A Engineering Materials and Processes Glossary http://www.amari-ireland.com/online-tools/glossary/aluminium/a

29. TAFE NSW -Technical and Further Education Commission QUESTIONS Moodle XML: Some questions in 10106 Non-Ferrous 1.Define all the glossary terms. 2.Aluminium has been dubbed solid electricity. Producing 1 kg of Aluminium uses 91 MJ. Calculate the cost to produce 1 kg of aluminium based on current domestic electricity charges. What rate would you expect a smelter to pay? 3.It has been stated that aluminium is the most economically viable material for recycling. Comment on this statement using a comparison of current recycling values for other common scrap materials like metals, plastics and paper products. Ref: http://en.wikipedia.org/wiki/Aluminium. List the proportions of Aluminium that are lost during recycling.http://en.wikipedia.org/wiki/Aluminium 4.Why have car radiators switched from copper to aluminium? Explain why these two metals dominate other areas like evaporators and condensers in air conditioning and heat exchangers for heat reclamation systems for reducing energy losses in manufacturing and process plants. 5.Explain the age hardening process and mechanism for an aluminium alloy such as Duralumin. 6.Explain why Aluminium is highly reactive yet is used for its corrosion resistance. EMMAT101A Engineering Materials and Processes