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Lecture 2: Introduction to Aluminum Alloys

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1 Lecture 2: Introduction to Aluminum Alloys
MATSE 259 Lecture 2: Introduction to Aluminum Alloys Christopher L. Muhlstein, Ph.D. Department of Materials Science and Engineering The Pennsylvania State University University Park, PA

2 Last Lecture Fundamentals of materials science and engineering
Classes of materials properties Three classes of materials Steel nomenclature

3 Lecture 2: Key Concepts and References
Aluminum alloy nomenclature Introduction to phases Reference (Callister) sects. 3.12, 4.3, 5.1 pps chapter 6

4 Al Structural Alloys Lotus Elise 190 hp 1984 lbs 0-60 mph - 4.9 sec
top speed mph mpg highway $46K

5 Automotive Application of Al Alloys
Lotus versatile vehicle architecture system (VVA) Almost all “aluminum high pressure die-castings, stampings, and extrusions Advanced Materials & Processes, July 2005, p 29

6 Which “aluminum” is it? Not the same designation system as steels

7 Aluminum Alloy Overview
Low density (~34% of steel) High thermal and electrical conductivity Corrosion resistant in ambient air Low melting point (660°C) Modified mechanical properties via cold work, alloying, and heat treating

8 Aluminum Alloy Nomenclature
Aluminum Association Number 4 digit number + temper designation (letter and sometimes numbers) Wrought vs. cast designation 4 digits, no punctuation (e.g. 6061) 4 digits, decimal point between last two digits (e.g )

9 Wrought Aluminum Alloy Nomenclature
First digit indicates alloy group 1XXX Aluminum ≥99.00% 2XXX Copper 3XXX Manganese 4XXX Silicon 5XXX Magnesium 6XXX Magnesium + Silicon 7XXX Zinc 8XXX other elements 9XXX Unused series

10 1XXX Series Wrought Aluminum Alloys
10XX are unalloyed Last two digits give minimum aluminum percentage 1035 contains 99.35% aluminum The second digit indicates control over specific impurities (e.g. silicon)

11 Cast Aluminum Alloy Nomenclature
First digit indicates alloy group 1XX.X Aluminum >99.00% 2XX.X Copper 3XX.X Silicon with added copper and/or magnesium 4XX.X Silicon 5XX.X Magnesium 7XX.X Zinc 8XX.X Tin 9XX.X Other elements Second two digits identify specific alloy Last digit indicates casting (0) or ingot (1) Letter may be appended, in some cases

12 1XX.X Series Cast Aluminum Alloys
Second two digits indicate minimum aluminum percentage 135.0 Aluminum is a 99.35% aluminum casting 135.1 Aluminum is a 99.35% aluminum ingot

13 Material Structure Amorphous materials Single crystal materials
Polycrystalline materials Grain boundaries Isotropic and anisotropic properties Small crystalline nuclei Growth of crystallites Solidified Optical micrograph Schematic of stages of solidification of a polycrystalline material; the square grids depict unit cells Callister, Materials Science and Engineering: An Introduction (2003)

14 Structural Materials are Complicated!
Names? Crystal structure(s)? Microstructure? Transmission electron micrograph of 7150-T651 Optical micrographs of various cast irons. Callister, Materials Science and Engineering: An Introduction (2003)

15 Microstructural Evaluation (Optical)
Optical Microscopy Grind Polish Etch/stain/anodize Image

16 Etchants Reveal Microstructure
Polished Gray Iron Polished and Etched Gray Iron

17 Wrought Aluminum Microstructures
10% Reduction 40% Reduction 5457-O plate, Barker’s reagent 80% Reduction ASM, Metals Handbook Volume 9 (1995)

18 Steel Microstructures
Pearlite Tempered Martensite Martensite Spheroidite Callister, Materials Science and Engineering: An Introduction (2003)


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