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Chapter Two
Aluminum Extrusion Alloys
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• Recyclable and Nontoxic• Lightweight• Strong• High Strength to Weight Ratio• Resilient• Corrosion-Resistant• Thermally Conductive• Reflective• Electrically Conductive• Nonmagnetic Noncombustible and Non-sparking• Cryogenically Strong
• Attractive• Wide Range of Finishes• Virtually Seamless• Complex Integral Shapes• Fastening and Assembly• Joinable• Fabrication• Tolerancing• Cost-Effective• Short Lead Times
Aluminum’s Material Advantages:
Aluminum Extrusion’s Process Advantages:
Advantages of Aluminum Extrusions
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Temperature Classification of Extruded Metals
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Aluminum Alloys
• Heat treatable and non heat treatable– 2xxx, 6xxx, 7xxx (HT)– 1xxx, 3xxx, 5xxx (NHT)
• Mechanical performance – Product properties (Strength, ductility)– Workability (during forming)
• Corrosion characteristics - composition• Processing aspects• Cost • Applications
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6xxx Alloys Profiles
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Aluminum Alloys
Designation Principal Alloying Element Typical Alloy Characteristics1xxx Minimum 99% aluminum High corrosion resistance
Excellent finishabilityEasily joined by all methodsLow strengthPoor machinabilityExcellent workabilityHigh electrical and thermalconductivity
2xxx Copper High strengthRelatively low corrosion resistanceExcellent machinabilityHeat treatable
3xxx Manganese Low to medium strengthGood corrosion resistancePoor machinabilityGood workability
4xxx Silicon Not available as extruded products5xxx Magnesium Low to moderate strength
Excellent marine corrosionresistanceVery good weldablity
6xxx Magnesium & Silicon Most popular extrusion alloy classGood extrudabiltyGood strengthGood corrosion resistanceGood machinabilityGood weldabilityGood formabilityHeath treatable
7xxx Zinc Ver high strengthGood machinabilityHeat treatable
8xxx Other ----------------------
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Common Tempers
• O Fully annealed• H112 Strain-hardened; used for non-heat-treatable
alloys• T1 Cooled from elevated temperature and
naturally aged • T4 Solution heat-treated and naturally aged• T5 Cooled from elevated temperature and
artificially aged• T6 Solution heat-treated and artificially aged
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Aluminum Extrusion Process
• Billet casting • Homogenization• Extrusion process• Cooling/quenching• Straightening
– ~1/2 % (plastic “permanent”deformation)– 1- 3% (“elimination” of residual stresses)
• Precipitation treatment (age hardening)• Finishing operations:
– Machining, Anodizing, Painting, Joining
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Temperatures
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Aluminum Extrusion Parameters
Press Force 10-100 MN …….tonContainer Diameter 100 - 650 mm ……inchesFlow Stress 300-1500 N/mm2 ……ksiBillet Length 300-1500 mm ……inchesBillet Temp. 450-550 oC ……FExit Speed- High Extrudability 25-100 m/min …….ft./min- Low Extrudability 0.5-10 m/min …….ft./minExtrusion Ratio, R 20:1 to 100:1
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Chemical Composition vs. Performance – T6 Conditions
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Phase Diagram
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Al -Mg2Si
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Extrusion Sequence
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Press Quenching
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Physical Simulation of Extrusion of 6xxx AA
OBJECTIVES• To predict the physical response of an
aluminum alloy to specific processing conditions (temperature, strain, strain rate).
• Thermal cycle simulation– homogenization through ageing
• Compression testing– deformation modeling
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Extrusion Thermal Cycle
O. Reiso, Dr. Tech. Thesis, Trondheim, Norway, 1992.
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ProcedureThermal Simulation
Extrusion (Exit Temperature)
Preheat
High
Low
Low High
Low Preheat Low Extrusion
Low Preheat High Extrusion
High Preheat High Extrusion
High Preheat Low Extrusion
(Gas or Induction)
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Gleeble Setup
Jaws
Sample
Quench Spray Head
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Homogenized Microstructure
6063 AA
SEM Image AlFeSi
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Low Preheat (7900F) - Low Extrusion (9250F)
6063 AA
Keller’s etch
60 m
Mg2Si
AlFeSi
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High Preheat (8600F) -High Extrusion (10400F)
6063 AA
Keller’s etch
26 m
AlFeSi
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Low Preheat (7900F) - Low Extrusion (9250F) + T6 aged
6063 AA
SEM Image Mg2Si
3 m
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High Preheat (8600F) - High Extrusion (10400F) + T6 age
6063 AA
Keller’s etch
26 m
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1xxx Series (NHT)
• Super purity (SP) aluminum (99.99%)• Commercial purity (CP) aluminum (99%)• Low mechanical properties
– Annealed SP - YS: 7-11 MPa• Decorative finish (architecture)• Chemical process equipment• Electrical conductors
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3xxx Series (NHT)
• Al-Mn– Mn up to 1.25% (solubility @ 1.82%)– To avoid formation of Al6Mn - low ductility
• Al-Mn-Mg (3105; Al-0.55Mn-0.5Mg)• Combination of properties
– Moderate strength– High ductility– Very good corrosion resistance
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5xxx Series (NHT)
• Al-Mg alloys• Medium strength alloys • Good corrosion resistance • Excellent resistance to marine environment• Good extrudability• UTS from 125 MPa (5005; Al-0.8Mg) to
310 MPa for 5456 in annealed conditions
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2xxx Series (Al-Cu) (HT)
• High mechanical properties– Enhanced age hardening by strain hardening– T8 temper can be up to 35% stronger than T6
• Good welding performance • Complex physical metallurgy
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2xxx Series (Al-Cu-Mg) (HT)
• Duraluminum discovered in Berlin in 1906 by Alfred Wilm (Al-3.5Cu-0.5-0.5Mg-0.5Mg)
• Used for Zeppelin airships• Alloy 2017 is a modified version of
duraluminum• Lower fracture toughness than 7xxx alloys
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7xxx Series (HT) (Al-Zn-Mg-Cu)
• The strongest alloys in the Al family• Cu added to improve resistance to stress
corrosion cracking• Significantly lower extrudability• Aerospace application
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8xxx Series
• Other alloys• 8001 (Al-1.1Ni-0.6Fe) with excellent
corrosion resistance• 8011 (Al-0.75Fe-0.7Si) bottle caps because
of very good ductility• Amorphous aluminum alloys belong to this
group as well
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Homogenization
• Uniform chemistry (no chemical segregation)
• Uniform microstructure– dendrites– grain size– alloying elements
• Elimination of casting defects
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• Form at the interdendritic regions upon casting• Almost a continuous network
-Al9Fe2Si2
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AlFeSi Intermetallics
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• Form from pre-existing - during homogenization• “necklace structure”
-Al8Fe2Si
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25 um
6063 Homogenization
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• Examine 3D AlFeSi particle morphology as function of heat treatment time– Size, Shape, Interconnectivity
Unhomog.
-AlFeSiHomog.
-AlFeSi
Morphological Evolution
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Case Study - Homogenization
•2D and 3D Microstructure Characterization Tools–Light Optical Microscopy (2D)–Scanning Electron Microscopy (2D)
•EBSD (2D) and FIB (3D)–Transmission Electron Microscopy
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FIB Milling
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2D and 3D Projections
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3 D Morphology
•Import each 2D section into Matlab•Input distance between each “slice”•Plot using MathCad