Fundamentals of aluminium metallurgy – Production, processing and applicatins
Edtted by Roger Lumley (2010)
BRIEF CONTENTS
Introduction to aluminium metallurgy
- Aluminium as an engineering material
- The development of aluminium alloys
- Cast aluminium alloys
- Wrought aluminium alloys
- Production of aluminium
- Uses of aluminium
- Conclusion
Part I – Production and casting of aluminium and its alloys
Production of alumina
- Introduction to the aluminium oxides
- Al minerals – mining and processing
- Alumina production processes
- The Bayer alumina refinery
- Alumina microstructure
- Impurities
- Production of speciality aluminas
- Alumina production trend
Production of primary aluminium
- Introduction
- Raw materials used in the aluminium production process
- Energy efficiency in the utilisation of carbon anodes
- The carbon anodes
- Electrolyte materials
- The cathode and cathode materials
- Current efficiency
- Cell amperage increase
- Cell lines
- Health, environment and safety (HES)
- Inert anodes
- The past, present and future of primary aluminium production
Production of secondary aluminium
- History of secondary aluminium
- Sources of raw materials
- Processing
- Cost drivers
- Future trends
- Further reading
- Reference
Ingot casting and casthouse metallurgy of aluminium and its alloys
- Direct chill casting
- Heat flow and solidification
- Macrosegregation
- Typical surface defects
- Gas pressurised extrusion billet casting
- Rolling slab technology
- Special variants of DC casting
- DC casting safety
- Chain conveyor casting
- Melt treatment
- Conclusion
- Notes
Casting of aluminium alloys
- Introduction
- Aluminium casting alloys
- Microstructure control in aluminium foundry alloys
- Filling the casting
- Feeding and porosity
- Casting processes
- Summary
Quality issues in aluminum castings
- Introduction
- Standard molds
- Effect of solidification time
- Theoretical basis for the quality index
- Effect of inclusions and porosity on quality
- Fatigue failure
- Sources of casting defects
- Effect of metal treatment and transfer on quality
- Possible improvements in fatigue life
- Conclusion
Case studies in aluminium casting alloys
- Introduction
- The effect of the alloy specification range onmicrostructure and properties
- An impurity that reduces castability and increasescasting defects
- The effect of grain refinement on defect formation
- The effect of excess titanium on foundry alloys
- Selecting the right master alloy for grain refinement
in terms of effectiveness and cost optimisation - Selecting the right master alloy for eutectic modification
in terms of effectiveness and cost optimisation - Summary
High pressure die casting of aluminium and its alloys
- History of high pressure die casting
- The die casting process
- Aluminium alloys used in die casting
- Defects in die casting
- Conclusion
Progress on the heat treatment of high pressure die castings
- Introduction
- Role of alloying elements during solution treatment
- Role of alloying elements during age hardening
- Application to industrially produced parts and
commercial heat treatment facilities - Implications for redesign of high pressure die castings
- Conclusion
- Notes
Part II – Metallurgical properties of aluminium and its alloys
Work hardening in aluminium alloys
- Introduction
- Fundamentals of work hardening
- Models of work hardening
- Applications of work hardening models to industrial alloys
- Commercial aspects of work hardening
- Conclusion and future trends
environment and safety (HES)
- Introduction
- Al-Cu based alloys
- Al-Cu-Mg based alloys
- Al-Mg-Si based alloys
- environment and safety (HES)
- Precipitation in Al alloys under severe plastic deformation
- Conclusion
Solute partitioning to enhance mechanical properties of aged aluminium alloys
- Introduction
- Solute partitioning through compositional change
- Studies of underaged alloys
- Secondary precipitation
- Conclusion
Vacancies in aluminium and solute-vacancy interactions in aluminium alloys
- Introduction
- Experimental studies of vacancies and solute-vacancy interactions
- Modelling
- Conclusion
Modeling the kinetics of precipitation processes in aluminium alloys
- Introduction
- Physical processes controlling precipitation
- Current approaches to modeling precipitation kinetics
- Coupling precipitation and plastic deformation
- Future trends and perspectives
environment and safety (HES), structural features and properties
- Introduction
- Severe plastic deformation techniques used in processing of Al alloys
- Producing ultrafine-grained aluminium alloys by means of SPD techniques
- Mechanical properties of UFG Al alloys at room temperature
- Innovation potential of UFG Al alloys
- Conclusion
Design for fatigue crack growth resistance in aluminum alloys
- Introduction
- Background and current state of knowledge
- Materials, processing, mechanical properties and fatigue crack growth testing
- Fatigue crack propagation in the near-threshold regime
- Fatigue crack propagation mechanisms in Regions II and III of crack growth
- Kmax and stress ratio effects on fatigue crack growth
- A dual parameter DK-Kmax approach to fatigue crack growth
- Kmax sensitivity and data normalization for generating design curves
- Conclusion
Fracture resistance in aluminium
- Introduction
- Fracture in uni-axial tension
- environment and safety (HES)
- Fracture in aluminium alloy castings
- environment and safety (HES)
- environment and safety (HES)
- Fracture in aluminium particulate metal-matrix composites
- environment and safety (HES)
- environment and safety (HES)
Corrosion and corrosion protection of aluminium
- Introduction
- General, galvanic and pitting corrosion
- environment and safety (HES)
- Environmentally assisted cracking
- Corrosion protection in the aircraft structure
- environment and safety (HES)
trailing edge strip
Part III – Processing and applications of aluminium and its alloys
Joining of aluminium and its alloys
- Introduction
- Mechanical joining
- Fusion welding
- Solid state welding
- Brazing
- Adhesive bonding
- Conclusion
Aluminium powder metallurgy
- Introduction
- The press and sinter powder metallurgy process
- Sintering fundamentals
- Sintering of aluminium
- PM aluminium alloys and their applications
- Future trends
Laser sintering and rapid prototyping of aluminium
- Introduction
- The skeleton
- Infiltration
- Dimensional changes
- Conclusion
Aluminium sheet fabrication and processing
- Introduction
- Aluminium alloys and specifications
- The aluminium sheet fabrication processing route and microstructure evolution
- Parameters and metallurgical effects in Al alloy sheet processing
- Integrated material and through-process modelling
- Conclusion
Application of modern aluminium alloys to aircraft
- Introduction
- Drivers for materials selection and
aluminum alloy product development for aircraft - Performance criteria and property requirements
for primary structure of subsonic aircraft - Structure–property relationships
- New products and recent manufacturing technologies
- Conclusion
Materials selection and substitution using aluminium alloys
- Introduction
- Fundamental material selection strategies
- Material selection for specific scenarios
- Non-stationary fatigue-limited application
- Multi-objective problems and numeric optimisation
- Multiple objective material selection
- Environmental consequence of material selection
- Conclusion
Some usuful figures from this book
Figure 3.1 – Flow sheet of the Hall-Hйroult process
[Figure 3.1 in Production of primary aluminium]
Schematic of phenomena taking place during fluxing with argon containing chlorine gas
[Figure 5.8 in Ingot casting and casthouse metallurgy of aluminium]
Schematic diagram of a cold chamber high-pressure die casting (HPDC) machine.
[Figure 3.1 in Casting of aluminium alloys]
Schematic illustration showing the principle of a vacuum-assisted die casting technique
[Figures 6.2 (a) and (b) in Casting of aluminium alloys]
Schematic showing the low pressure die casting (LPDC) process
[Figure 6.4 in Fundamentals of aluminium metallurgy]
Schematic showing the sand casting process
[Figure 6.5 in Casting of aluminium alloys]