Fundamentals of Aluminium Metallurgy: Recent Advances









Edited by Roger Lumley (2018)


Introduction: Aluminium, the Strategic Material

Chapter 1. New Research Techniques in Aluminium Alloy Development

  • Introduction
  • Transmission Electron Microscopy
  • Atom Probe Tomography
  • Small-Angle X-Ray Scattering
  • Combinational and Correlative Characterization Approaches
  • Conclusion

Chapter 2. Additive Manufacturing of Aluminium-Based Alloys and Composites

  • Introduction
  • Additive Manufacturing Processes for Aluminium Alloys
  • Aluminium Alloys for Additive Manufacturing
  • Aluminium-Matrix Composites by AM
  • Summary

Chapter 3. How to Design and Buy Aluminium Castings

  • The Design Process
  • Elements of Good Casting Design
  • Equal and Unequal Sections
  • Junctions
  • Gates, Risers, and Rigging
  • The Relationship Between Casting Method, Number of Parts, and Acjievable Tolerances
  • Specification of Safety Factors
  • Factors of Safety on Critical Applications
  • Factors of Safety and Materials With Uncertainties
  • Casting Factors
  • Specification of NDT
  • Rework and In-Process Welding
  • Summary

Chapter 4. Aluminium Investment Casting and Rapid Prototyping for Aerospace Applications

  • Introduction
  • The Pattern
  • Rapid Prototyping for Investment Casting
  • The Production of High-Integrity Investment Casting
  • Towards a Fundamental Understanding of the Requirements of Casting Factor 1.0 and a Quality Model for Premium Aluminium Investment Casting
  • Experiments
  • Comparison to Production Components and Test Bars
  • Determinations and Verification of Casting Factor 1.0 for a Premium Investment Casting Process Using A-356-T6 Alloy
  • Summary and Conclusions

Chapter 5. Advances in the Sand Casting of Aluminium Alloys

  • Introduction
  • Moulding Types
  • Ablation Casting
  • Alternative Casting Methods
  • Printed Sand Moulds and Cores for Casting

Chapter 6. New Hypoeutectic/Hypereutectic Die-Casting Alloys and New Permanent Mould Casting Alloys That Rely on Strontium for Their Die Soldering Resistance

  • Introduction
  • The Elements that Provides Die Soldering Resistance at the Lowest Volume Fraction Means Lower Mn and Higher Fe Can Be Used in Structural Aluminium Die-Casting Alloys
  • Strontium, Its Thermodynamics in Aluminium Melt and Its Measured Benefits in Providing Die Soldering Resistance as Strontium Aluminate at 500 ppm
  • Using Strontium in Permanent Mold Alloys to Create the Low-Pressure PM Casting Process Without a Die Coating and 16 New PM Casting Alloys
  • Using Strontium to Create Unique Microstructures for Die Cast Hypereutectic Al-Si-(Cu)-Mg Alloys Having Elongation Over 2%
  • Structural Aluminium Die-Casting Alloys With the Same Numeric Designations as Existing Registered PM and Die-Casting Aluminium Association Alloys
  • Analysing Effects of Iron on T5 Mechanical Properties for B380, 387, 362, F380, and 368 Using Quality Index
  • Conclusions

Chapter 7. Thermal Conductivity of Aluminium High-Pressure Die Castings

  • Introduction
  • Motor
  • Voltage Inverter
  • Thermal Conductivity of Metals and Allys
  • Values of Thermal Conductivity for Aluminium Castings
  • The Role of Alloy Composition and Heat Treatment on Thermal Conductivity of Die Castings
  • Age Hardening
  • Alloys 1 and 2
  • Alloys 3-5
  • Microstructures
  • Summary

Chapter 8. Advanced Casting Technologies Using High Shear Melt Conditioning

  • Introduction
  • High Shear Melt Conditioned Direct-Chill Casting of Al Alloys
  • Reduction of Macrosegregation and Microporosity
  • Efficient Degassing of Aluminium Alloy Melts by High Shear Melt Conditioning Technology
  • Physical Modelling of the High Shear Processing
  • Summary

Chapter 9. Treatment by External Fields

  • Introduction
  • Electromagnetic Stirring
  • Vibration
  • Pulsed Power Techniques
  • Grain Refinement Mechanisms
  • Conclusions and Future Developments

Chapter 10. Automotive Wrought Aluminium Alloys

  • Automotive Lightweighting and Wrought Aluminium
  • Common Processing Methods
  • General Metallurgy and Strengthening Mechanisms in Automotive Wrought Al
  • Heat-Treatable Alloys
  • Nonheat-Treatable Alloys
  • Application of Aluminium Alloys in Automotive Design and Manufacture
  • Future Automotive Wrought Al Potential

Chapter 11. Aluminium Lithium Alloys

  • Introduction
  • A Brief History
  • Third Generation Al-Li Alloys
  • Physical Metallurgy of Al-Cu-Li Alloys
  • Processing
  • Strengthening Mechanisms
  • Conclusions

Chapter 12. Aluminium Scandium Alloys

  • Introduction
  • Scandium – State of the Art
  • Sc Containing Al Alloys
  • The Antirecrystallization Effect of Scandium
  • Effect of Scandium on The Corrosion Performance
  • The Superplasticity Effect of Scandium
  • Applications of Al-Sc Alloys
  • Conclusions

Chapter 13. Control of Distortion in Aluminium Heat Treatment

  • Introduction
  • Distortion and its Effects in Aluminium Alloys
  • Distortion Mechanisms
  • Control of Distortion by Modification of Alloy Composition
  • Distortion During Solution Heat Treatment
  • Distortion During Quenching of Aluminium Components
  • Distortion During Ageing Heat Treatment
  • Control of Distortion by Stress Relaxation Through Mechanical Working
  • Control of Distortion by Stress Relaxation Through Thermal Treatment
  • Summary

Chapter 14. Recent Insights Into Corrosion Initiation at the Nanoscale

  • Introduction
  • Microstructures
  • Nanostructure
  • Corrosion From the Micron-Scale to the Nanoscale
  • Aluminium Surface
  • Corrosion in Corrosion Susceptible Nanostructures
  • Conclusions