Name : Ziad Mohamed Ahmed Mohamed

Group : 1
Table of contents :
1.Introduction
2.Intoduction about non-ferrous alloys
3. Aluminium alloys
Introduction
 Metallurgy is a field of materials science and
engineering that studies the physical and chemical
behavior of metal elements, their intermetallic
compounds and their mixtures (called alloys).
Metallurgy includes metal science and technology; that
is, the way science is applied to metal production, and
the engineering of metal parts used in products
designed for consumers and manufacturers. Metallurgy
is different from metal processing technology. The way
that metal processing relies on metallurgy is similar to
the way that medicine relies on medicine for
technological advancement. Practitioners in metallurgy
are called metallurgists. The study of metallurgy is
additionally partitioned into two general classifications:
substance metallurgy and actual metallurgy. Substance
metallurgy is essentially worried about the decrease and
oxidation of metals, and the compound presentation of
metals. Subjects of study in substance metallurgy
incorporate mineral handling, the extraction of metals,
thermodynamics, electrochemistry, and compound
corruption (corrosion). conversely, actual metallurgy
centers around the mechanical properties of metals.
Introduction about non-ferrous alloys
 Non-ferrous metals are those containing no significant
amounts of iron. Pure metals are non-ferrous, except for
iron (Fe), also called ferrite from ferrum, meaning iron.
Non-ferrous metals are generally more expensive than
iron. However, it is used for desirable properties such
as light weight (aluminum), high conductivity (copper),
non-magnetism, corrosion resistance (zinc). Some non-
ferrous materials, such as bauxite, which is used as flux
in blast furnaces, are used in the steel industry. Other
non-ferrous metals such as chromite, pyrolusite, and
wolframite are used in the production of iron alloys.
However, many non-ferrous metals have a low melting
point, which makes them less suitable for high
temperature applications.
 There are various non-ferrous materials, all of which
contain iron-free metals and alloys. Nonferrous metals
include aluminum, copper, lead, nickel, tin, titanium,
zinc, and copper alloys such as brass and bronze.
Other rare or precious non-ferrous metals include gold,
silver, platinum, cobalt, mercury, tungsten, berylium,
bismuth, cerium, cadmium, niobium, indium, gallium.
 Aluminium alloys
 With the growth of aluminum in the weld manufacturing
industry and the acceptance of aluminum as an
excellent alternative to steel in many applications, the
need for people involved in the development of
aluminum projects to become familiar with the materials
of this group is increasing. .. To fully understand
aluminum, it is advisable to start with an understanding
of the aluminum identification / designation system, the
many aluminum alloys available, and their properties.

 Aluminium alloys and their characteristics

1. 1XXX series (non heat treatable -With ultimate tenile
strength ) This series is often referred to as the
pure aluminum series because it must contain at
least 99.0% aluminum. They are weldable.
However, due to the narrow melting range, some
considerations are required to create an acceptable
welding process. In manufacturing, these alloys are
mainly selected for their excellent corrosion
resistance, for example in special chemical tanks
and pipes, or their excellent conductivity in
busbar applications. These alloys have relatively
 low mechanical properties and are rarely
considered in general structural applications.
These base alloys are often welded with the
appropriate filler or 4xxx filler, depending on the
application and performance requirements.
2. 2XXX series (heat-treatable with ultimate tenile
strength from 27 to 60 ksi ) These are aluminum /
copper alloys (0.7-6.8% copper added), high-
strength, high-performance alloys widely used in
aerospace applications. They have excellent
strength over a wide temperature range. It is
believed that some of these alloys cannot be
welded by the arc welding process because they
are susceptible to high temperature cracking and
stress corrosion cracking. However, others are very
well arc welded with the correct welding
techniques. These base materials are often welded
with high-strength 2xxx series fillers for
performance, but depending on the application and
service requirements, silicon or 4xxx series fillers
containing silicon and copper. It may be welded.
3. 3XXX series (Non heat-treatable with ultimate
strength from 16 to 41 ksi ) These are AlMg alloys
 These are aluminum / copper alloys (0.7-6.8%
copper added), high-strength, high-performance
alloys widely used in aerospace applications. They
have excellent strength over a wide temperature
range. It is believed that some of these alloys
cannot be welded by the arc welding process
because they are susceptible to high temperature
cracking and stress corrosion cracking. However,
others are very well arc welded with the correct
welding techniques. These base materials are often
welded with high-strength 2xxx series fillers for
performance, but depending on the application and
service requirements, silicon or 4xxx series fillers
containing silicon and copper. It may be welded.
4. 4XXX series (heat-treatable &Non heat-treatable
with ultimate tensile strength of 25 to 55ksi ) These
are aluminum / silicon alloys (with 0.6-21.5%
silicon added) and are the only series containing
both heat treatable and non heat treatable alloys.
Adding silicon to aluminum lowers the melting
point and improves fluidity during melting. These
properties are desirable for filler materials used in
both fusion welding and brazing. For this reason,
 this series of alloys is mainly used as a filler
material. Silicon, apart from aluminum, cannot be
heat treated. However, many of these silicone
alloys have been developed with the addition of
magnesium or copper, giving them the ability to
respond well to solution heat treatments. These
heat treatable filler alloys are typically used only
when the welded component undergoes post-weld
heat treatment.
5. 5XXX series (Non-Heat treatable -with ultimate
tensile strength of 18 to 51 ksi ) These are
aluminum / magnesium alloys (0.2 to 6.2%
magnesium additives) and have the highest
strength of any non-heat treated alloy. In addition,
this series of alloys is easy to weld and for these
reasons it is used in a variety of applications such
as shipbuilding, transportation, pressure vessels,
bridges and buildings.
6. 6XXX Series – (heat treatable – with ultimate tensile
strength of 18 to 58 ksi) These are aluminum /
magnesium-silicon alloys (about 1.0% magnesium
and silicon additives), widely used in the welding
industry, mainly used in the form of extruded parts
 and incorporated into many structural parts. .. The
addition of magnesium and silicon to aluminum
produces magnesium silicate compounds that can
be solution-treated to improve strength. These
alloys are inherently sensitive to solidification
cracks and should not be arc welded
spontaneously (without filler metal).
7. 7XXX Series – (heat treatable – with ultimate tensile
strength of 32 to 88 ksi) These are the aluminum /
zinc alloys (zinc additions ranging from 0.8 to
12.0% Contains some high strength aluminum
alloys. These alloys are widely used in high
performance applications such as aircraft,
aerospace, and sports equipment for competition.

The Aluminum Alloy Designation

System
 In North America, Aluminum Association Inc. Is
responsible for the allocation and registration of
aluminum alloys. Currently, there are over 400 forged
aluminum alloys and forged aluminum alloys, and over
200 aluminum alloys in the form of castings and ingots
 are registered with the Aluminum Association. The
limits on the chemical composition of alloys of all these
registered alloys are the Teal Book of the Aluminum
Association entitled "International Alloy Designation
and Chemical Composition Restrictions on Forged
Aluminum and Forged Aluminum Alloys" and "Forged
Aluminum and Forged Aluminum Alloys". It is in the
pink book titled. The "Designation and Chemical
Composition Restrictions" includes aluminum alloys in
the form of castings and rods. These publications are
very useful for welding engineers when it is important to
develop the welding process and to consider the
relationship between chemistry and its crack
sensitivity.
 Aluminum alloys can be divided into several groups
based on the specific properties of the material, such as
their ability to respond to thermal and mechanical
treatments and the major alloying elements added to
aluminum alloys. Looking at the aluminum alloy
numbering / labeling system identifies the above
properties. Forged and cast aluminum parts have
different identification systems. Forged 4-digit system
and cast 3-digit and 1-digit place systems.
 Wrought aluminium alloy
designation system
 We shall first consider the 4-digit wrought aluminum
alloy identification system.
 The first digit (Xxxx) indicates the principal alloying
element, which has been added to the aluminum alloy
and is often used to describe the aluminum alloy series,
i.e., 1000 series, 2000 series, 3000 series, up to 8000
series .

 Alloy series  Principal alloying

system
 1xx  99.00% Minimum Al
 2xx  Copper
 3xx  Manganese
 4xx  Silicon
 5xx  Magnesium
 6xx  Magnesium and
silicon
 7xx  Zinc

 Cast Aluminium Designation System
 The cast alloy designation system is based on a 3 digit-
plus decimal designation xxx.x (i.e. 356.0). The first digit
(Xxx.x) indicates the principal alloying element, which
has been added to the aluminum alloy.

 Alloy Series  Principal alloying

element
 1xx.x  99% Minimum Al
 2xx.x  Copper
 3xx.x  Silicon plus Copper
and /or Magnesium
 4xx.x  Silicon
 5xx.x  Magnesium
 6xx.x  Unused series
 7xx.x  Zinc
 The second and third digits (xXX.x) are arbitrary
numbers used to identify a particular alloy in the series.
The number after the comma indicates whether it is a
cast (.0) or a bar (.1 or .2). The uppercase prefix
indicates a change in a particular alloy.
 Example: Alloy A356.0 Uppercase A (Axxx.x) indicates a
change in Alloy 356.0. The number 3 (A3xx.x) indicates
silicon plus copper and / or magnesium. 56 (Ax56.0)
 indicates the alloy in the 3xx.x series and .0 (Axxx.0)
indicates the final shape casting, not the ingot.

 Al-si alloy
 It is becoming more and more important due to
economic and ecological requirements Reduce the
weight of the vehicle. As one of such goals AlSi cast
alloys Manufactures automotive parts that operate at
ambient and relatively high temperatures (up to 200 ° C)
ºC) Due to excellent properties such as cheap
manufacturing, excellent castability, high Specific
strength and recyclability [1, 2]. Cu and Mg are generally
Allows for strength and heat treatment potential at room
temperature and high temperature [3]. The structure of
these cast alloys contains αAl dendrite as the main
component. It is decorated with eutectic Si particles
and many intermetallic compound phases such as
Al2Cu. Mg2Si, Fe-containing phase, etc. Fine structure
size, morphology and distribution . Features determine
the mechanical properties of these alloys .It is known to
be nifty The fine structure improves tensile properties.
Improvement of microstructure . It can be achieved by
high cooling rates or chemical modifications. Use of
AlSiCuMg alloy However, at temperatures above 230ºC,
 Si particles become coarser. Dissolution of Cu and Mg-
containing phases.
 Aluminium alloys are grouped according to the major
alloying elements they contain. The 4XXX group is
alloyed with silicon for ease of casting. Silicon is good
in metallic alloys used for casting. This is because it
increases the fluidity of the melt, reduces the melting
temperature, decreases the contraction associated with
solidification and is very cheap as a raw material.
 Silicon also has a low density (2.34 g cm-3), which may
be an advantage in
reducing the overall
weight of the cast
component. Silicon has a
very low solubility in
aluminium; it therefore
precipitates as virtually
pure silicon, which is hard
and hence improves the
abrasion resistance.
 The aluminum-silicon alloy forms a eutectic with 11.7%
by weight of silicon and has a eutectic temperature of
577oC. It represents the typical composition of a cast
 alloy because it has the lowest possible melting
temperature. Therefore, Al12Si weight percent alloys are
common.

 Al-Si Phase Diagram

 The starting point is the AlSi
phase diagram, which is a fairly
commercially important diagram.
To develop more complex alloys
and understand their behavior. Si
is a common pollution Although it
is an aluminum alloy, it is also a
deliberate alloy additive for both cast and forged
aluminum alloys. The Al cast alloy can contain an
amount of about 5 to 22 weight percent Si. Si at this
level Improves the fluidity and castability of aluminum.
Cast alloys 3xx.x and 4xx.x (USA) The name of the
Aluminum Association is very popular in the industry.
Hypereutectic (alloy 12.6% or more of Si (eutectic
composition) contains primary Si particles. Improved
wear resistance. Near eutectic AlSi alloys are common
cast alloys and can be cast. With various technologies:
sand casting, die casting, gravity die casting are the
most together .
 Al-12Si (Low Magnification ,Unetched )
 A dark semi-circular feature is a casting defect (pore)
caused by shrinkage as the liquid
solidifies. Otherwise, the
microstructure consists of gray silicon
strips in an aluminum-rich white matrix.
The alloy has a slight sub-eutectic
composition, but there is evidence that solidification
began with primary aluminum dendrites (the aluminum
dendrite arm section is visible). This is because the
sample did not solidify in equilibrium. Equilibrium
coagulation requires painfully slow cooling rates that
cannot be achieved by industrial practice.

 Al-12Si (High Magnification ,Unetched )

 Shows a coarse silicon plate in an
aluminum matrix. Dark features are
shrink holes and casting defects. Silicon
is very brittle because it has a diamond
crystal structure. Therefore, large plates
made of silicon impair mechanical properties.
 Silicon is very brittle because it has a diamond crystal
structure. Therefore, large plates made of silicon impair
mechanical properties. Silicon nucleates on aluminum
phosphide particles that are present as impurities in the
melt. Adding a small amount of sodium to the melt
triggers phosphorus, making silicon more difficult to
precipitate. Therefore, coagulation is suppressed at low
temperatures where the nucleation rate is high. This
significantly refines the microstructure.

 Al-12Si-0.02Na (Low Magnification ,Unetched

)
 A dark feature is a casting defect (pore)
caused by shrinkage as the liquid
solidifies. The structure of this sodium-
modified alloy is much finer than that of
the Al12Si sample. At this magnification,
the silicon particles are barely visible.
Again, note the major dendrites of aluminum due to non-
equilibrium solidification.

 Al-12Si-0.02Na (High Magnification

,Unetched )
 Highly purified silicon particles because the
microstructure is modified with sodium.

 Al-Cu Alloy
 Aluminum-copper alloy generally containing 2-10% Cu
Together with other additives it forms an important
family of alloys. With the cast Aluminum-copper forged
alloy reacts to solution treatment, Subsequent aging
with increased or decreased strength and hardness At
once. Maximum reinforcement is 4-6% Cu, Depending
on the impact of other existing components .The
Properties Aluminum-copper alloy sheet
Assembled. Aging characteristics of binary aluminum
copper Alloys have been studied more closely than any
other system, In reality, there are very few dual
aluminum-copper alloys on the market. Many
 Commercially available alloys contain other alloying
elements.

Al-Cu alloy phase diagram

 This AlCu phase
diagram shown is
only stretched to
about 60% by
weight of copper.
And about 54 wt. %
Cu is "split" by a
particular phase.
This "split" is Two
parts of the figure
Must be observed
Separately. Diagram
Very up to 54 percentage points Similar to "standard"
State diagram. The intermetallic compound phase is Not
named "or $", but Other Greeks have been assigned
Letter (I don't have one Strict practice). This is the
phase The right is called 2, but it's different Treated as
its name Exactly the same Apart as a beta phase

Al-Cu-Mg alloy
 The main benefits of adding magnesium to it Aluminum-
copper alloy is a possible increase
in strength after melting Heat
treatment and quenching. With a
specific alloy forging material For
this type, high ductility increases
strength When aging at room
temperature. Further increase due
to artificial aging Strength can be
achieved, especially at the yield
point, but a significant amount is
required. Loss of tensile
elongation. About for both cast and forged alloys made
of aluminum / copper 0.5% Mg is effective for changing
aging characteristics. In black smith The effect of
magnesium additives on cuts, strength can be
maximized with Material artificially aged by cold
deformation before aging (Fig.). 11). As Cold forging
also affects the strength of nature, as shown in Figure
12. Aged aluminum-copper alloy with or without
magnesium additives. The effect of magnesium on the
corrosion resistance of aluminum-copper Alloys varies
depending on product type and heat treatment.
Processes of forming Aluminium alloys
 Aluminum molding is also a variant of aluminum or
aluminum alloy Specific shapes by hot or cold rolling,
stretching, extruding or forging. Aluminum is easy to
use and is used in a variety of products. It is strong,
corrosion resistant, and highly conductive. Lots of
Products made in aluminum forging factories are sold to
others Manufacturer for further processing or
incorporation into consumer goods. The main industrial
users of molded aluminum products are construction
and Construction, transportation, electricity, containers,
packaging Industrial sector.

 Processes of forming Copper alloys

 Copper molding line produces ~ the same type of
copper or copper alloy Products: (1) Plates, wide rigid
metal pieces, typically over 1/4 inch thick Used for
copper structural parts. (2) Sheet, wide part of flexible
metal It is less than 1/4 inch thick and has little rigidity.
(3) Strips, usually treated as follows Copper coil used
for gutters, seals, wireless components, moldings,
weather forecasts Strips, washers, membranes. (4) Wire
with a circular cross section It's flexible. (5) Circular
cross section rod, rigidity and used for shields,
fasteners, jewelry, welding wires, chains, hooks,
electricity Conductor; (6) Tube, which is a commonly
used long hollow cylinder Liquid transport and heat
transfer applications. (7) The forged product Formed by
taking almost any shape and applying pressure to the
die or roller metallic. About two-thirds of all copper and
copper alloy products formed It is a rod and a wire.
Building construction and electrical and electronic
equipment Product manufacturers are the largest users
of molded copper materials. Next, industrial machinery
and equipment, consumer goods, shipping. Very few
companies practice forging.
 References
1. https://www.esabna.com/us/en/education/blog/unde
rstanding-the-aluminum-alloy-designation-
system.cfm
2. https://www.phase-
trans.msm.cam.ac.uk/abstracts/M7-8.html
3. Al-Si Cast Alloys -Microstructure and Mechanical
Properties at Ambient and Elevated Temperature,
MOHAMMADREZA ZAMANI
Department of Materials and Manufacturing
SCHOOL OF ENGINEERING, JÖNKÖPING
UNIVERSITY
Jönköping, Sweden 2015
4. Aluminum: Properties and Physical Metallurgy, J.E.
Hatch, Ed., American Society for Metals, 1984 .