ALUMUNIUM AND ITS ALLOYS

ADVANTAGE :-

White lustrous metal, malleable & ductile,

high resistance to corrosion.

Melting temp. is 1250°F, Tensile strength is

13,000 psi.

It is Approx. 3 times lighter than MS.

It is used in the a/c because of high strength
to weight ratio.

It is available in nature as Corundum,

Bauxite, Mica etc.
ALLUMUNIUM ALLOY DESIGNATION

Designated by 4 digit no system and is broken in

3 distinct groups.

Groups are 1xxx, 2xxx-8xxx, 9xxx ( not used)

In 4 digit, first digit indicates the type of alloy

(major alloying elements),

Second digit indicates specific alloy modifications

The last two digit indicates the hundredth of 1
% above the original 99% designation by the
first digit.

2xxx-----Cu 6xxx----Mg & Si

3xxx----Mn 7xxx----Zn

4xxx----Si 8xxx----other elements

5xxx----Mg
 HARDNESS IDENTIFICATION

The temper designation follows alloy

designation after a dash i.e 7075-T6.

Temper designation follow by letter O, F, H, or

T which is again followed by a number.

F : Fabricated
O : Annealed
H : Stain Hardened
 T : Temper
H ½ or H1 or H3 : Degree of Hardness.

The second digit after H represent the

relative hardness.

When 1 is the first digit after H, the temper

has been produced by cold working.

If the digit is 2, that means the material has

been cold worked to a harder temper.
When 3 is the 1st digit, it indicates the material
has been cold worked, & than stabilized by
heating the material for a short time at a slightly
elevated temp.

The temper designation for heat treated alloys

are follows:

#T : Treated to produce
stable temper.

# T2 : Annealed(Cast products
only)
# T3 : Solution treated & than
cold worked.
# T4 : Solution heat treated.
# T5 : Artificially aged only.
# T6 : Solution heat treated &
artificially aged.
# T5 to T10 : Artificially aged.
 CORROSION ON AL ALLOYS

Pure Al is very resistant to atmospheric

corrosion.

When alloyed with other material, corrosion

resisting properties decreases.

Pitting of the surface of Al alloys is 1 type of

corrosion.

The eating away of the surface is accelerated

by salt water or moisture.
An electrical action can also eat away the Al
alloy if a dissimilar metal or impurities are
present.

Anti corrosive treatment given to Al alloy is

ANODIZING.
 ALCLAD

The term alclad consists of an Al alloy core

coated with a layer of pure Al to a depth of
approx.

5.5% on each side if the thickness is less

than 0.064 inch

2.5% on each side if the thickness is over

0.064 inch.
Advantages of Alclad

Prevent contact with any corrosive agents.

Protect the core electrolytically by

preventing attack caused by scratching or
from abrasions.

After years of service, it regain its original

strength.
 TESTING OF MATERIALS
AL, AL-ALLOY & AL CLAD

1. Bend Test :

Al is soft & can be bend to any shape

easily

Al alloy is hard to bend

Alcad is springy to bend.

2. Weight Test :
Al will be lighter
Alclad is slight heavier
Al alloy is more heavy.

3. Chemical Test :
Caustic soda solution will turn pure
Al white
Al alloy black
Al clad surface white.
 Heat Treatment of Al Alloy Rivets

Loose fitting
Cap
Steel tube

Salt in molten
state
Specification Time Temperature To be used
within
Air Furnace
2017 T 1 hr. 925º – 950ºF 10 minutes
2024 T 1 hr. 910º – 930ºF 10 minutes
Salt Bath
2017 T 30 Min. 925º – 950ºF 1 hour
2024 T 30 Min. 910º – 930ºF 20 minutes
 RIVETS

REQUIRED HT BEFORE CAN BE DRIVEN AS

DRIVING RECEIVED

2017 2024 2117

AFTER HT, IT SHOULD BE WITHIN 20 MINUTES

USED WITHIN 1 HR

IDENTIFIED BY A SMALL IDENTIFIED BY 2 SMALL

RAISED TITS IN CENTRE RADIAL DASHES ON THE
PRERIPHERY

Both are high strength rivets, must be kept in ice box,

& both are ice box rivets
 WELDING OF AL ALLOYS

SEAM WELDING

SPOT WELDING

ELECTRIC ARC

GAS WELDING
 HEAT TREATMENT

Apart from annealing, two types of heat

treatments are given to Aluminium alloys

Solution Treatment

Precipitation Treatment
 SOLUTION TREATMENT

Metal is heated to high temperature

(910 – 9500F) for sufficient time, alloying
elements are made soluble in Aluminium at
high temperature and they enter into solid
solution in Al.

It increases strength and hardness, the metal

is then quenched in cold water rapidly to
retain this condition and is known as solution
treatment.
It is usually done in a salt bath heated by gas,
oil or electricity or in electric furnace.

The salt bath is composed of fused sodium

nitrate or a mixture of 50% sodium nitrate
and 50% potassium nitrate.

In the electric air furnace, provision should be

incorporated for circulating the air.
The length of time the material must be
soaked depends upon –

Nature of the material

The prior treatment of the

materials

The thickness of the material

The type of heat treating process.

 PRECIPITATION TREATMENT

The purpose of this treatment is to induce

age hardening property in the material
which was previously solution treated by
holding it at an elevated temperature for a
specific time.

On cooling they start precipitating and this

process is completed with in 48 hours.
This precipitation occurs at ordinary room
temperature in the case of 2017 and 2024
material and the process is completed within
48 hours.

The precipitates is in the form of extremely

fine particle which due to their keying action,
greatly increase the strength.
 AL-ALLOY CASTINGS

There are three ways of casting :-

Sand casting

Permanent mould

Die – casting.
 SAND CASTING

It is the most commonly used method and is

used for casting complicated shapes or where
only a few parts are required.

Wooden patterns are made for sand casting

and sometime white metal is used.

Sand moulds are made and the patterns are

used to make the impression in the moulds.
Molten metal is poured in the sand moulds
and cooled in the same.
 TOLERANCE IN THE PATTERN

Shrinkage allowance of 5/32“ per foot

Machining allowance of 1/16“ per foot is

provided in the pattern.

Al-alloy sand casting cannot be

manufactured with a wall thickness of less
than 1/8“.
 PERMANENT MOULD CASTINGS

In this process, metal moulds are used.

The manufacture of this mould is relatively

expensive and is mainly used when a large
number of castings are required.

In mould casting, the molten metal is fed into

the mould by gravity. The mould will chills
the molten metal as it comes in contact with it.
Chilling results is more rapid solidification and
a finer grains.

This finer grains makes permanent mold

castings more susceptible to heat treatment and
improves their corrosion resistance and
physical properties.

Due to the metal mould a fairly smooth finish is

obtained on the castings.

Casting can be produced a tolerance of +0.01".

 DIE CASTINGS

It consists of forcing molten metal under

pressure into water cooled dies.

The imposition of pressure and chilling of

molten metal results in homogenous fine grain
castings.

Castings have excellent finish and accurate

dimensions can be produced with + 0.0025“.
It is possible to produce thin section as 0.030“
to 0.040“ but 1/16“ is preferred, even holes are
cored to size ready for reaming or tapping.

Because of accurate dimensioning and fine

finish, a little or no machining is required.