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Fundamentals of aluminium metallurgy: Production, processing and applicationsEdited by R Lumley, CSIRO Light Metal Flagship, Australia
Woodhead Publishing Series in Metals and Surface Engineering No. 37
- provides a comprehensive overview of the production, properties and processing of aluminium, and its applications in manufacturing industries
- considers many issues of central importance in aluminium production and utilization considering quality issues and design for fatigue growth resistance
- metallurgical properties of aluminium and its alloys are further explored with particular reference to work hardening and applications of industrial alloys
Aluminium is an important metal in manufacturing, due to its versatile properties and the many applications of both the processed metal and its alloys in different industries. Fundamentals of aluminium metallurgy provides a comprehensive overview of the production, properties and processing of aluminium, and its applications in manufacturing industries.
Part one discusses different methods of producing and casting aluminium, covering areas such as casting of alloys, quality issues and specific production methods such as high-pressure diecasting. The metallurgical properties of aluminium and its alloys are reviewed in Part two, with chapters on such topics as hardening, precipitation processes and solute partitioning and clustering, as well as properties such as fracture resistance. Finally, Part three includes chapters on joining, laser sintering and other methods of processing aluminium, and its applications in particular areas of industry such as aerospace.
With its distinguished editor and team of expert contributors, Fundamentals of aluminium metallurgy is a standard reference for researchers in metallurgy, as well as all those involved in the manufacture and use of aluminium products.
ISBN 1 84569 654 9
ISBN-13: 978 1 84569 654 2
November 2010
864 pages 234 x 156mm hardback
£190.00 / US$325.00 / €230.00
Usually dispatched within 24 hours
About the editor
Dr Roger Lumley is Principal Research Scientist at CSIRO's Light Metals Flagship in Melbourne, Australia. He has internationally-recognised expertise in the design and processing of aluminium alloys.
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Contents
PART 1 PRODUCTION AND CASTING OF ALUMINIUM AND ITS ALLOYS
PART 1 PRODUCTION AND CASTING OF ALUMINIUM AND ITS ALLOYS
PART 2 METALLURGICAL PROPERTIES OF ALUMINIUM AND ITS ALLOYS
PART 2 METALLURGICAL PROPERTIES OF ALUMINIUM AND ITS ALLOYS
PART 3 PROCESSING AND APPLICATIONS OF ALUMINIUM AND ITS ALLOYS
PART 3 PROCESSING AND APPLICATIONS OF ALUMINIUM AND ITS ALLOYS
Introduction to aluminium metallurgy
R N Lumley, CSIRO Light Metals Flagship, Australia
- Aluminium as an engineering material
- The development of aluminium alloys
- Cast aluminium alloys
- Wrought aluminium alloys
- Production of aluminium
- Uses of aluminium
- Conclusions
- References
PART 1 PRODUCTION AND CASTING OF ALUMINIUM AND ITS ALLOYS
PART 1 PRODUCTION AND CASTING OF ALUMINIUM AND ITS ALLOYS
Production of alumina
J Metson, University of Auckland, New Zealand
- Introduction to the aluminium oxides
- Al minerals - mining and processing
- Alumina production processes
- The Bayer alumina refinery
- Alumina microstructure
- Impurities
- Production of specialty aluminas
- Alumina production trends
- Acknowledgements
- References
Production of alumina
J Metson, University of Auckland, New Zealand
- Introduction to the aluminium oxides
- Al minerals - mining and processing
- Alumina production processes
- The Bayer alumina refinery
- Alumina microstructure
- Impurities
- Production of specialty aluminas
- Alumina production trends
- Acknowledgements
- References
Production of primary aluminium
H Kvande, Qatar University, Qatar
- Introduction
- Raw materials used in the aluminium production process
- Energy efficiency in the utilization of carbon anodes
- The carbon anodes
- Electrolyte materials
- The cathode and cathode materials
- Health, environment, and safety (HES)
- Inert anodes
- The past, present, and future of primary aluminium production
- Acknowledgements
- References
Production of primary aluminium
H Kvande, Qatar University, Qatar
- Introduction
- Raw materials used in the aluminium production process
- Energy efficiency in the utilization of carbon anodes
- The carbon anodes
- Electrolyte materials
- The cathode and cathode materials
- Health, environment, and safety (HES)
- Inert anodes
- The past, present, and future of primary aluminium production
- Acknowledgements
- References
Production of secondary aluminium
G Wallace, Sims Aluminium Pty Limited, Australia
- History of secondary aluminium
- Sources of raw material
- Processing
- Cost drivers
- Future trends
- Sources of further information and advice
- References
Production of secondary aluminium
G Wallace, Sims Aluminium Pty Limited, Australia
- History of secondary aluminium
- Sources of raw material
- Processing
- Cost drivers
- Future trends
- Sources of further information and advice
- References
Ingot casting and casthouse metallurgy of aluminium and its alloys
J F Grandfield, Grandfield Technology Pty Ltd, Australia
- Direct chill casting
- Heat flow and solidification
- Macro-segregation
- Typical surface defects
- Gas pressurised extrusion billet casting
- Rolling slab technology
- Special variants of DC casting
- Chain conveyor casting
- Melt treatment
- Impurity measurement
- Conclusions
- References
Ingot casting and casthouse metallurgy of aluminium and its alloys
J F Grandfield, Grandfield Technology Pty Ltd, Australia
- Direct chill casting
- Heat flow and solidification
- Macro-segregation
- Typical surface defects
- Gas pressurised extrusion billet casting
- Rolling slab technology
- Special variants of DC casting
- Chain conveyor casting
- Melt treatment
- Impurity measurement
- Conclusions
- References
Casting of aluminium alloys
A K Dahle, University of Queensland, Australia
- Introduction
- Aluminium casting alloys
- Microstructure control in aluminium foundry alloys
- Filling the casting
- Feeding and porosity
- Casting processes
- Conclusions
- References
Casting of aluminium alloys
A K Dahle, University of Queensland, Australia
- Introduction
- Aluminium casting alloys
- Microstructure control in aluminium foundry alloys
- Filling the casting
- Feeding and porosity
- Casting processes
- Conclusions
- References
Quality issues in aluminium castings
G K Sigworth, GKS Engineering Services, USA
- Introduction
- 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
- Conclusions
Quality issues in aluminium castings
G K Sigworth, GKS Engineering Services, USA
- Introduction
- 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
- Conclusions
Case studies in aluminium casting alloys
J A Taylor, University of Queensland, M A Easton, Monash University and D H St John, University of Queensland, Australia
- Introduction
- The effect of the alloy specification range on microstructure and properties
- An impurity that reduces castability and increases casting 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
- Conclusions
- References
Case studies in aluminium casting alloys
J A Taylor, University of Queensland, M A Easton, Monash University and D H St John, University of Queensland, Australia
- Introduction
- The effect of the alloy specification range on microstructure and properties
- An impurity that reduces castability and increases casting 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
- Conclusions
- References
High pressure diecasting of aluminium and its alloys
M T Murray, M Murray & Associates Pty Ltd, Australia
- History of high pressure die casting
- The die casting process
- Aluminium alloys used in die casting
- Defects in die casting
- Conclusions
- References
High pressure diecasting of aluminium and its alloys
M T Murray, M Murray & Associates Pty Ltd, Australia
- History of high pressure die casting
- The die casting process
- Aluminium alloys used in die casting
- Defects in die casting
- Conclusions
- References
Progress on the heat treatment of high pressure diecastings
R N Lumley, CSIRO Light Metals Flagship, Australia
- 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 diecastings
- Conclusions
- References
Progress on the heat treatment of high pressure diecastings
R N Lumley, CSIRO Light Metals Flagship, Australia
- 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 diecastings
- Conclusions
- References
PART 2 METALLURGICAL PROPERTIES OF ALUMINIUM AND ITS ALLOYS
PART 2 METALLURGICAL PROPERTIES OF ALUMINIUM AND ITS ALLOYS
Work hardening of aluminium alloys
W J Poole and J D Embury, University of British Columbia and D J Lloyd
Novelis Global Technology Centre, Canada
- Introduction
- Fundamentals of work hardening
- Models of work hardening
- Applications of work hardening models to industrial alloys
- Commercial aspects of work hardening
- Conclusions and future trends
- Acknowledgements
- References
Work hardening of aluminium alloys
W J Poole and J D Embury, University of British Columbia and D J Lloyd
Novelis Global Technology Centre, Canada
- Introduction
- Fundamentals of work hardening
- Models of work hardening
- Applications of work hardening models to industrial alloys
- Commercial aspects of work hardening
- Conclusions and future trends
- Acknowledgements
- References
Precipitation and solute clustering in aluminium: advanced characterization techniques
G Sha, R K W Marceau and S P Ringer, University of Sydney, Australia
- Introduction
- Aluminium (Al) Copper (Cu) based alloys
- Aluminium (Al) Copper (Cu) Magnesium (Mg) based alloys
- Aluminum (Al) Magnesium (Mg) Silicone (Si) based alloys
- Aluminium (Al) Zinc (Zn) Magnesium (Mg) (Copper (Cu)) based alloys
- Precipitation in Al alloys under severe plastic deformation
- Conclusions
- Acknowledgements
- References
Precipitation and solute clustering in aluminium: advanced characterization techniques
G Sha, R K W Marceau and S P Ringer, University of Sydney, Australia
- Introduction
- Aluminium (Al) Copper (Cu) based alloys
- Aluminium (Al) Copper (Cu) Magnesium (Mg) based alloys
- Aluminum (Al) Magnesium (Mg) Silicone (Si) based alloys
- Aluminium (Al) Zinc (Zn) Magnesium (Mg) (Copper (Cu)) based alloys
- Precipitation in Al alloys under severe plastic deformation
- Conclusions
- Acknowledgements
- References
Solute partitioning to enhance mechanical properties of aged aluminium alloys
I J Polmear, Monash University, Australia
- Introduction
- Solute partitioning through compositional change
- Studies of underaged alloys
- Secondary precipitation
- Conclusions
- Acknowledgments
- References
Solute partitioning to enhance mechanical properties of aged aluminium alloys
I J Polmear, Monash University, Australia
- Introduction
- Solute partitioning through compositional change
- Studies of underaged alloys
- Secondary precipitation
- Conclusions
- Acknowledgments
- References
Vacancies in aluminium and solute-vacancy interactions in aluminium alloys
A Somoza, Universidad Nacional del Centro de la Provincia de Buenos Aires and Comisión de Investigaciones Científicas de la Provincia de Buenos Aires, Argentina, A Dupasquier, Politecnico di Milano, Italy
- Introduction
- Experimental studies of vacancies and solute-vacancy interactions
- Modelling
- Conclusions
- Acknowledgements
- References
Vacancies in aluminium and solute-vacancy interactions in aluminium alloys
A Somoza, Universidad Nacional del Centro de la Provincia de Buenos Aires and Comisión de Investigaciones Científicas de la Provincia de Buenos Aires, Argentina, A Dupasquier, Politecnico di Milano, Italy
- Introduction
- Experimental studies of vacancies and solute-vacancy interactions
- Modelling
- Conclusions
- Acknowledgements
- References
Modeling the kinetics of precipitation processes in aluminium alloys
C R Hutchinson, Monash University, Australia
- Introduction
- Physical processes controlling precipitation
- Current approaches to modeling precipitation kinetics
- Spherical precipitates
- Non-spherical precipitates (plates, rods, laths)
- Coupling precipitation and plastic deformation
- Future trends and perspectives
- References
Modeling the kinetics of precipitation processes in aluminium alloys
C R Hutchinson, Monash University, Australia
- Introduction
- Physical processes controlling precipitation
- Current approaches to modeling precipitation kinetics
- Spherical precipitates
- Non-spherical precipitates (plates, rods, laths)
- Coupling precipitation and plastic deformation
- Future trends and perspectives
- References
Ultrafine grained aluminium alloys: processes, structural features and properties
Y Estrin, Monash University, Australia, M Murashkin and R Valiev, Ufa State Aviation Technical University, Russia
- Introduction
- Severe plastic deformation (SPD) techniques used in processing of Al alloys
- Producing ultrafine grained aluminium alloys (UFG) Al alloys by means of SPD techniques
- Mechanical properties of UFG Al alloys at room temperature
- Innovation potential of UFG Al alloys
- Conclusions
- Acknowledgements
- References
Ultrafine grained aluminium alloys: processes, structural features and properties
Y Estrin, Monash University, Australia, M Murashkin and R Valiev, Ufa State Aviation Technical University, Russia
- Introduction
- Severe plastic deformation (SPD) techniques used in processing of Al alloys
- Producing ultrafine grained aluminium alloys (UFG) Al alloys by means of SPD techniques
- Mechanical properties of UFG Al alloys at room temperature
- Innovation potential of UFG Al alloys
- Conclusions
- Acknowledgements
- References
Design for fatigue crack growth resistance in aluminium alloys
D A Lados, Worcester Polytechnic Institute, USA
- Introduction
- Background and current state of knowledge
- Materials, processing, mechanical properties, and fatigue crack growth (FCG) 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 FCG
- A dual parameter ΔK-Kmax approach to FCG
- Kmax sensitivity and data normalization for generating design curves
- Conclusions
- References
Design for fatigue crack growth resistance in aluminium alloys
D A Lados, Worcester Polytechnic Institute, USA
- Introduction
- Background and current state of knowledge
- Materials, processing, mechanical properties, and fatigue crack growth (FCG) 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 FCG
- A dual parameter ΔK-Kmax approach to FCG
- Kmax sensitivity and data normalization for generating design curves
- Conclusions
- References
Fracture resistance in aluminium
J F Knott, University of Birmingham, UK
- Introduction
- Fracture in uni-axial tension
- Fracture in thin sheet; stretching and deep-drawing operations
- Fracture in aluminium alloy castings
- Fracture in high-strength wrought alloys; fracture toughness
- The fracture toughness of aluminium alloys: micro-structural aspects
- Fracture in aluminium particulate metal-matrix composites
- Effects of serrated yielding (dynamic strain-aging) on fracture
- Future trends: optimised properties vs
- “fitness for purpose”
- References
Fracture resistance in aluminium
J F Knott, University of Birmingham, UK
- Introduction
- Fracture in uni-axial tension
- Fracture in thin sheet; stretching and deep-drawing operations
- Fracture in aluminium alloy castings
- Fracture in high-strength wrought alloys; fracture toughness
- The fracture toughness of aluminium alloys: micro-structural aspects
- Fracture in aluminium particulate metal-matrix composites
- Effects of serrated yielding (dynamic strain-aging) on fracture
- Future trends: optimised properties vs
- “fitness for purpose”
- References
Corrosion and corrosion protection of aluminium
N Birbilis, Monash University and B Hinton, Defence Science and Technology Organisation (DSTO), Australia
- Introduction
- General, galvanic, and pitting corrosion
- Localised corrosion: intergranular and exfoliation
- Environmentally assisted cracking
- Corrosion protection in the aircraft structure
- Summary case study: corrosion of a C-130J Hercules aircraft wing trailing edge strip
- Acknowledgements
- References
Corrosion and corrosion protection of aluminium
N Birbilis, Monash University and B Hinton, Defence Science and Technology Organisation (DSTO), Australia
- Introduction
- General, galvanic, and pitting corrosion
- Localised corrosion: intergranular and exfoliation
- Environmentally assisted cracking
- Corrosion protection in the aircraft structure
- Summary case study: corrosion of a C-130J Hercules aircraft wing trailing edge strip
- Acknowledgements
- References
PART 3 PROCESSING AND APPLICATIONS OF ALUMINIUM AND ITS ALLOYS
PART 3 PROCESSING AND APPLICATIONS OF ALUMINIUM AND ITS ALLOYS
Joining of aluminium and its alloys
S Lathabai, CSIRO Process Science and Engineering, Australia
- Introduction
- Mechanical joining
- Fusion welding
- Solid state welding
- Brazing
- Adhesive bonding
- Conclusions
- References
Joining of aluminium and its alloys
S Lathabai, CSIRO Process Science and Engineering, Australia
- Introduction
- Mechanical joining
- Fusion welding
- Solid state welding
- Brazing
- Adhesive bonding
- Conclusions
- References
Aluminium powder metallurgy
S H Huo, M Qian and G B Schaffer, University of Queensland and E Crossin, The University of Queensland, Australia and RMIT University, Australia
- Introduction
- The press and sinter powder metallurgy process
- Sintering fundamentals
- Sintering of aluminium
- PM aluminium alloys and its applications
- Future trends
- Acknowledgements
- References
Aluminium powder metallurgy
S H Huo, M Qian and G B Schaffer, University of Queensland and E Crossin, The University of Queensland, Australia and RMIT University, Australia
- Introduction
- The press and sinter powder metallurgy process
- Sintering fundamentals
- Sintering of aluminium
- PM aluminium alloys and its applications
- Future trends
- Acknowledgements
- References
Laser sintering and rapid prototyping of aluminium
T B Sercombe,University of Western Australia, Australia
- Introduction
- The skeleton
- Infiltration
- Dimensional changes
- Conclusions
- Acknowledgements
- References
Laser sintering and rapid prototyping of aluminium
T B Sercombe,University of Western Australia, Australia
- Introduction
- The skeleton
- Infiltration
- Dimensional changes
- Conclusions
- Acknowledgements
- References
Aluminium sheet fabrication and processing
J Hirsch, Hydro Aluminium Deutschland GmbH, Germany
- 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
- Conclusions
- Acknowledgements
- References
Aluminium sheet fabrication and processing
J Hirsch, Hydro Aluminium Deutschland GmbH, Germany
- 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
- Conclusions
- Acknowledgements
- References
Application of modern aluminium alloys to aircraft
E A Starke, University of Virginia and J T Staley, Alcoa, Retired, USA
- 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
- Conclusions
- References
Application of modern aluminium alloys to aircraft
E A Starke, University of Virginia and J T Staley, Alcoa, Retired, USA
- 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
- Conclusions
- References
Materials selection and substitution using aluminium alloys
M Leary, RMIT University, Australia
- 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
- Conclusions
- Acknowledgements
- References
Materials selection and substitution using aluminium alloys
M Leary, RMIT University, Australia
- 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
- Conclusions
- Acknowledgements
- References