This lecture provides a background on aluminium alloys suitable for impact extrusion. It draws attention to raw material parameters which may affect the properties of impact extruded parts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
This lecture helps to understand how the properties of forgings evolve during the manufacturing process. General understanding of metallurgy and deformation processes is assumed.
This document provides an overview of aluminium powder metallurgy, including:
1) Various processes for producing and consolidating aluminium alloy powders such as atomization, mechanical alloying, compaction, and sintering.
2) How powder metallurgy can extend the useful property range of aluminium alloys through rapid solidification and compositions not possible with ingot metallurgy.
3) Examples of powder metallurgy aluminium alloys for applications requiring low density, high strength, and high temperature capabilities.
4) Characterization methods for analysing properties of aluminium powders such as composition, microstructure, particle size, and shape.
This lecture gives information on the types of aluminium alloys available and the semi-fabrication processes used in their manufacture. The treatment is not detailed and anyone requiring further information will use other TALAT material or the contained references.
TALAT Lecture 1302: Aluminium Extrusion: Alloys, Shapes and PropertiesCORE-Materials
This lecture provides sufficient information on the extrusion of aluminum and the performance of extruded products to ensure that students, users and potential users of those products can understand the fabrication features that affect properties and economics. It shows how, in consequence, alloy choice for any end application depends not only on the characteristics required for that end use but also on production requirements. General knowledge in materials engineering and some knowledge about aluminium alloy constitution and heat treatment is assumed.
This lecture provides a view of types of joints in aluminium structures and how to design and calculate frequently used joints. Basic structural mechanics and knowledge of design philosophy, structural aluminium alloys and product forms is assumed.
This lecture reviews briefly the commercially available superplastic aluminium alloys and gives their processing and service properties. General background in production engineering and material science is assumed.
TALAT Lecture 5104: Basic Approaches to Prevent Corrosion of AluminiumCORE-Materials
This lecture describes important measures for the prevention of corrosion of unprotected, bare
aluminium. Basic knowledge of corrosion behaviour of aluminium and some knowledge of the electrochemical nature of corrosion is assumed
This lecture helps to understand how the properties of forgings evolve during the manufacturing process. General understanding of metallurgy and deformation processes is assumed.
This document provides an overview of aluminium powder metallurgy, including:
1) Various processes for producing and consolidating aluminium alloy powders such as atomization, mechanical alloying, compaction, and sintering.
2) How powder metallurgy can extend the useful property range of aluminium alloys through rapid solidification and compositions not possible with ingot metallurgy.
3) Examples of powder metallurgy aluminium alloys for applications requiring low density, high strength, and high temperature capabilities.
4) Characterization methods for analysing properties of aluminium powders such as composition, microstructure, particle size, and shape.
This lecture gives information on the types of aluminium alloys available and the semi-fabrication processes used in their manufacture. The treatment is not detailed and anyone requiring further information will use other TALAT material or the contained references.
TALAT Lecture 1302: Aluminium Extrusion: Alloys, Shapes and PropertiesCORE-Materials
This lecture provides sufficient information on the extrusion of aluminum and the performance of extruded products to ensure that students, users and potential users of those products can understand the fabrication features that affect properties and economics. It shows how, in consequence, alloy choice for any end application depends not only on the characteristics required for that end use but also on production requirements. General knowledge in materials engineering and some knowledge about aluminium alloy constitution and heat treatment is assumed.
This lecture provides a view of types of joints in aluminium structures and how to design and calculate frequently used joints. Basic structural mechanics and knowledge of design philosophy, structural aluminium alloys and product forms is assumed.
This lecture reviews briefly the commercially available superplastic aluminium alloys and gives their processing and service properties. General background in production engineering and material science is assumed.
TALAT Lecture 5104: Basic Approaches to Prevent Corrosion of AluminiumCORE-Materials
This lecture describes important measures for the prevention of corrosion of unprotected, bare
aluminium. Basic knowledge of corrosion behaviour of aluminium and some knowledge of the electrochemical nature of corrosion is assumed
TALAT Lecture 4205: Testing Methods for Welded JointsCORE-Materials
This lecture gives information about the relevant non-destructive and destructive testing methods for aluminium welded joints. Background in production welding and quality assurance is assumed.
TALAT Lecture 3503: Finishing and other Supplementary OperationsCORE-Materials
This lecture describes supplementary fabrication measures for impact extruded parts and gives some examples of finished impacts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
TALAT Lecture 2301: Design of Members Example 4.4: Bending moment resistance ...CORE-Materials
This 3 sentence summary provides the key details about the document:
1) The document is a 10 page example from a lecture on designing members for bending moment that analyzes the bending moment resistance of a welded hollow section with outstands using a class 4 cross section.
2) It presents the geometry, material properties, nodes, and elements of the hollow cross section and performs iterative calculations of the effective cross section area, stress distribution, and effective thicknesses accounting for any heat affected zones to determine the bending moment resistance.
3) The example is considered comprehensive because it shows calculations in detail, covers all classes of cross sections, and demonstrates how to increase effective thickness for non-fully stressed elements through
TALAT Lecture 3801: Manufacturing Examples and FundamentalsCORE-Materials
This lecture describes the fundamentals of the superplastic behaviour phenomenon of aluminium alloys and the basic process parameters which govern the manufacturing of superplastic sheet metal parts. General background in production engineering and material science is assumed.
This document provides an overview of application characteristics for rivet and clinch joints. It discusses design considerations such as choosing rivet diameters and distances from edges. It also covers material and tooling parameters that influence joint quality like surface finish. Testing methods are described for shear-tensile, fatigue, and impact tests. Sample geometries and results are shown. Finally, it briefly discusses cost considerations for different joining technologies.
TALAT Lecture 2301: Design of Members Example 5.5: Axial force resistance of ...CORE-Materials
This 3-page document provides an example calculation for determining the axial force resistance of a laced column. It includes dimensions, material properties, and calculations of various parameters needed for the analysis. Key steps and results are shown, such as determining the effective length, flexural buckling resistance, and checking that the lacing can resist the required shear force. In the end, it is determined that the lacing can adequately resist the applied axial load of 270 kN.
This lecture describes the factors important for the quality assurance of adhesive joining; it gives information about the destructive and non-destructive testing methods for the quality control of adhesive joining. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
This lecture describes fabrication processes for superplastic forming, i.e. female and male die forming, and the criteria for selecting the correct process. General background in production engineering and material science is assumed.
TALAT Lecture 3505: Tools for Impact ExtrusionCORE-Materials
This lecture provides knowledge about design philosophy and tool materials for impact tools, which are a cost factor and eminently important for successful impact extrusion. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
This lecture describes the detailed processes of single-step and multiple-step clinching; it shows the differences of the various clinching methods concerning the amount of shearing; it illustrates the major differences in mechanical properties of clinch joints compared with resistance spot welds. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lecture 4101 is assumed.
TALAT Lecture 4107: General Summary and Future TrendsCORE-Materials
This lecture points out the need of data sources for designing mechanical joints; it describes concepts for FEM-Modelling of mechanical joints. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lectures 4101- 4106 is assumed.
TALAT Lecture 4702: Factors Influencing the Strength of Adhesive JointsCORE-Materials
This lecture describes the factors governing the strength of adhesive joints in order to appreciate these factors for the design of adhesively bonded joints, i.e. geometry of joint, stiffness and strength of the adjoining parts, stress distribution in the adhesive layer as well as the effects of humidity and ageing. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 4703: Design and Calculation of Adhesive JointsCORE-Materials
This lecture describes the basic types of loadings of adhesive joints and to give examples of recommended joint designs; it shows how to calculate the strength of adhesive joints. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
This lecture describes the fundamentals of bending and folding aluminium sheet; it also describes different methods in design of folding tools. Background in production engineering and sheet metal forming and familiarity with the subject matter covered in TALAT This lectures 3701- 3705 is assumed.
TALAT Lecture 4101: Definition and Classification of Mechanical Fastening Met...CORE-Materials
This document provides an overview of mechanical fastening methods for joining aluminum parts, including definitions and classifications. It discusses screw joints, folds, rivets, and clinching. Screw joints can be pierced, through, or blind holes. Folds are formed locking joints created through folding, interlocking, and pressing sheets together. Riveting includes indirect and direct methods. Blind rivets have a predetermined break point. The document aims to introduce the principal types of mechanical fastening methods for aluminum.
TALAT Lecture 4300: Beam Welding Processes of AluminiumCORE-Materials
The document provides information on beam welding processes for aluminium, including:
- Electron beam welding principles and process steps for deep welding. It describes terms used and discusses weldability of aluminium alloys.
- Laser welding principles and comparisons to electron beam welding. Solid-state lasers commonly used for thinner sheets while gas lasers used for thicker sheets.
- Laser cutting principles and comparisons of laser beam cutting to plasma cutting. Laser cutting well suited for aluminium.
- References 14 figures and discusses objectives of introducing beam welding and cutting techniques for aluminium. Provides overview of key beam welding and cutting topics.
This lecture defines important terms of the process of stretch forming and it describes the basic processes of stretch forming. Background in production engineering and familiarity with the subject matter covered in TALAT This lecture 3701 is assumed.
TALAT Lecture 4701: Terms and Definitions for Adhesive BondingCORE-Materials
This lecture defines the terms and definition of adhesive bonding of metals; it describes the basic physical/chemical characteristics of adhesive bonding; it also describes the characteristics and the properties of adhesives used in metal bonding. General background in production engineering and material science, some knowledge of the physics and chemistry of metallic surfaces and polymer science is assumed.
TALAT Lecture 4601: Introduction to Brazing of Aluminium AlloysCORE-Materials
This lecture describes the characteristics of brazing aluminium and the process involved; it helps to understand the use potential and the limitations of brazing aluminium. Basic knowledge of aluminium alloys designation system, surface treatment and corrosion behaviour is assumed.
This lecture gives background to calculation methods for aluminium members in order to understand the specific behavior of statically loaded aluminium alloy structures. Basic structural mechanic, design philosophy and structural aluminium alloys and product forms is assumed.
TALAT Lecture 3705: Drawing of Automotive Sheet Metal PartsCORE-Materials
This lecture describes the special requirements for the successful fabrication of automotive aluminium sheet metal parts with respect to material properties, machinery and drawing equipment and tools. Background in production engineering, some knowledge of sheet metal forming principles and familiarity with the subject matter covered in TALAT This lectures 3701- 3704 is assumed.
This lecture describes the important factors governing weldability of aluminium, such as influence of alloying elements, combinations of base material and filler materials and edge preparation for welding. Basic knowledge in metallurgy of aluminium is assumed.
TALAT Lecture 4205: Testing Methods for Welded JointsCORE-Materials
This lecture gives information about the relevant non-destructive and destructive testing methods for aluminium welded joints. Background in production welding and quality assurance is assumed.
TALAT Lecture 3503: Finishing and other Supplementary OperationsCORE-Materials
This lecture describes supplementary fabrication measures for impact extruded parts and gives some examples of finished impacts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
TALAT Lecture 2301: Design of Members Example 4.4: Bending moment resistance ...CORE-Materials
This 3 sentence summary provides the key details about the document:
1) The document is a 10 page example from a lecture on designing members for bending moment that analyzes the bending moment resistance of a welded hollow section with outstands using a class 4 cross section.
2) It presents the geometry, material properties, nodes, and elements of the hollow cross section and performs iterative calculations of the effective cross section area, stress distribution, and effective thicknesses accounting for any heat affected zones to determine the bending moment resistance.
3) The example is considered comprehensive because it shows calculations in detail, covers all classes of cross sections, and demonstrates how to increase effective thickness for non-fully stressed elements through
TALAT Lecture 3801: Manufacturing Examples and FundamentalsCORE-Materials
This lecture describes the fundamentals of the superplastic behaviour phenomenon of aluminium alloys and the basic process parameters which govern the manufacturing of superplastic sheet metal parts. General background in production engineering and material science is assumed.
This document provides an overview of application characteristics for rivet and clinch joints. It discusses design considerations such as choosing rivet diameters and distances from edges. It also covers material and tooling parameters that influence joint quality like surface finish. Testing methods are described for shear-tensile, fatigue, and impact tests. Sample geometries and results are shown. Finally, it briefly discusses cost considerations for different joining technologies.
TALAT Lecture 2301: Design of Members Example 5.5: Axial force resistance of ...CORE-Materials
This 3-page document provides an example calculation for determining the axial force resistance of a laced column. It includes dimensions, material properties, and calculations of various parameters needed for the analysis. Key steps and results are shown, such as determining the effective length, flexural buckling resistance, and checking that the lacing can resist the required shear force. In the end, it is determined that the lacing can adequately resist the applied axial load of 270 kN.
This lecture describes the factors important for the quality assurance of adhesive joining; it gives information about the destructive and non-destructive testing methods for the quality control of adhesive joining. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
This lecture describes fabrication processes for superplastic forming, i.e. female and male die forming, and the criteria for selecting the correct process. General background in production engineering and material science is assumed.
TALAT Lecture 3505: Tools for Impact ExtrusionCORE-Materials
This lecture provides knowledge about design philosophy and tool materials for impact tools, which are a cost factor and eminently important for successful impact extrusion. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
This lecture describes the detailed processes of single-step and multiple-step clinching; it shows the differences of the various clinching methods concerning the amount of shearing; it illustrates the major differences in mechanical properties of clinch joints compared with resistance spot welds. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lecture 4101 is assumed.
TALAT Lecture 4107: General Summary and Future TrendsCORE-Materials
This lecture points out the need of data sources for designing mechanical joints; it describes concepts for FEM-Modelling of mechanical joints. General mechanical engineering background and familiarity with the subject matter covered in TALAT This lectures 4101- 4106 is assumed.
TALAT Lecture 4702: Factors Influencing the Strength of Adhesive JointsCORE-Materials
This lecture describes the factors governing the strength of adhesive joints in order to appreciate these factors for the design of adhesively bonded joints, i.e. geometry of joint, stiffness and strength of the adjoining parts, stress distribution in the adhesive layer as well as the effects of humidity and ageing. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 4703: Design and Calculation of Adhesive JointsCORE-Materials
This lecture describes the basic types of loadings of adhesive joints and to give examples of recommended joint designs; it shows how to calculate the strength of adhesive joints. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
This lecture describes the fundamentals of bending and folding aluminium sheet; it also describes different methods in design of folding tools. Background in production engineering and sheet metal forming and familiarity with the subject matter covered in TALAT This lectures 3701- 3705 is assumed.
TALAT Lecture 4101: Definition and Classification of Mechanical Fastening Met...CORE-Materials
This document provides an overview of mechanical fastening methods for joining aluminum parts, including definitions and classifications. It discusses screw joints, folds, rivets, and clinching. Screw joints can be pierced, through, or blind holes. Folds are formed locking joints created through folding, interlocking, and pressing sheets together. Riveting includes indirect and direct methods. Blind rivets have a predetermined break point. The document aims to introduce the principal types of mechanical fastening methods for aluminum.
TALAT Lecture 4300: Beam Welding Processes of AluminiumCORE-Materials
The document provides information on beam welding processes for aluminium, including:
- Electron beam welding principles and process steps for deep welding. It describes terms used and discusses weldability of aluminium alloys.
- Laser welding principles and comparisons to electron beam welding. Solid-state lasers commonly used for thinner sheets while gas lasers used for thicker sheets.
- Laser cutting principles and comparisons of laser beam cutting to plasma cutting. Laser cutting well suited for aluminium.
- References 14 figures and discusses objectives of introducing beam welding and cutting techniques for aluminium. Provides overview of key beam welding and cutting topics.
This lecture defines important terms of the process of stretch forming and it describes the basic processes of stretch forming. Background in production engineering and familiarity with the subject matter covered in TALAT This lecture 3701 is assumed.
TALAT Lecture 4701: Terms and Definitions for Adhesive BondingCORE-Materials
This lecture defines the terms and definition of adhesive bonding of metals; it describes the basic physical/chemical characteristics of adhesive bonding; it also describes the characteristics and the properties of adhesives used in metal bonding. General background in production engineering and material science, some knowledge of the physics and chemistry of metallic surfaces and polymer science is assumed.
TALAT Lecture 4601: Introduction to Brazing of Aluminium AlloysCORE-Materials
This lecture describes the characteristics of brazing aluminium and the process involved; it helps to understand the use potential and the limitations of brazing aluminium. Basic knowledge of aluminium alloys designation system, surface treatment and corrosion behaviour is assumed.
This lecture gives background to calculation methods for aluminium members in order to understand the specific behavior of statically loaded aluminium alloy structures. Basic structural mechanic, design philosophy and structural aluminium alloys and product forms is assumed.
TALAT Lecture 3705: Drawing of Automotive Sheet Metal PartsCORE-Materials
This lecture describes the special requirements for the successful fabrication of automotive aluminium sheet metal parts with respect to material properties, machinery and drawing equipment and tools. Background in production engineering, some knowledge of sheet metal forming principles and familiarity with the subject matter covered in TALAT This lectures 3701- 3704 is assumed.
This lecture describes the important factors governing weldability of aluminium, such as influence of alloying elements, combinations of base material and filler materials and edge preparation for welding. Basic knowledge in metallurgy of aluminium is assumed.
Lidding foils for FORMPACK and thermoformed blister_e_1Erwin Dr.Pasbrig
1. Lidding foils for blister packaging of pharmaceuticals have been in use since the 1960s and come in different varieties depending on the type of opening needed and other criteria.
2. Lidding foils are made of aluminum foil that can be soft or hard tempered. They are coated with lacquers and other treatments for properties like push-through ability, peelability, printability, and child resistance.
3. The main types of lidding foils are push-through foils, peelable foils, and peel-push foils, which differ in how the consumer opens the packaging. Push-through foils are most common.
FINAL REVIEWADAFASFSAFASFAFSFSGGaGGV HBKJSJohn Ajish
This document evaluates the mechanical properties of an aluminum matrix composite reinforced with zirconium dioxide and graphite particles. It describes creating composite specimens with varying weight fractions of graphite (5%, 10%, 15%) and a constant 4% zirconium dioxide added to an aluminum 6061 matrix via stir casting. The experiments will evaluate the tensile strength, compressive strength, wear resistance, and microstructure of the composites using various mechanical tests. The goal is to study how the mechanical properties of the aluminum composite relate to the processing and addition of the ceramic reinforcements.
This document provides a 23-page overview of resistance spot welding of aluminium and its alloys. It discusses:
1) The suitability of aluminium alloys for spot welding and how the surface condition, chemical composition, and metallurgical condition affect it.
2) The different physical properties of aluminium compared to steel that influence the spot welding process, such as higher electrical and thermal conductivity in aluminium.
3) Key factors in spot welding aluminium like the oxide film that must be removed, various surface pretreatment methods, and machine parameters that differ from steel due to aluminium's properties.
This document discusses the machinability of aluminum alloys. It begins by defining machinability as the ease with which a material can be machined, which depends on its physical properties and cutting conditions. Aluminum alloys are widely used for machining due to their low cutting temperatures and densities. The document then covers the machining process for aluminum alloys and various factors that affect machinability, such as chip formation, surface finish, tool wear and cutting forces. Specific aluminum alloys suitable for machining like EN-2011 and 6262 are also identified. The document concludes by listing example applications of machined aluminum and references used.
This document discusses aluminum alloys, including their types, heat treatment, and common alloying elements. It covers casting and wrought alloys, with casting alloys further divided based on their alloying elements like copper, silicon, magnesium, zinc, and tin. Heat treatable alloys can be strengthened through heat treatment to form precipitates, while non-heat treatable alloys rely on solid solution strengthening. Common alloying elements are discussed along with their effects on properties and example commercial alloys.
This lecture describes the processes of electroless, electrolytic, as well as physical and chemical vapour deposition of metals on the aluminium surface in order to achieve variations in its surface properties for functional and decorative purposes. Some knowledge of the surface properties of metals, metallurgy and electrochemistry of aluminium and familiarity with the subject matter covered in TALAT This lectures 5101, 5102, 5105 is assumed.
In general, aluminium alloys have excellent machining properties compared with other common engineering metals.The lecture describes the machinability of aluminium alloys, the necessary tools and equipments in order to obtain optimum results. General background in production engineering and machine tools is assumed.
The document investigates the tribological properties of Ni-Cr and Al2O3 13TiO2 coatings deposited via detonation spraying on two types of grey cast iron (GI250 and GIHC). Pin-on-disc wear tests were performed on coated and uncoated samples under different loads. Results show coated samples experienced significantly lower weight loss than uncoated samples. Specifically, the Al2O3 13TiO2 coating on GI250 substrate showed the lowest cumulative weight loss. SEM analysis indicated the coatings were uniform and dense. In conclusion, detonation spraying was effective in depositing wear-resistant coatings on grey iron to reduce wear loss.
This document discusses aircraft materials, focusing on aluminum alloys. It provides an overview of the basic requirements for aircraft materials, including high strength, stiffness, corrosion resistance, and fatigue resistance. Common structural materials are aluminum, magnesium, titanium, and composite materials. Important aluminum alloys for aircraft include the 2xxx, 6xxx, and 7xxx series. Properties of specific alloys like 2024, 6061, 7075 are presented. Casting aluminum alloys and their microstructure and properties are also reviewed.
This document discusses two new aluminum-lithium alloys, 2099 and 2199, for aerospace applications. It summarizes a trade study conducted between Alcoa and Bombardier using these alloys, which highlighted weight and performance benefits when alloys with optimized properties are selected for specific aircraft applications. Testing showed that 2199 plate provided up to 25% lower weight than alternatives for lower wing skins, while 2099 extrusions and 2199 sheet were best for lower wing stringers and fuselage skins, respectively. Properties of 2199 plate compared favorably to the incumbent 2024 alloy, with lower density, better corrosion resistance, and fatigue crack growth performance.
TALAT Lecture 1202: Metallography of Aluminium AlloysCORE-Materials
This lecture aims at providing a survey of the metallographic techniques available for the examination of aluminium and its alloys. The information must be sufficient to be sure that the students and the users are able to choose the most suitable technique to solve their problems in the examination of samples. The lecture should contain a direct understanding of the main problems in the metallography of the different classes of aluminium materials.
Dr. B. Kiran Naik
Project guide: Prof. Debasish Sarkar
Department: Mechanical Engineering
NIT Rourkela, Rourkela – 769008 (Odisha), India
Date: 20/04/2022
Fortran Programming
Introduction to Fortran
Fortran Basics
Variables and Data Types
Arrays
Control Structures
Functions and Subroutines
Input/Output Statements
Fortran Examples
Conclusion
TALAT Lecture 1255: Metallurgical Background to Alloy Selection and Specifica...CORE-Materials
This lecture outlines the metallurgical principles of alloy selection and specifications. Basic knowledge of physics and chemistry and some familiarity with TALAT lectures 1201 through 1205 is assumed.
The document provides information on 11 aluminum die casting alloys, including their chemical compositions, typical material properties, die casting characteristics, and applications. It states that Alloy A380 is the most widely used due to its favorable properties and ease of production. The other alloys have specialized characteristics making them more suitable for specific applications like intricate components, high strength at elevated temperatures, corrosion resistance, or pressure tightness. The document provides detailed tables on the chemical compositions, material properties, and die casting/machining characteristics of each alloy to help guide alloy selection for different design needs.
This document discusses welding of aluminum and its alloys. It describes the key properties of aluminum including its light weight, corrosion resistance, and electrical conductivity. It outlines the different alloy designations and their major alloying elements. The document discusses strengthening mechanisms in aluminum alloys such as solid solution strengthening, precipitation hardening, and strain hardening. It also covers issues that can occur during welding of aluminum like solidification cracking, hot cracking, and softening in the heat-affected zone. Overall, the document provides a comprehensive overview of aluminum alloys and considerations for welding this important metal.
a small presentation about machinability and Al machinability
containing:
Definition of Machinability
Machinability of Aluminum Alloys
How to improve the mach inability of Al alloy?
Cutting force during machining of aluminum alloys
Chip formation and chip segmentation
Surface of Machined Aluminium Alloys
MACHINABILITY RATINGS
This document discusses aluminum alloys. It describes the different alloying elements used in aluminum alloys and their effects, including copper, manganese, silicon, magnesium, zinc, and others. It discusses the properties and applications of various common aluminum alloy series, including 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, and 7xxx. It also covers casting aluminum alloys and the Russian standard classification system. In summary, it provides an overview of the composition, properties, and uses of the major types of wrought and casting aluminum alloys.
The document provides information on various types of building and construction materials including:
- Mild steel grades such as S235 JR and their mechanical properties.
- Cold rolled steel grade DC01 and its surface finishes.
- Galvanized steels with specifications for coatings like G60 and qualities like DX51D.
- Stainless steels grades 304 and 316 and their mechanical properties.
- Aluminum alloys 5052 and 6063 with conversion tables.
- Guidelines for bi-metallic contact between different metals.
- Hot-dip galvanization process and comparisons of standards like ISO 1461 and ASTM A123 for coating thickness.
Similar to TALAT Lecture 3501: Alloys and Properties (20)
Series of powerpoint slides showing three different drawing processes used in the manufacture of wires, rod, tubes and drinks cans. The slides are adapted from the University of Liverpool "Materials Processing" lectures [MATS214] by Dr J. Wilcox.
The document describes several test geometries used to determine the failure strengths of composite materials, including the Double Cantilever Beam test for mode I failure, the End Notch Flexure test for mode II failure, and the Mixed-mode Interlaminar Fracture test for mixed mode I/II failure. It also lists the Single Cantilever Beam test for skin debonding energy in composite sandwiches, the Centre Notch Flexure test for thin skin debonding, and the Interlaminar Shear Strength test, a three point bend test to determine shear strength.
The document describes several common composite manufacturing techniques including wet lay-up, vacuum bagging, compression moulding, filament winding, pultrusion, and resin transfer moulding. Each technique involves different processes for combining fibres and resin such as applying layers by hand, using pressure and heat, winding fibres onto a rotating mandrel, pulling fibres through a resin bath, or injecting resin into a mould containing dry fibres. The techniques are suited for different part geometries and production volumes.
The role of technology in sporting performanceCORE-Materials
The lecture answers the questions of how much effect does engineering technology have on sport, is technology only used to increase performance and what are the "new technologies" being introduced. Courtesy of Prof Claire Davies, School of Metallurgy and Materials, University of Birmingham.
The chapter describes principles of the chemical analysis in the SEM and TEM. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives insight into the scanning electron microscope technique. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives insight into the transmission electron microscope technique. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter explains the diffraction of electrons and demonstrates what it can reveal. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
Electrons and their interaction with the specimenCORE-Materials
The chapter explains the behaviour of electrons within a specimen and shows how they interact with the atoms of the sample. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives the comparison of electron microscopy with other imaging and analysis techniques. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives the basic principles of microscopy. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
TALAT Lecture 5301: The Surface Treatment and Coil Coating of AluminiumCORE-Materials
This lecture describes the continuous coil coating processes for aluminium in sufficient detail in order to understand the industrial coating technology and its application potential. General background in materials engineering and familiarity with the subject matter covered in TALAT This lectures 5100 and 5200 is assumed.
This lecture describes the process of anodic oxidation of aluminium, which is one of the most unique and commonly used surface treatment techniques for aluminium; it illustrates the weathering behaviour of anodized surfaces. Some familiarity with the subject matter covered in TALAT This lectures 5101- 5104 is assumed.
This lecture describes the key factors associated with conversion coatings on aluminium can be appreciated, such as general and local behaviour of the aluminium surface, range of conversion coatings and interrelationships, requirements of conversion coating, tailor-making of coatings, current and future issues. Some familiarity with the subject matter covered in TALAT This lectures 5101, 5102, 5201 is assumed.
TALAT Lecture 5105: Surface Treatment of AluminiumCORE-Materials
This lecture helps to understand the general principles, methods, properties and applications of plating on aluminium. Some knowledge in general electrochemistry is assumed.
TALAT Lecture 5103: Corrosion Control of Aluminium - Forms of Corrosion and P...CORE-Materials
This document discusses various forms of corrosion that can affect aluminium and aluminium alloys. It describes general corrosion that can occur in acid and neutral solutions. It also covers localized corrosion such as pitting, crevice, filiform, and biological corrosion. Factors influencing galvanic and intergranular corrosion are presented. The document also discusses mechanically assisted degradation like erosion, fretting corrosion, and corrosion fatigue. It concludes with descriptions of stress corrosion cracking and hydrogen embrittlement.
TALAT Lecture 5102: Reactivity of the Aluminium Surface in Aqueous SolutionsCORE-Materials
This lecture provides better understanding of the electrochemistry of aluminium; it gives an introduction to the other lectures. Some knowledge in aluminium metallurgy, simple chemistry (thermodynamics and kinetics), electricity and general electrochemistry is assumed.
TALAT Lecture 5101: Surface Characteristics of Aluminium and Aluminium AlloysCORE-Materials
This lecture provides a realistic view of the aluminium surface in order to understand the need for "effective" surface treatment. Some knowledge in aluminium metallurgy is assumed.
TALAT Lecture 4704: Surface Preparation and Application ProceduresCORE-Materials
This lecture describes the important aspects of surface preparation and pretreatments for adhesive joining of aluminium parts; it illustrates the methods and equipment necessary to obtain good adhesive bonds. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
How to Fix the Import Error in the Odoo 17Celine George
An import error occurs when a program fails to import a module or library, disrupting its execution. In languages like Python, this issue arises when the specified module cannot be found or accessed, hindering the program's functionality. Resolving import errors is crucial for maintaining smooth software operation and uninterrupted development processes.
Reimagining Your Library Space: How to Increase the Vibes in Your Library No ...Diana Rendina
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TALAT Lecture 3501: Alloys and Properties
1. TALAT Lecture 3501
Alloys and Properties
8 pages, 6 figures
Basic Level
prepared by Klaus Siegert and Manfred Kammerer, Institut für Umformtechnik,
Universität Stuttgart
Objectives:
− To provide a background on aluminium alloys suitable for impact extrusion
− To draw attention to raw material parameters which may affect the properties of
impact extruded parts
Prerequisites:
− Basic knowledge about the formability of metals
− Background in mechanical engineering
Date of Issue: 1994
EAA- Euro p ean Aluminium Asso ciatio n
2. 3501 Alloys and Properties
Table of Contents:
3501 Alloys and Properties ..................................................................................2
3501.01 General Information on Alloys and Raw Materials ................................ 2
Aluminium Alloys for Impact Extrusion .................................................................2
Reference Values for the Strength of Aluminium Alloy Impacts............................3
Flow Curves and Fow Stresses ................................................................................4
Raw Materials, Blanks and Slugs ............................................................................5
Lubricants ................................................................................................................5
Tool Life as a Function of Amounts of Lubricant ...................................................6
3501.02 Literature: ................................................................................................... 8
3501.03 List of figures............................................................................................... 8
3501.01 General Information on Alloys and Raw Materials
Aluminium Alloys for Impact Extrusion
Figure 3501.01.01 lists the different types of aluminium alloys used for impact
extrusion together with an evaluation considering different aspects. All aluminium
alloys of the non-heat-treatable and heat-treatable types can be impact extruded,
especially when in their soft annealed state. (See also DIN 1712, part 3 and DIN 1725,
part 1).
TALAT 3501 2
3. Aluminium Designation Relative merit values1) under various aspects
according to Impact Decorative Joining Remarks
Alloys DIN 1712, p.3 extrud- anodising process3)
and ability 2)
for Impact DIN 1725, p.1
S L
Extrusion Pure and high purity aluminium (DIN 1712, part3)
Aluminium alloys
Al99.5 1 2 2 1 Main material for impacts
for impact
Al99.7 1 2 2 1
extrusion
1)
Al99.8 1 1 2 1
Merit values,
falling from 1 to 4; Al99.9 1 1 2 1 Chemical brightening possible
"-" = not suitable Non-heat-treatable alloys (DIN 1725, part 1)
2)
Valuation is valid
for the original soft AlMn 2 - 2 1
annealed state AlRMg0.5 2 1 2 2 Chemical brightening possible
3)
S = weldability; AlMg1 2 2 2 2
L = suitability for AlMg3 4 2 1 -
brazing.
AlMg2Mn0.3 3 3 1 -
Strength loss due
to welding and Heat-treatable alloys (DIN 1725, part 1)
soldering must be AlMgSi0.5 2 1 2 3
considered! AlMgSi1 3 2 2 3
AlZn4.5Mg1 3 - 2 - Used only in artificially aged state
Source: Aluminium AlCuMg1 4 - - - Only for parts with heavy wall thickness
-Zentrale e.V. AlZnMgCu0.5 4 - - - which are used only in an aged state
alu
Training in Aluminium Application Technologies
Aluminium Alloys for Impact Extrusion 3501.01.01
In order to obtain high quality impacts, it is important to use materials which exhibit a
homogeneous fibre structure or a uniform fine-grained structure. A non-homogeneous
structure affects not only the chemical and physical properties of the impacts but also
their form. An unsymmetrical grain structure can have a large effect on flow stress
which in turn might lead to excentricity of the part, warpage or uneven distribution of
wall thicknesses.
Reference Values for the Strength of Aluminium Alloy Impacts
Figure 3501.01.02 tables reference values for the strength of aluminium alloy impacts.
The aluminium alloys Al99,9, Al99,8. Al99,7 and Al99,5 are mainly used for
manufacturing tubes and cans. The alloys AlMgSi0,5 and AlMgSi1 can be considered to
be standard materials for impact extrusion. Care must be taken during the machining of
the alloys AlZn4,5Mg1 and AlZnMgCu0,5, since the emulsions used can lead to
corrosion.
TALAT 3501 3
4. Reference
Designation State Strength in N/mm² Elongation
Values for Rm (σB) Rp0.2 (σ0.2) A5 (%)
the Strength Al99.5/ annealed 70 25 40
Al99 impact extruded 130 110 6
of Impacts Al99.7/ annealed 60 18 40
Al99.8 impact extruded 120 100 4
Attainable 40
Al99.9 annealed 40 15
mechanical properties, impact extruded 100 80 4
not minimum values AlMn annealed 90 35 24
impact extruded 170 145 4
1)
By impact extruding AlRMg0.5 annealed 80 25 23
directly after solution impact extruded 140 110 4
AlMg1 annealed 105 35 24
treatment and quenching
impact extruded 165 145 4
("freshly quenched" state)
AlMg3 annealed 190 80 20
and then aging, 90% of impact extruded 265 215 4
the strength of the AlMg2Mn0.3 annealed 155 60 20
state "artificially impact extruded 230 200 4
aged" can be attained. AlMgSi0.5 annealed, imp. extr. 165 145 4
1) artificially aged 245 195 10
AlMgSi1 annealed, imp. extr. 190 170 4
1) artificially aged 310 260 10
AlZn4.5Mg1 artificially aged 350 290 10
AlCuMg1 naturally aged 400 350 10
AlZnMgCu0.5 artificially aged 500 450 7
Source: Aluminium-Zentrale e.V.
alu
Training in Aluminium Application Technologies
Reference Values for the Strength of Impacts 3501.01.02
Flow Curves and Fow Stresses
Figure 3501.01.03 shows flow curves and flow stresses of some aluminium alloys (at
left) and the effect of state of heat treatment of AlMgSi1-slugs on the flow behaviour (at
right). Flow curves are needed for the calculation of forces for the impact extrusion
process. For further flow curves, refer to the VDI guideline 3500.
Flow Curves and Flow Stresses
Flow curves for various annealed Flow stress as a function of
aluminium alloys at room temperature heat treatment state of the slug
600 State: annealed 600 Artificially aged
ϕ = 5 x 10 s
-4 -1
N/mm² N/mm² Naturally aged
AlMg3
Flow stress, kf
Flow stress, kf
400 400
AlCuMg
Hot worked
AlMgSi(Mn)
200 200 Soft
Al99.5
AlMgSi1
RT
0 0
0 1 2 3 0 1 2 3
True strain ϕ True strain ϕ
Source: J.Hardt Source: H.G.Roczyn
alu
Flow Curves and Flow Stresses 3501.01.03
Training in Aluminium Application Technologies
TALAT 3501 4
5. Raw Materials, Blanks and Slugs
Figure 3501.01.04 gives information regarding the manufacturing of slugs and blanks,
their required surface condition and their properties. Cold rolled sheets and rods or tubes
from which blanks and slugs are obtained by blanking or sawing, respectively, are
standardised in DIN 1745, part 1 and DIN 59604. Round rods of pure aluminium or
aluminium alloys are extruded with so-called multiple extrusion dies, i.e. three or four
die openings are arranged around the centre of the die. In a final step these rods are cold
drawn to size and final dimensions. Since the material is pressed through the multiple
die not only from the centre portion of the billet but also from its outer areas, such round
rods may exhibit different grain sizes in any one cross-section. As a result, impact
extruded parts can warp in unexpected amounts and wall thicknesses may vary.
Therefore, care should be exercised, that only single-strand extruded rods are taken as
base material for slugs and blanks.
Raw Materials; Blanks and Slugs
Manufacturing raw materials
The raw material consists almost exclusively of stamped or sawed blanks
and slugs available from extruders or stockists
Surface condition of raw material
Blank, ground, tumbled, blasted
Requirements of raw material
! The weight of blanks or slugs is allowed to vary only within a narrow
tolerance range
! Minimum clearance between slugs and die: 0.3 to 0.4mm
! Maximum tolerance for round slugs and blanks is h11 (larger deviations in
diameter lead to positioning errors)
! A uniform grain size. Varying grain size can lead to variations in dimensions
Source: Schlosser; Brix
alu
Training in Aluminium Application Technologies
Raw Materials; Blanks and Slugs 3501.01.04
Lubricants
Figure 3501.01.05 lists the different lubricants used and the methods of applying them.
Because of environmental considerations, water-soluble lubricants like alkalinen soaps
and liquid lubricants based on oil are being increasingly used. Zinc stearate and zinc
behenate have nowadays to compete with
− Lubrimet GTT (Sapilub Ltd. Co. Wangen, Zurich) based on paraffin without
chlorinated solvents and heavy metal soaps with optimal solubility in water,
− Glisapal SM-155 (Nußbaum Co., Matzingen), a water-soluble, solvent-free,
powdery lubricant based on alkaline soaps, not suitable for anneal degreasing and
solvent cleaning,
TALAT 3501 5
6. − and liquid lubricants based on oil, like Bonderlube VP 4404/5 (Chemetall Co.,
Frankfurt), with sulphur compounds, but free from chloroparaffins and metal
organic compounds or
− Multipress 9391 (Zeller and Gmelin Co., Eislingen), a fully synthetic oil.
In individual cases, coating layers serving as carriers for lubricants (aluminium,
phosphate) are used.
Lubricants
Lubricants used
! Zinc stearate and zinc behenate (insoluble in water)
! Alkaline soaps (water soluble)
! Liquid lubricants based on oil (water soluble)
Methods of applying lubricants
! Spraying
! Coating
! Sprinkling, powdering
! Dipping
! Tumbling
Source: D.Schlosser
alu
Training in Aluminium Application Technologies
Lubricants 3501.01.05
Tool Life as a Function of Amounts of Lubricant
Figure 3501.01.06 illustrates the influence of amount of lubricant used (g/m²) on tool
life. As can be clearly seen, too little or too much lubrication reduces the tool life. If the
lubricant used is insufficient, cold welding can occur between tool and work-piece. If
too much lubricant is used, then the lubricant accumulation leads to defects in contour
replication and to lubricant indentations in the tool. In these cases, the tool has to be
cleaned very often. The surface roughness of slugs and blanks has an effect on the tool
life. Experiments have shown that smooth slugs reduce the life of tools because the
smooth slug surface offers hardly any cavities and pits in which the lubricant can be
anchored.
TALAT 3501 6
7. Tool Life as a Function of Amounts of Lubricant
Cold Contour
welding defects
failure optimum failure
Tool life
Relative lubricant amount in g/ m²
Source: D.Schlosser
alu
Training in Aluminium Application Technologies
Tool Life and Lubricant Amounts 3501.01.06
TALAT 3501 7
8. 3501.02 Literature:
1) F.Ostermann: Technische Kaltfließpreßteile aus Aluminium. In seminar volume
"Gestalten und Fertigen von technischen Fließpreßteilen aus Aluminium", Institut
für Umformtechnik, Universität Stuttgart, 15.-16. June, 1992
2) D.Schlosser: Einflußgrößen auf das Fließpressen von Aluminium und
Aluminiumlegierungen und ihre Auswirkung auf die Weiter- und
Fertigbearbeitung der fließgepreßten Rohteile. In seminar volume "Gestalten und
Fertigen von technischen Fließpreßteilen aus Aluminium", Institut für
Umformtechnik, Universität Stuttgart, 15.-16. June, 1992
3) D.Brix: Kaltfließpressen von Leichtmetall - Qualität und Wirtschaftlichkeit. Draht
1975/5, p. 216-219
4) VDI-Richtlinie 3138: Kaltfließpressen von Stählen und Nichteisenmetallen,
Grundlagen, part 1. Beuth-Verlag, Berlin, 1970
5) Aluminium-Zentrale e.V., Report No. 29 "Aluminium für technische
Fließpreßteile", Düsseldorf, 1982
3501.03 List of figures
Figure No. Figure Title (Overhead)
3501.01.01 Aluminium Alloys for Impact Extrusion
3501.01.02 Reference Values for the Strength of Impacts
3501.01.03 Flow Curves and Flow Stresses
3501.01.04 Raw Materials; Blanks and Slugs
3501.01.05 Lubricants
3501.01.06 Tool Life and Lubricant Amounts
TALAT 3501 8