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History of Metal
Metal
Copper used for 7,500 years Bronze used for 4,000 years Iron and Steel used for3,000 years Aluminum used for 120 years
Christian Oersted was the first to produce the first few drops of Aluminum in 1808 1869 two tons of Aluminum were produced
Cap on the Washington Monument French Court created tableware A Crown for the King or Denmark Josephines Cross
first commercial batch of Aluminum was produced on Thanksgiving Day 1888 Production Capabilities Lower Price
Cooking utensils Electrical wire and cable Foil Auto bodies Engine parts used by the Wright Brothers
Aluminum Abundance
3rd
Oxygen
47%
28%
Silicon
8%
Process: Recycling
The
Process: Recycling
Recycling
To produce one pop can it takes roughly .5kwh, which is enough energy to run a laptop for 11hrs The 66 billion cans recycled last year is equivalent to 181.5 billion extra hours on a laptop
181.5kwh = $5,478,000,000
Process: Mining
Bauxite
Process: Refining
Bauxite
Bauxite is ground and mixed with lime and caustic soda It is then heated in a high-pressure container What is left is Aluminum Oxide
Process: Smelting
Aluminum
Smelting is the process in which an electrolytic reduction turn Aluminum Oxide (Alumina) into Aluminum
(Aluminum Oxide)
Process
Billet
Process: Fabrication
Types of Fabrication
Extrusion Press
Extrusion Press
Main Cylinder
Dummy Block
Produces Pressure
Extrusion Press
Tool
Stack
Die die ring die, backer,
Hollow
Solid
die: mandrel
ring
die
bolster,
die cap
sub-bolster
sub-bolster
Bolster
A thin layer of lubricant is added to the billet and ram to prevent the two parts from sticking together
Ram applies pressure to the dummy block and moves the billet into the container
Billet
Billet squeezes through the opening(s) in the die creating the extruded shape
While
the Aluminum is being extruded the temps are monitored closely to maintain optimal performance temps
Liquid nitrogen flows around some parts of the die to keep cool, which prevents oxides from forming on the die and altering the shape of the extrusion
Extrusion Press
Dies
Not all the billet can be used The process leaves an Oxide rich skin which is discarded
While being cooled by fans or various other methods to bring back down to room temperature
Post Extrusion
Re-aligns molecules and increases strength and hardness Called Work Hardening
Work Hardening: mechanical deformation of metal or alloy at temperatures below those at which recrystallization occurs. Cold worked metal may be brought back to the original state of workability by proper annealing.
Sawing
F-O-W-H-T--
As fabricated: produces a wide variety of strengths which can vary from lot to lot Annealed: thermal treatments to reduce mechanical properties (dead soft metal) Solution Heat-treated: after heat treating metal spontaneously age hardens (7XXX) Strain-hardened: cold working Thermally treated to produce tempers other that F, O or H. Multiple subdivisions
Subdivisions of T temper
Some apply only to specific alloy or processes
T1-T2-T3-T4-T5--
Cooled from an elevated temperature and naturally aged Cooled from an elevated temperature, cold worked and naturally aged Solution heat-treated, cold worked and naturally aged Solution heat-treated and naturally aged Cooled from an elevated temperature and artificially aged (T1+ artificial aging)
Subdivisions of T tempers
T6-T7--
Solution heat-treated and artificially aged (T4+ artificial aging) Solution heat-treating and overaged / stabilized
Thermally overaging carries aluminum past its maximum strength to control for special characteristics
T8-T9--
T10--
Solution heat-treated, cold worked and artificially aged Solution heat-treated, artificially aged and cold worked Cooled from elevated temperature, cold worked and aged artificially (usually cast products)
Ratio
Low extrusion ratios have little mechanical work hardening performed on it High extrusion ratios have more mechanical work hardening
Factor
is called
Very large perimeter with very low weight
Ratio
Post Production
Testing
Mechanical Properties
Tensile: Maximum pulling load before failure (snap) Yield: The stress at which a specific parameter set is exhibited Elongation: The maximum stretch before failure Rockwell Penetration Test: A hardness test based on skin penetration under fixed conditions