Professional Documents
Culture Documents
Objectives of Chapter 13
Explore the properties and applications of Cu, Al, and Ti alloys in load-bearing applications.
Chapter Outline
Aluminum Alloys Magnesium and Beryllium Alloys Copper Alloys Nickel and Cobalt Alloys Titanium Alloys Refractory and Precious Metals
Hall-Heroult process - An electrolytic process by which aluminum is extracted from its ore. Temper designation - A shorthand notation using letters and numbers to describe the processing of an alloy. H tempers refer to cold-worked alloys; T tempers refer to age-hardening treatments.
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
6
Figure 13.1 Production of aluminum in an electrolytic cell.
6
10
10
Figure 13.2 (a) FeAl3 inclusions in annealed 1100 aluminum ( 350). (b) Mg2Si precipitates in annealed 5457 aluminum alloy ( 75). (From ASM Handbook, Vol. 7, (1972), ASM International, Materials Park, OH 44073.)
11
11
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
12
12
Figure 13.4 (a) Sand-cast 443 aluminum alloy containing coarse silicon and inclusions. (b) Permanent-mold 443 alloy containing fine dendrite cells and fine silicon due to faster cooling. (c) Die-cast 443 alloy with a still finer microstructure ( 350). (From ASM Handbook, Vol. 7, (1972), ASM International, Materials Park, OH 44073.)
13
13
14
14
15
15
Example 13.1 SOLUTION a. Load = F = y A = 70.000 (/4) (0.5 in.)2 = 13,744 lb b. The yield strength of the aluminum alloy is 36,000 psi. Thus: A = (/4)d2 = F/y = 13,744/36,000 = 0.38 in.2 d = 0.697 in. Density of steel = = 7.87 g/cm3 = 0.284 lb/in.3 Density of aluminum = = 2.70 g/cm3 = 0.097 lb/in3 c. Weight of steel = Al = (/4)(0.5in)2(12)(0284) = 0.669 lb/ft Weight of aluminum = Al = (/4)(0.697)2 (2) (12) (0.097) = 0.444 lb/ft Although the yield strength of the aluminum is lower than that of the steel and the cable must be larger in diameter, the aluminum cable weighs only about half as much as the steel cable. When comparing materials, a proper factor-ofsafety should also be included during design. 16 16
17
17
18
18
19
19
20
20
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
21
Figure 13.5 The magnesium-aluminum phase diagram.
21
22
22
23
23
24
24
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Figure 13.6 Binary phase diagrams for the (a) copper-zinc, (b) copper-tin, (c) copperaluminum, and (d) copperberyllium systems.
25
25
27
27
Example 13.6 SOLUTION 1. Heat the alloy to 950oC and hold to produce 100% . 2. Quench the alloy to room temperature to cause to transform to martensite, , which is supersaturated in copper. 3. Temper below 565oC; a temperature of 400oC might be suitable. During tempering, the martensite transforms to and 2. The amount of the 2 that forms at 400oC is:
4. Cool rapidly to room temperature so that the equilibrium does not form.
28
28
29
29
30
30
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
31
Figure 13.7 The effect of temperature on the tensile strength of several nickel-based alloys.
31
Figure 13.8 (a) Microstructure of a superalloy, with carbides at the grain boundaries and precipitates in the matrix ( 15,000). (b) Microstructure of a superalloy aged at two temperatures, producing both large and small cubical precipitates ( 10,000). (ASM Handbook, Vol. 9, Metallography and Microstructure (1985), ASM International, Materials Park, OH 44073.)
32
32
Example 13.7 Design/Materials Selection for a High-Performance Jet Engine Turbine Blade
Design a nickel-based superalloy for producing turbine blades for a gas turbine aircraft engine that will have a particularly long creep-rupture time at temperatures approaching 1100oC.
33
33
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Figure 13.9 (a) A turbine blade designed for active cooling by a gas. (b) The high-temperature capability of superalloys has increased with improvements in manufacturing methods (for Example 13.7).
34
34
Example 13.7 SOLUTION First, we need a very stable microstructure. Addition of aluminum or titanium permits the precipitation of up to 60 vol% of the phase during heat treatment and may permit the alloy to operate at temperatures approaching 0.85 times the absolute melting temperature. Second, we might produce a directionally solidified or even single-crystal turbine blade (Chapter 8). In directional solidification, only columnar grains. We would then heat treat the casting to assure that the carbides and precipitate with the correct size and distribution. Finally, the blade might contain small cooling channels along its length. Air for combustion in the engine can pass through these channels, providing active cooling to the blade, before reacting with fuel in the combustion chamber. 35
35
36
36
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Figure 13.10 Portions of the phase diagrams for (a) titanium-tin, (b) titaniumaluminum, (c) titaniummolybdenum, and (d) titaniummanganese.
37
37
38
38
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
39
Figure 13.11 The effect of temperature on the yield strength of selected titanium alloys.
39
Figure 13.12 (a) Annealing and (b) microstructure of rapidly cooled alpha titanium ( 100). Both the grain boundary precipitate and the Widmansttten plates are alpha. (From ASM Handbook, Vol. 7, (1972), ASM International, Materials Park, OH 44073.)
40
40
Figure 13.13 Annealing of an alpha-beta titanium alloy. (a) Annealing is done just below the transformation temperature, (b) slow cooling gives equiaxed grains ( 250), and (c) rapid cooling yields acicular grains ( 2500). (From Metals Handbook, Vol. 7, (1972), ASM International, Materials Park, OH 44073.)
41
41
Figure 13.14 (a) Heat treatment and (b) microstructure of the alpha-beta titanium alloys. The structure contains primary (large white grains) and a dark matrix with needles of formed during aging (250). (From ASM Handbook, Vol. 7, (1972), ASM International, Materials Park, OH 44073.)
42
42
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Figure 13.15 Sketch of a heat exchanger using titanium tubes (for Example 13.8).
43
43
Example 13.8 SOLUTION Provided that the maximum operating temperature is below 535oC so that the oxide film is stable, titanium might be a good choice to provide corrosion resistance at elevated temperatures. A commercially pure titanium provides the best corrosion resistance. Pure titanium also provides superior forming and welding characteristics and would, therefore, be our most logical selection. If pure titanium does not provide sufficient strength, an alternative is an alpha titanium alloy, still providing good corrosion resistance, forming characteristics, and weldability but also somewhat improved strength.
44
44
45
45
Example 13.9 SOLUTION To achieve high strengths, we might consider an alphabeta titanium alloy. Because of its availability, the Ti-6% Al-4% V alloy is a good choice. The alloy is heated to about 1065oC, which is in the all- portion of the phase diagram. When the heat treatment is performed in the all- region, the tempered martensite has an acicular structure, which reduces the rate of growth of any fatigue cracks that might develop.
46
46
49
49