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Aluminum and Its Different Graded Alloys

G. Avinash, V. V. N. Sarath* and A. Yeswanth

Department of Mechanical Engineering, Pragati Engineering College, Surampalem, Peddapuram, India

Abstract

Mixtures of chemical elements called alloys must contain at least one metal. The properties of the metal, such as conductivity, flexibility, opacity, and luster, will all be retained in the final alloy product, unlike metal-based chemical compounds. However, alloys may also have additional properties not found in pure metals, such as increased strength or hardness. One well-known alloy among all was aluminum; based on its availability and its individual properties, usage of this material was increased. It was highly occupied in aerospace, followed by the automobile and industrial sectors. These alloys are categorized into different series grades based on their elements, which play a prominent role in their utilization due to their properties. This paper mainly focused on different grades of alloys, and the work performed by various researchers was presented. Among these, an intense study was conducted on a few of them, creating future scope for the others. It summarizes the following: parameters and powder materials, welding on alloys, recrystallization evolution, microstructure and texture analysis, extrusion profiles and wear study, production steps, precipitation mechanisms, heat treatment evolution, etc. Some of the applications were also presented for a better understanding of alloys.

Keywords: Aluminum alloys, heat treatment process, recrystallization evolution, micro structural and surface texture analysis, powder form materials

1.1 Introduction

An aluminum alloy is an alloy with aluminum (Al) as the primary metal. Copper, magnesium, manganese, silicon, tin, nickel, and zinc are common alloying elements as presented in Figure 1.1. Casting and wrought alloys were categorized into heat-treatable and non-heat-treatable. Most of the aluminum is used to make wrought items such as rolled plates, foils, and extrusions.

Due to its superior performance and acceptable qualities over currently available aluminum or its alloys, a metal matrix composite like aluminum is preferable for industrial applications. The utilization of these metallic matrix materials was higher due to the various aspects that may influence the further addition of ceramic materials. Since the invention of metal-skinned aircraft, aluminum alloys played a significant role in aerospace manufacturing. In addition to being far less explosive than other alloys with a very high percentage of magnesium, aluminum-magnesium alloys are also lighter than other aluminum alloys [1].

Similarly, these materials have an excellent strength-to-weight ratio, which is one of the reasons it has been so well-liked in sectors like aerospace. Apart from this, corrosion resistance is one of aluminum’s other vital advantages. Aluminum alloy offers excellent resistance to air corrosion in various environmental conditions.

Different identification standards are used for wrought and cast aluminum alloys as shown in Figure 1.2. A four-digit number specifies the alloying elements used to identify wrought aluminum.

A four- to five-digit number with a decimal point is used for cast aluminum alloys. Table 1.1 defines the digit following the decimal point denotes the form, while the digit in the hundreds place denotes the alloying components (cast shape or ingot).

Figure 1.1 Aluminum alloy with various elements.

Figure 1.2 Aluminum alloys with different graded series.

Table 1.1 Four-digit series of aluminum alloys with main elements.

1.1.1 AA1XXX Series

Material shape and type significantly influence the tensile properties; a comparison was made between the AA1100 and SS400, which states that width might also impact the material’s properties [2]. While under different strain rates, samples were tested and compared with the simulation analysis, which finally showed a satisfactory result [3]. The AA1100 aluminum alloy and mild steel materials were studied under the different welded, various parameters conditions and defined its mechanical properties [4]. Along with this, for maximum strength and minimum corrosion rate, tool parameters and friction stir welding (FSW) process were optimized by the RSM technique on this AA1100 [5, 6]. Friction stir spot welding was performed using a drilling machine at a variable rotational speed, it was concluded that the thickness of 3-mm sheets has a greater potential for welding, and the maximum tensile value was recorded at the highest value of rotational speed [7, 8]. Mixing Ni and Sic powders in different ratios to AA1200. Its surface alloying is performed, and microstructure is observed under various aspects. Finally, it states that hardness occurred in the alloyed zone around two to four times in the heated zone [9]. Similarly, the aluminum surface was studied under different compositions using Ni, Ti, and Sic powders and states that among various compositions, the highest percentage of Ni with Ti and Sic receives maximum hardness, which is 13 times higher than pure aluminum [10].

1.1.2 AA2XXX Series

Tensile and notch strengths were determined in the range of 78° to −423°F for alloys of 2014, 2024, 2219, and 6061 in various conditions and observed toughness and flexibility [11]. A comparative study was made between the three different AA2000 series in the aspect of uniaxial fatigue loading and its responses; finally, AA 2624-T351 alloy is the most advisable material [12, 13].

Similarly, with NaCl on AA2024-T351 aluminum alloy, its intergranular corrosion and crystallographic pitting were explored [14]. The essential goal of this article is to discover the improvement and utilization of aluminum alloys in aerospace industries. In this contrast, the upgrades in mechanical properties of the Al-Cu, Al-Zn, and Al-Li alloys are mentioned [15]. Corrosion, hardness, and microstructural change brought on by SiC and Zr additions to a 2xxx series of Al-Cu alloy was investigated [16, 17].

1.1.3 AA3XXX Series

This paper examines hot-tearing sensitivity on AA3000 with different alloy contents utilizing restricted rod casting molds. The results validated that Cu and Fe product affects hot-tearing resistance [18]. On AA3003, the recrystallized evolution, grains, and kinetics were also carried out on cold-rolled continuous cast of aluminum alloys. Similarly, microstructure and texture analysis were also performed under the different thicknesses of 3003 alloys. Along with this to study its mechanical behavior in samples with different pores, FE analysis was conducted on it [19–22].

On AA3004 alloy, tensile tests were performed in the extruded alloy with equal-channel angular pressing (ECAP) under different temperatures. Hot and cold rolled samples received good mechanical values at 573 K. During the study on this alloy, intermetallic particle control is necessary during annealing and strip casting processes, which may influence cube texture after recrystallization [23, 24]. Apart from this, the impact of temperature and stress on texture improvement in aluminum alloy AA 3004 has been studied in a sequence of multi-pass rolling experiments; finally, the texture is observed without appreciable results except for an interactive effect [25]. Similarly, a commercial grade 3004 alloy that has been solution-treated at two different temperatures (580°C and 400°C) has had the impact of warm/hot-rolling temperature evaluated on its microstructure and texture [26].

1.1.4 AA4XXX Series

The morphology study on the 4XXX series, i.e., AlSi5Cu2Mg alloy, revealed their chemical composition, shape, and three intermetallic phases based on parameters [27]. Furthermore, the hot compression–induced deformation behavior of aluminum alloy 4032 was investigated and concluded that flow stress was highly influenced by temperature and strain rate [28]. The aggregate of silicon and nickel in an aluminum matrix affects exquisite wear resistance. Similarly, rice husk ash (RHA) and coal ash were also used in Al 4032 and studied its wear resistance [29–31].

In 4032 series, A silicon hollow glass microspheres (SIHGM) on a metal matrix composites are presented and its influence on mechanical and tribological properties was studied, along with this, the wire’s microstructure and modification performance on 4032 aluminum alloy may be conducted, from which it was discovered that preparation procedures had a substantial impact on the microstructures of Al-10Sr, which...