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Aluminum Processing Current Topics in Research

Aluminum Processing Current Topics in Research. Outline: Aluminum production (ore to raw Al) Aluminum processing 1. Casting 2. Extrusion and Rolling 3. Heat treatment. Aluminum production: 1. Ore to Alumina. Bauxite ore: Dissolve in NaOH and separate impurities.

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Aluminum Processing Current Topics in Research

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  1. Aluminum Processing Current Topics in Research Outline: Aluminum production (ore to raw Al) Aluminum processing 1. Casting 2. Extrusion and Rolling 3. Heat treatment

  2. Aluminum production: 1. Ore to Alumina Bauxite ore: Dissolve in NaOH and separate impurities

  3. Aluminum production: 1. Ore to Alumina Precipitate pure Al(OH)3 Filter and Heat to pure Al2O3

  4. Aluminum production: 2. Alumina to Al metal Aluminum oxide dissolved in molten salt bath and electrolysis

  5. Aluminum processing: i. casting Al melted with alloying elements (Mg, Cu, Zn, Si,..) Cast into “logs” (like a tree) or slabs

  6. Aluminum processing: i. casting “Direct-Chill” casting Microstructure in casting

  7. Aluminum processing: i. casting Alloys have dendritic solidification “Dendrite” = branches like a tree A. Large grains B. Segregation C. Porosity Most casting research related to these problems

  8. Aluminum processing: i. casting A. Large grains - add nucleating agent

  9. Aluminum processing: i. casting B. Segregation – requires diffusion heat-treatment Research required to predict how long.

  10. Aluminum processing: i. casting C. Porosity – not a problem unless connected to outer surface

  11. Aluminum processing: ii. Extrusion Mechanics of extrusion Large reductions possible due to compressive stress.

  12. Aluminum processing: ii. Extrusion “Hot-working”

  13. Aluminum processing: ii. Rolling Hot-rolling and Cold rolling

  14. Aluminum processing: ii. Heat-treatment Age-hardening alloys require heat-treatment, usually after final shaping. Review from Class 1. 2. Callister, p. 323

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