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Processing of Aluminium into Products

Dr. Trond Furu, Hydro

(2) 2011-01-10

Content

- Hydro Value Chain- Extrusion and rolling process chains- Metallurgical parameters affecting

processability and product properties- Examples of aluminium products

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Aluminium is all around us

• Light metal

• Strong

• Long-life

• High corrosion resistance

• Good conductor for heat and electricity

• Good reflector (light & heat)

• Good ductility

• Completely impermeable and odour free

• 100% recyclability

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Primary Casting Fabrication

Furnace-operationFiltration

Castingtechn.

EI, SI, FAingots

Homo-genization.

TP*

AnnealingPotlinetechn.Liquidmetal

Recycling

Sorting and upgrading

Anodequality

Oxidequality

Techno-logy

Crude oilquality

Bauxitequality

SheetProfiles

Formingoperations

Surfacetreatment

Customerprocesses

RawmaterialsCoke

RawmaterialsAlumina

Fuelquality

* TP = Thermo mechanical processing (extrusion, rolling)

Refinery techno-

logy

Value chain of extruded, rolled and foundry alloy products

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Casting

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The casthouse

Casting centre

Launder

Rod feeder

SIR unit

Furnace

Tapping vehicle

RAM station

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Main alloying elements in extruded and rolled aluminium alloysG r o u p * *

P e r i o d 1

I A 1 A

1 8

V I I I A8 A

1 1

H 1 . 0 0 8

2 I I A 2 A

1 3

I I I A3 A

1 4I V A4 A

1 5V A5 A

1 6V I A6 A

1 7V I I A

7 A

2 H e4 . 0 0 3

2 3

L i 6 . 9 4 1

4 B e 9 . 0 1 2

5

B1 0 . 8 1

6

C1 2 . 0 1

7

N1 4 . 0 1

8

O1 6 . 0 0

9 F

1 9 . 0 0

1 0

N e2 0 . 1 8

8 9 1 0 3

1 1 N a 2 2 . 9 9

1 2 M g 2 4 . 3 1

3 I I I B3 B

4I V B4 B

5V B5 B

6 V I B6 B

7 V I I B

7 B- - - - - - - V I I I - - - -

- - - - - - - - - - 8 - - - - - - -

1 1 I B 1 B

1 2I I B2 B

1 3

A l2 6 . 9 8

1 4

S i2 8 . 0 9

1 5

P3 0 . 9 7

1 6

S3 2 . 0 7

1 7

C l3 5 . 4 5

1 8

A r3 9 . 9 5

4 1 9 K

3 9 . 1 0

2 0 C a 4 0 . 0 8

2 1

S c4 4 . 9 6

2 2

T i4 7 . 8 8

2 3

V5 0 . 9 4

2 4

C r5 2 . 0 0

2 5

M n5 4 . 9 4

2 6

F e5 5 . 8 5

2 7

C o5 8 . 4 7

2 8 N i

5 8 . 6 9

2 9 C u6 3 . 5 5

3 0

Z n6 5 . 3 9

3 1

G a6 9 . 7 2

3 2

G e7 2 . 5 9

3 3

A s7 4 . 9 2

3 4

S e7 8 . 9 6

3 5

B r7 9 . 9 0

3 6

K r8 3 . 8 0

5 3 7

R b 8 5 . 4 7

3 8 S r

8 7 . 6 2

3 9

Y8 8 . 9 1

4 0

Z r9 1 . 2 2

4 1

N b9 2 . 9 1

4 2

M o9 5 . 9 4

4 3

T c( 9 8 )

4 4

R u1 0 1 . 1

4 5

R h1 0 2 . 9

4 6 P d

1 0 6 . 4

4 7 A g1 0 7 . 9

4 8

C d1 1 2 . 4

4 9

I n1 1 4 . 8

5 0

S n1 1 8 . 7

5 1

S b1 2 1 . 8

5 2

T e1 2 7 . 6

5 3

I 1 2 6 . 9

5 4

X e1 3 1 . 3

6 5 5

C s 1 3 2 . 9

5 6 B a 1 3 7 . 3

5 7

L a *1 3 8 . 9

7 2

H f1 7 8 . 5

7 3

T a1 8 0 . 9

7 4

W1 8 3 . 9

7 5

R e1 8 6 . 2

7 6

O s1 9 0 . 2

7 7

I r1 9 0 . 2

7 8 P t

1 9 5 . 1

7 9 A u1 9 7 . 0

8 0

H g2 0 0 . 5

8 1

T l2 0 4 . 4

8 2

P b2 0 7 . 2

8 3

B i2 0 9 . 0

8 4

P o( 2 1 0 )

8 5

A t( 2 1 0 )

8 6

R n( 2 2 2 )

7 8 7

F r ( 2 2 3 )

8 8 R a ( 2 2 6 )

8 9

A c ~( 2 2 7 )

1 0 4

R f( 2 5 7 )

1 0 5

D b( 2 6 0 )

1 0 6

S g( 2 6 3 )

1 0 7

B h( 2 6 2 )

1 0 8

H s( 2 6 5 )

1 0 9

M t( 2 6 6 )

1 1 0 - - -

( )

1 1 1 - - -

( )

1 1 2

- - -( )

1 1 4

- - -( )

1 1 6

- - -( )

1 1 8

- - -( )

L a n t h a n i d e S e r i e s *

5 8

C e1 4 0 . 1

5 9

P r1 4 0 . 9

6 0

N d1 4 4 . 2

6 1

P m( 1 4 7 )

6 2

S m1 5 0 . 4

6 3

E u1 5 2 . 0

6 4

G d1 5 7 . 3

6 5 T b 1 5 8 . 9

6 6 D y1 6 2 . 5

6 7

H o1 6 4 . 9

6 8

E r1 6 7 . 3

6 9

T m1 6 8 . 9

7 0

Y b1 7 3 . 0

7 1

L u1 7 5 . 0

A c t i n i d e S e r i e s ~ 9 0

T h2 3 2 . 0

9 1

P a( 2 3 1 )

9 2

U( 2 3 8 )

9 3

N p( 2 3 7 )

9 4

P u( 2 4 2 )

9 5

A m( 2 4 3 )

9 6

C m( 2 4 7 )

9 7 B k ( 2 4 7 )

9 8 C f

( 2 4 9 )

9 9

E s( 2 5 4 )

1 0 0

F m( 2 5 3 )

1 0 1

M d( 2 5 6 )

1 0 2

N o( 2 5 4 )

1 0 3

L r( 2 5 7 )

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The casthouse

Casting centre

Launder

Rod feeder

SIR unit

Furnace

Tapping vehicle

RAM station

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Sheet ingot

Extrusion ingot

Foundry alloys

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FinishingSawing and packing

Bundels ShippingSawing of extrusion ingotExtrusion ingot after casting

Sawing of sheet ingot

Sheet ingots ready for shipping

Packing … … and marking

Casting strands cut to ingots

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Extrusion

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Melt treatment Casting Homogenizing Billet preheating

Extrusion CoolingStretching

Cutting

Storing

Ageing

User

Recycling

FORMING

Process-route for extrusion

Extrusion

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Microstructure characteristics that affect processability and control material properties in aluminium alloys

Mg5Si6

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Temperature-time profile along the extrusion process chain

DC - CASTING HOMOGENIZING EXTRUSION FORMING AGEING

Tem

pera

ture

Homogenization Preheating Extrusion Cooling AgeingTime

~ 580 °C

440-490 °C

185 °C

~ 700 °C

Casting

2 - 3 hours

~ 200 °C/h

5-45minutes(induction)or gas

0.5 - 1min intotal(~5 sec.)in defor-mationzone)

Forcedair orwater 5 hours

~ 600 °C

200 - 500 °C/h

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Grain structure evolution during the extrusion process

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Al-Mg-Zn-ZrAl-Mg-Zn

1mm 1mm

Al-Mg-Si Al-Mg-Si-Mn

500 um 500 um

Typical microstructures in extruded profiles

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Grain structure influence crack nucleation and growth (formability)

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Effect of grain structure on fatigue

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Corrosion attack preferentially along grain boundaries

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Rolling

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rollingingots

size up to0,6x2 / 2x8,5m

break-downhot mill

multi-standrolling

line

six-highcold mill

coil-annealfurnace

The process chain and industrial equipment of Aluminium sheet production

break-down tandemcasting - homogenization - hot rolling - cold rolling - annealing

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grai

nste

xtur

es

Evolution of the typical microstructures in theindustrial Aluminium sheet production chain

part

icle

s

AlMg1Mn1

break-down tandemcasting - homogenization - hot rolling - cold rolling - annealing

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Forming operations

End-user processes

Surface processes(anodising/laquering/..)Welding/joining

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CastingExamples of products from Foundry Industry

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meter millimeter micrometer nanometer

1 nm1 nm

Al

From Macro to Micro to Nano

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Scanning Electron Microscope (SEM), Hydro

Transmission Electron Microscope (TEM), NTNU

Instruments in use to analyse structures on micro and nano-levels

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Sensitivity analysis by through process modellingWhat is the effect of changing casting parameters on the final strength in the alloy?

DC - CASTING

HOMOGENIZING

EXTRUSION

Finite element model developed for simulating DC casting of sheet ingots and extrusion billets by calculating the time-evolution of the heat-transfer and the fluid flow in the liquid and solid

ALSIM

Predicts the solidification process and subsequently the homogenization process in commercial, multi-component aluminium alloys, with compensation for solid-state diffusion and particle growth undercoolings.

Alstruc

Predicts the precipitation and dissolution of Mg2Si particles (includes spheres, rods and plates)

Mg2Si

DAS(Cooling rate)

Primary phasesSolid solution

Predicts the precipitation of the strengthening β’’-Mg5Si6particles, and the resultant yield stress.

NaMoAGEING

DispersoidsSolid solution

Solid solution

Mg5Si6 particlesYield stress

NaMo

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Thank you for your attention