Aluminum : technology, industry, and applications / Robert E. Sanders and Graeme J. Marshall.

Format:

Book

Author/Creator:

Sanders, Robert E., 1952- author.

Marshall, Graeme J., author.

Language:

English

Subjects (All):

Aluminum alloys.

Physical Description:

1 online resource (528 pages)

Edition:

First edition.

Place of Publication:

[Place of publication not identified] : ASM International, [2023]

Summary:

Aluminum: Technology, Industry, and Applications provides an overview of the processes, practices, and trends associated with the use of aluminum as an engineering material. This resourceful and practical book includes chapters on mining and smelting, ingot and continuous casting, shape casting, hot and cold rolling, extrusion and drawing, forging, and secondary operations. It discusses the factors involved in the selection of product forms, alloy compositions, and temper designations with emphasis on manufacturability, component performance, sustainability, and cost. The book also describes the role of aluminum in aerospace, automotive, trucking, rail, marine, packaging, appliance, and building and infrastructure applications, noting major advancements as well as challenges. It also includes content that traces the development of the aluminum industry from its beginnings to its current state, from the perspective of the individuals and organizations who shaped it. It is for anyone working in or serving the aluminum industry and those who have interest in its past, present, and exciting future.

Contents:

Intro

Contents

Preface

Acknowledgments

About the Authors

Robert (Rob) E. Sanders

Graeme J. Marshall

Introduction-Aluminum as an Industrial Material

Discovery of Aluminum

Origins of the Industry

From Discovery to Commercialization

Developing the Market

Evolution of the Aluminum Industry

Creation of Alcan from Alcoa

World War II

Post-WWII

Post-WWII Growth in North America

Postwar Growth of Alcan

Pechiney and Alusuisse

Unraveling and Realignment of the Industry

Alcan Mergers, Acquisitions, and Deconstruction

Deconstructing Alcoa

Evolution from Vertical Integration

Summary

Mining, Refining, Smelting, and Recycling

Where Does Aluminum Come From?

Refining-The Bayer Process

Smelting

Reducing the CO2 Cost of Aluminum Products

On the Horizon-Can the Carbon Anode Be Eliminated?

Primary Aluminum

Standard Grades of Primary Aluminum

Higher Purity Aluminum

Cost of Aluminum

Scrap and Recycling

Strengthening and Heat Treatment of Aluminum

Alloy Designation Systems

Wrought Alloys

Strengthening of Aluminum

Solid-Solution Strengthening

Work Hardening and Softening

Precipitation Hardening

Temper Designations

Non-Heat-Treatable Temper Designations

Work-Hardened Tempers (H1x)

Annealed and Softened Tempers (H2x, H3x, and H4x)

Heat-Treatment Process

Quench Sensitivity

Aged Conditions

Direct Chill Ingot and Continuous Casting Processes

Melting and Alloying

Recycling

Molten Metal Treatment

Degassing

Control of Inclusions

Ingot Grain Refining

Direct Chill Casting

Direct Chill Ingot Microstructure

Continuous Casting Methods

Slab Casters-Twin-Block and Twin Belt

Continuous Casters-The Holy Grail for Sheet Production?

Wheel-Belt Casters

Aluminum Shape Casting.

What Is a Casting?

Aluminum Shape-Casting Processes

Expendable-Mold Casting

Sand-Mold Casting

Permanent (Metal) Mold Casting

Metal Feeding

Mold Materials

Gravity Die Casting

Low-Pressure Die Casting

High-Pressure Die Casting

Casting Alloys

Cast Alloy Families

1xx.0 Family

2xx.0 Family

3xx.0 Family

4xx.0 Family

Aluminum-Silicon Alloys

5xx.0 Family

7xx.0 Family

8xx.0 Family

Casting Quality and Performance

Premium Engineered Castings

Solidification Rate

Grain Refinement

Modification of Al-Si Eutectics

Hot Isostatic Pressing

Heat Treatment of Cast Products

Solution Heat Treatment

Quenching

Aging of Castings

Production of Aluminum Rolled Products

Ingot Preparation

Ingot Preheating and/or Homogenization

Microstructure

Preheat Furnaces

Hot Rolling

Dimensional

Surface Quality

Mill Configurations

Edge Cracking

Aluminum Rolling Mills

Plate Production

Cross-rolling

Metallurgical Evolution during Hot Rolling

Cold Rolling of Sheet and Foil

Finishing Operations

Mechanical Processes

Surface Treatments

Lithographic Sheet

Heat Treatment of Thick Sheet and Plate

Thick Heat-Treated Plate

Packaging and Shipping

Aluminum Extrusion and Wire Drawing

Extrusion Process

Extrusion Alloys and Process

Direct Extrusion of Soft (6xxx) Extrusion Alloys

Extrusion of Hard Alloy Products

Direct versus Indirect Extrusion

Heat Treatment

Hollows and Tubes

Rod and Bar Products

Free-Machining Alloys and Products

Weldable 6xxx and 7xxx High-Strength Structural Alloys

Secondary Operations

Production of Wire Products

Aluminum Forging

What Is Forging?

Types of Forging Processes

Forging Equipment.

Forging Process

Forging Alloys

Forged Products

Forged Pistons

Automotive Components

Wheels for Light Vehicles

Heavy Truck Wheels

Aircraft

Product, Alloy, and Temper Selection

Introduction to Alloy and Product Selection

Common Alloy Sheet

1100 versus 1200

5052 versus 5754

6061 versus 6082

Important Physical Properties

Aluminum Alloy Density

Elastic Modulus

Coefficient of Thermal Expansion

Electrical Conductivity

Thermal Conductivity

Mechanical Properties

Tensile Testing

Effect of Temperature

Fracture Toughness

Testing for Toughness

Fatigue

Aluminum Corrosion

Water Staining of Aluminum

Atmospheric Corrosion

Galvanic Corrosion

Pitting Corrosion

Crevice Corrosion

Intergranular Corrosion

Exfoliation Corrosion

Stress Corrosion Cracking

Corrosion Fatigue

Filiform Corrosion

Corrosion Test Methods

Customer Manufacturing Processes

Formability

Mill Product Surface

Specialty Rolled Finishes

Bright Finishes

Anodizing

Coated or Painted Aluminum

Room Temperature Joining

Mechanical Fastening

Solid-State Welding

Adhesive Bonding

Elevated Temperature Joining

Brazing

Effect of Alloy

Arc Welding

Properties of Welded Alloys

Filler Alloys

Resistance Spot Welding

Machining

Aluminum in Aircraft and Space Applications

Commercial Aircraft

Modern Aircraft Manufacturing

Buy-to-Fly Ratio

Wing Structure

Fuselage

Aerospace Alloys

Importance of T7x Tempers

Military Aircraft

Aluminum in Space

NASA Rover on Mars

Looking Ahead

Aluminum in Light Vehicles

Aluminum Shaped Castings

The Story of the Vega Aluminum Engine

Cast Aluminum Wheels

Automotive Aluminum Rolled Products

Early Developments.

Sheet Components for Light Vehicles

Closure or Skin Panels

Outer Body Sheet Alloys

Natural Aging and Shelf Life

Preaging

Sheet Formability

Surface Finish

Inner Panels

Structural Autobody Sheet

Early Body Structure Development

Body Structure Alloys

Ford F150

Heat Exchangers

Production

Corrosion Performance

Automotive Aluminum Extruded Products

Alloys and Production Process

Forming

Aluminum in Ground Transportation

Early Uses of Aluminum in Ground Transportation

Trucks

UPS Truck Driver Interview

Heavy Trucks and Trailers

Dry Vans

Tankers

Grain Haulers

Dump Trucks

Truck Cabs

China and Trucking

Buses-School, City, and Long Distance

Railroad Freight Applications

Coal Cars

Other Freight Applications

Subways and Light Rail

Passenger High-Speed Railroad Applications

Building High Speed Rail Cars

High Speed Rail in China

Aluminum in Military Vehicles

Aluminum in Marine Transportation

Small Boats

Alloys for Shipbuilding

Corrosion

Alloys for Outboard Engines

Aluminum Ships

Fast Ferries

Naval Vessels

Aluminum Packaging Products

Foil Packaging Products

Foil Alloys

Aseptic Packaging

Drink and Food Applications

Dairy Applications

Household Foil

Medical, Pharmaceutical, and Cosmetic Packaging

Semirigid Containers

Beverage and Food Cans

Brief History of the Aluminum Can

Beverage Can Body

Beverage Can Lid Manufacture

Tab Formation

Food Cans

Can Metallurgy

Can Body Stock

Earing

Can End Stock

Aluminum Food Cans and Bottles

Impact Extruded Containers

Aluminum Closures

Aluminum Building Products

Early Use and Development

Extruded Products

Rolled Products

Painted Sheet.

Composite Panels

Lighting and Window Coverings

Anodized Quality Sheet

Heating, Ventilation, and Air Conditioning Applications

Cast Products

Aluminum in Household Goods and Appliances

Cookware

Surface Finishes on Aluminum

Consumer Electronics and TVs

Consumer Electronics

Home Interiors

Window Blinds

Underfloor Heating

Ladders and Other Tools

Luggage and Briefcases

Outdoor Furniture

Aluminum in Art

Aluminum, Art, and Architecture

Aluminum in Infrastructure

Electrical Conductors

Electrical Conductor 8xxx Alloys

Local Distribution

Roads and Bridges

Saguenay River Bridge at Arvida

Highway Signs, Traffic Signals, and License Plates

License Plates

Aluminum Lighting Standards (Light Poles)

Recyling for Used Lighting Standards

Aluminum Guard Rails and Handrails

Railroad and Highway Crossings

Solar Energy Generation

Agriculture and Industrial Applications

Aluminum in Sports and Recreation

Water Sports

Diving

Baseball

Bat Forming

Bat Alloys

Hockey, Tennis, and Racquet Sports

Easton Sports

Track and Field

Snowmobiles, Jet Skis, and Golf Carts

Aluminum Cricket Bat

Bicycles

Parts of the Bicycle

Alloys and Production

Sports Wheelchairs

Motorcycles

Travel Trailers and Recreational Vehicles

Camping Equipment

Aluminum and Its Importance for Sustainability

Current State of Recycling

Prospects for the Future

Recycling Buildings and Infrastructure

Automotive Aluminum Recycling

Used Beverage Cans

Decarbonizing Aluminum Production

Noncarbon Sources of Electricity

Reducing Downstream Energy Requirements and Emissions

What´s Next for Recycling?

Missing Cans

Access to Recycling

Public Awareness

Container Deposit Legislation.

Impact of Lightweighting.

Notes:

Description based on publisher supplied metadata and other sources.

Description based on print version record.

ISBN:

9781627084277

1627084274

9781523155187

1523155183

9781627084260

1627084266

OCLC:

1391441007