How do you make aluminum alloy castings

Update:18 May 2020
Summary:

Aluminum or aluminum alloy Aluminum alloys are used to […]

Aluminum or aluminum alloy

Aluminum alloys are used to make generators and automobile engines.
Aluminum alloy is used to manufacture generators and automobile engines. Marin Thomas / Getty Images

Aluminum alloy is a composition mainly composed of aluminum, to which other elements have been added. The alloy is made by mixing elements together when aluminum is molten (liquid), and liquid aluminum cools to form a uniform solid solution. Other elements may account for 15% of the alloy mass. The added elements include iron, copper, magnesium, silicon and zinc. Compared with pure metal elements, adding elements to aluminum can make the alloy have higher strength, workability, corrosion resistance, electrical conductivity and / or density. Aluminum alloys tend to be lightweight and resistant to corrosion.

 

This is a list of some important aluminum or aluminum alloys.

AA-8000: used for building wires according to national electrical codes
Alclad: an aluminum plate made by bonding high-purity aluminum to a high-strength core material
Aluminum lithium (lithium, sometimes mercury)
Alnico (aluminum, nickel, copper)
Birmabright (aluminum, magnesium)
Duralumin (copper, aluminum)
dal (aluminum, magnesium, manganese, silicon)
Magnesium (5% magnesium)
Magnox (magnesium oxide, aluminum)
Nambe (aluminum plus seven other unspecified metals)
Silumin (aluminum, silicon)
Titanium (aluminum, zinc, magnesium, copper, zirconium)
Zamak (zinc, aluminum, magnesium, copper)
Aluminum and magnesium, manganese and platinum form other complex alloys
Identify aluminum alloy
The alloy has a common name, but a four-digit number can be used for identification. The first digit of the number identifies the category or series of alloys.

Commercial pure aluminum also has a four-digit numeric identifier. The 1 series alloys are made of 99% or higher purity aluminum.

 

The main alloying element in the 2xxx series is copper. Heat treatment of these alloys can increase strength. These alloys are both strong and tough, but they are not as corrosion resistant as other aluminum alloys, so they usually require paint or coating for use. The most common aircraft alloy is 2024. The 2024-T351 alloy is one of the hardest aluminum alloys.

The main alloying element of this series is manganese, which usually contains a relatively small amount of magnesium. The most popular alloy in this series is 3003, which is feasible and moderate in strength. 3003 is used to make cookware. Alloy 3004 is one of the alloys used to make beverage aluminum cans.

Silicon is added to aluminum to make 4xxx alloy. This lowers the melting point of the metal without making it brittle. This series is used to manufacture welding wire. Alloy 4043 is used to make filler alloys for automobiles and structural parts.

The main alloying element in the 5 series is magnesium. These alloys are strong, weldable, and resistant to marine corrosion. These five alloys are used in the manufacture of pressure vessels and storage tanks, and in various marine applications. Alloy 5182 is used to make aluminum beverage can lids. Therefore, the aluminum can actually consists of at least two alloys!

Silicon and magnesium are present in 6 alloys. These elements combine to form magnesium silicide. These alloys are formable, weldable and heat treatable. They have good corrosion resistance and medium strength. The most common alloy in this series is 6061, which is used to make trucks and ship frames. The 6 series of extruded products are used to construct and manufacture iPhone 6.

 

Zinc is the main alloying element in the series beginning with 7. The resulting alloy can be heat treated and is very strong. The important alloys are 7050 and 7075, both of which are used to make aircraft.

These are aluminum alloys made with other elements. Examples include 8500, 8510, and 8520.

Currently, the series starting with the number 9 have not been used.

What is the strongest aluminum alloy?
Manganese added to aluminum increases strength and produces alloys with excellent workability and corrosion resistance. The highest strength alloy in the non-heat treatable grade is 5052 alloy.

Aluminum alloy classification
Generally, the two major categories of aluminum alloys are forged alloys and cast alloys. These two groups are divided into heat-treatable types and non-heat-treatable types. About 85% of aluminum is used for forging alloys. Cast alloys are relatively inexpensive to produce because of their low melting point, but they tend to have lower tensile strength than forged alloys.