Investing Instruments of Aluminium Equipment Combinations - Assignment Example

Aluminium casting alloys Name Institutional affiliation In the modern world, metallic components are designed to enhance performance (Saha et al., 2004). This performance is attained through alloy. The bonding between the metallic partners strengthens and toughens the alloy (Apelian, 2009). Aluminium alloys are generally used in engineering structure. The aluminium cast alloys allows specific performance metrics and processes. Alloys enable industries to work in more intelligent and effective way (Zolotorevskiĭ et al., 2007). The industries are able to optimise on advantages of the merits of the particular process. The components undergo several stages during the process of making the alloy. When making complex alloy the composition within it will determine differences during the heating process (Apelian, 2009). The main processes in casting of aluminium alloys include; piston plunger and piston plunger techniques. The elements used in casting aluminium alloys include; silicon, zinc, manganese, magnesium and copper (Saha et al., 2004). Aluminium alloys are most preferred because of the low cost effective products (Apelian, 2009). The industries producing these aluminium alloys have strategies that consider the needs of the communities around the industries (Batyshev, 2012). The designers and management appreciate boundary conditions and the constraint of their work (Wipo assigns patent, 2010 para 4). Aluminium alloys exhibit average mechanical process as compared to that of steel (Krstić Vukelja, et al., 2010). However, the improved technology the mechanical reliability of the alloy has been reinforced. The chemistry of reaction layers enhances the bond between the two metals. Aluminium copper alloys with less amounts of silicon have relative poor fluidity and resistance. The alloy quickly tears during solidification (Zolotorevskiĭ et al., 2007). The materials used to prepare these alloys have superior engineering properties. Aluminium has a specific weight which is substantially lower than other common metals (Zolotorevskiĭ et al., 2007). They have a high strength to weight ratio. This allows it to with stand high stress. The alloys also have a high resistance to corrosive environment. This is achieved by making an artificial oxide coat which acts as a wear resistance layer (Apelian, 2009). The alloys have a large range of solidifying. The alloy is an excellent conductor of electricity making it suitable for manufacture of electric wires (Batyshev, 2012). In addition, aluminium alloys have a strong homogeneity, which gives it a high reflectivity. This makes it an appealing material for decoration displays. The outstanding form ability in these alloys makes it suitable to be processed in a variety of ways (Krstić Vukelja, et al., 2010). However, these materials have their implications when used. The biggest problem is the formation of tears during solidification of the casting. These tears form as a result of inadequate permeability between the materials used in casting (Apelian, 2009). They are also caused by lack of strength of the dendrites network at the early stages of solidification. The adjustment of the alloy during casting procedure minimizes the tendency of the alloy to tear (Apelian, 2009). The most common process of making aluminium is through the horizontal continuous casting process (Krstić Vukelja, et al., 2010). The process begins by melting the material used to make the alloy. These materials are melted at melting furnace. The cast continues by passing through pairs of cooled rolls. The solidification of aluminium is achieved by passing it between water cooled rolls of a duo rolling mill (Krstić Vukelja, et al., 2010). The casting and deformation are completed in an opposite rotating rolls. Lubricant is sprayed on the rolls prevents the strip from sticking to the roll. The melted aluminium alloy elements solidify against the roll. The aluminium melts at the solidification front in order to prevent flow disturbance (Krstić Vukelja, et al., 2010). The testing of the alloy’s chemical composition, match up to the international standards. At the final stage, an aluminium titanium wire is introduced to remove the coarse crystal that had formed in the initial casting stage (Krstić Vukelja, et al., 2010). The whole process is quite attractive and simple. The main objective of the process is attaining quality characteristics of the alloy (Krstić Vukelja, et al., 2010). “The process of making alloys using the controlled diffusion solidification (CDS) relies on mixing liquid alloys of controlled chemistry and temperature” (Batyshev, 2012, 465). This controlled temperature allows the alloy to form a nucleus solid phase at a faster rate. The CDS process allows alloys to solidify over short temperatures ranges. The alloys produced are nondendritic with a microstructure that minimises tearing. Aluminium alloys are classified using a designated four digit number with a decimal point separating the third and fourth digit. The table below further explains the classification of the alloys (Classification of Aluminum Alloys, para. 1). The first digit indicates the alloy group according to the major element in the alloy composition. The second two digits indicate the alloy purity (Classification of Aluminum Alloys, para. 2). The last digit indicates product form; that is the casting or ingot. Casting is designated by ‘0’ while ingot is designated by ‘1’ or ‘2’ depending on the chemical composition. Any modification of the alloy is indicated by a serial letter before the numerical designation (Classification of Aluminum Alloys, para. 2). Number Series- Alloy Type Aluminium series Alloy type 1XX.X 99.0% minimum aluminium content 2XX.X Al + Cu 3XX.X Al + Si & Mg, or Al + Si & Cu, or Al + Si & Mg & Cu 4XX.X Al + Si 5XX.X Al + Mg 7XX.X Al + Zn 8XX.X Al + Sn Source: http://www.substech.com/dokuwiki/doku.php? The figure shows different series of alloys. (Batyshev, 2012). For example an alloy of 1xx.x series noted as 150.0 means the alloy contains 99.50% of aluminium (Classification of Aluminum Alloys, para. 4). The different series have different characteristics. Aluminium silicon alloys provides good casting ability. The alloy readily fills the dies during solidifying hence there is no hot tearing or hot cracking issues (Batyshev, 2012). Silicon has a high heat fusion which contributes to the alloy’s perfect fluidity. This contributes to the strength of the alloy to make it heat treatable. The Magnesium element in aluminium alloys strengthens and hardens the castings (Apelian, 2009).. In addition it provides an excellent corrosion resistance making it a perfect tool for mechanical and chemical use (Batyshev, 2012). Titanium on the other hand is used to refine aluminium grains (Wipo assigns patent, 2010 para 4). The combination of aluminium and titanium forms primary aluminium dendrites (Saha et al., 2004). Source: http://www.diecasting.org/research/wwr/WWR_AluminumCastAlloys.pdf The figure shows grain-refined aluminium (Saha et al., 2004). Manganese causes a beneficial change in morphology of aluminium alloy. It plays a crucial role in reducing soldering during cast melt. Manganese is mostly used to prepare 2xx and 7xx alloys since they suppress the grain growth in those systems (Apelian, 2009).. Zinc is suitably used in the 7xx series since it provides acceptable impurity in the secondary casting alloys. Zinc plays a neutral element in the casting alloys. It neither enhances nor detracts the properties of the alloy. It only adds weight to the alloy since it is relatively dense (Apelian, 2009). There are plants set up which recycle aluminium and use them to make alloys. The aluminium still has its properties even after being recycled. The recycled aluminium used to prepare alloy for making cylinder heads, crankcases and aluminium wheels (“Aluminium Casting Alloys”, 2011). This alloy has developed to become high-complex element in the market today. Companies are shifting focus to recycling aluminium from scrape and dross due to the high demand for raw material. In addition, the products are environment friendly hence environmental pollution is reduced. The plant has also employed approximately 600 people (“Aluminium Casting Alloys”, 2011). This has become a significance factor towards the economic benefits of the wide region this plant has covered. The company has several plants spread across Europe. The plant is a source of raw material for several other industries such as; rolling mills, automotive industry, building construction among others (“Aluminium Casting Alloys”, 2011). The recycle plants utilise all reside materials that arise from production and fabrication of aluminium alloys (“Aluminium Casting Alloys”, 2011). The metal is a suitable material for re-melting hence it saves on energy and retains its original value. The alloys made from scrap are with regard to ductility. The alloys standardisation procedure carried out in the recycling plants enable the experts to determine whether the alloys are suitable for specific casting procedures (“Aluminium Casting Alloys”, 2011). Inferior casting alloys are grouped together, whereas the stronger ones are groped together. The recycling procedure will substantially be influenced by the elements present in the alloys (“Aluminium Casting Alloys”, 2011). For instance, an aluminium silicon alloy will undergo a different procedure from aluminium manganese alloy. Alloys are used in various sectors. The 1xx series is used commercially to cast electric motor rotors. This is achieved since aluminium has a high conductivity. This conductivity makes it a suitable component for collector rings and conductor bars (Apelian, 2009). The 2xx series is the high strength aluminium casting of alloys. This allows the alloys to retain massive strength making it a suitable material for military and aerospace hardware. These alloys portray a high tensile and impact property that is required in this field (Apelian, 2009). The 3xx series alloy has superior casting characteristics and strength hence they prevalent in making aluminium copper alloys for electrical purposes. They are also suitable for automotive manifolds and pistons (Apelian, 2009). The 4xx alloy family is used where substantial casting ability is applied. It includes marine casting office equipment frames and food handling equipment. The 5xx alloy family is used for polishing finishes of metallic surfaces due to their high corrosion resistance (Apelian, 2009). 7xx alloys have a suitable property of high strength without heat treatment. Therefore, they are popular in making large machinery, mining and garden tools. Textile and trailer parts are also made from these series alloy (Apelian, 2009). The 8xx series are exclusively used for casting bushes and bearings (Zolotorevskiĭ et al., 2007). The alloy provides liquid tin lubrication that prevents catastrophic failure. References Aluminium Casting Alloys. (2011). Aleris. Retrieved from http://www.aleris.com/sites/default/files/Aluminium_Casting_Alloys_englishVersion_2011.pdf Apelian, D. (2009). Aluminum Cast Alloys: Enabling Tools for Improved Performance. North American Die Casting Association. Retrieved from http://www.diecasting.org/research/wwr/WWR_AluminumCastAlloys.pdf Batyshev, K. K. (2012). Casting of aluminum alloys with pressure crystallization. Part 1. Metal Science & Heat Treatment, 53(9/10), 463-471. Classification of Aluminum Alloys: SubsTech. (n.d.). Retrieved from http://www.substech.com/dokuwiki/doku.php?id=classification_of_aluminum_alloys Krstić Vukelja, E. E., Duplančić, I. I., & Lela, B. B. (2010). Continuous Roll Casting of Aluminium Alloys-- Casting Parameters Analysis. Metalurgija, 49(2), 115-118. Saha, D., Shankar, S., Apelian, D., & Makhlouf, M. M. (2004). Casting of aluminum-based wrought alloys using controlled diffusion solidification. Metallurgical and Materials Transactions, 35A (7), 2174-2180. Wipo assigns patent to tubitak for "process for producing improved grain refining aluminium-titanium-boron master alloys for aluminum foundry alloys" (turkish inventor). (2010, Sep 02). US Fed News Service, Including US State News, pp. n/a. Zolotorevskiĭ, V., Belov, N. A. & Glazoff, M. V. (2007). Casting Aluminum Alloys. 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The most common process of making aluminium is through the horizontal continuous casting process (Krstić Vukelja, et al., 2010). The process begins by melting the material used to make the alloy. These materials are melted at melting furnace. The cast continues by passing through pairs of cooled rolls. The solidification of aluminium is achieved by passing it between water cooled rolls of a duo rolling mill (Krstić Vukelja, et al., 2010). The casting and deformation are completed in an opposite rotating rolls.

Lubricant is sprayed on the rolls prevents the strip from sticking to the roll. The melted aluminium alloy elements solidify against the roll. The aluminium melts at the solidification front in order to prevent flow disturbance (Krstić Vukelja, et al., 2010). The testing of the alloy’s chemical composition, match up to the international standards. At the final stage, an aluminium titanium wire is introduced to remove the coarse crystal that had formed in the initial casting stage (Krstić Vukelja, et al., 2010). The whole process is quite attractive and simple.

The main objective of the process is attaining quality characteristics of the alloy (Krstić Vukelja, et al., 2010). “The process of making alloys using the controlled diffusion solidification (CDS) relies on mixing liquid alloys of controlled chemistry and temperature” (Batyshev, 2012, 465). This controlled temperature allows the alloy to form a nucleus solid phase at a faster rate. The CDS process allows alloys to solidify over short temperatures ranges. The alloys produced are nondendritic with a microstructure that minimises tearing.

Aluminium alloys are classified using a designated four digit number with a decimal point separating the third and fourth digit. The table below further explains the classification of the alloys (Classification of Aluminum Alloys, para. 1). The first digit indicates the alloy group according to the major element in the alloy composition. The second two digits indicate the alloy purity (Classification of Aluminum Alloys, para. 2). The last digit indicates product form; that is the casting or ingot.

Casting is designated by ‘0’ while ingot is designated by ‘1’ or ‘2’ depending on the chemical composition. Any modification of the alloy is indicated by a serial letter before the numerical designation (Classification of Aluminum Alloys, para. 2). Number Series- Alloy Type Aluminium series Alloy type 1XX.X 99.0% minimum aluminium content 2XX.X Al + Cu 3XX.X Al + Si & Mg, or Al + Si & Cu, or Al + Si & Mg & Cu 4XX.X Al + Si 5XX.X Al + Mg 7XX.X Al + Zn 8XX.X Al + Sn Source: http://www.substech.com/dokuwiki/doku.php? The figure shows different series of alloys.

(Batyshev, 2012). For example an alloy of 1xx.x series noted as 150.0 means the alloy contains 99.50% of aluminium (Classification of Aluminum Alloys, para. 4). The different series have different characteristics. Aluminium silicon alloys provides good casting ability. The alloy readily fills the dies during solidifying hence there is no hot tearing or hot cracking issues (Batyshev, 2012). Silicon has a high heat fusion which contributes to the alloy’s perfect fluidity. This contributes to the strength of the alloy to make it heat treatable.

The Magnesium element in aluminium alloys strengthens and hardens the castings (Apelian, 2009).. In addition it provides an excellent corrosion resistance making it a perfect tool for mechanical and chemical use (Batyshev, 2012). Titanium on the other hand is used to refine aluminium grains (Wipo assigns patent, 2010 para 4). The combination of aluminium and titanium forms primary aluminium dendrites (Saha et al., 2004). Source: http://www.diecasting.org/research/wwr/WWR_AluminumCastAlloys.pdf The figure shows grain-refined aluminium (Saha et al., 2004). Manganese causes a beneficial change in morphology of aluminium alloy.

It plays a crucial role in reducing soldering during cast melt. Manganese is mostly used to prepare 2xx and 7xx alloys since they suppress the grain growth in those systems (Apelian, 2009)..

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