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Understanding Aluminum
Alumunium is the most abundant non-ferrous element on earth which is a lightweight metal having
light properties, good corrosion resistance and good heat and heat conduction, easily formed either
through the process of formation or machining, and other good properties as metallic properties. In
nature, aluminum is a stable oxide that can not be reduced by reducing other metals. Reduction of
aluminum can only be done by electrolysis. In addition to its greatly increased mechanical strength
with the addition of Cu, Mg, Si. Mn, Zn, Ni, etc., either individually or together, also provide other
good properties such as corrosion resistance, wear resistance, low expansion coefficient and so on.
Aluminum alloys can be divided into two groups, namely aluminum wronglt alloy (sheet) and
aluminum costing alloy (cast rod). Aluminum (99.99%) has a specific gravity of 2.7 g / cm3, density
2,685 kg / m3, and melting point at 6600C, aluminum has a strength to weight ratio higher than
steel. The corrosion resistance of aluminum is obtained from the formation of the aluminum oxide
layer from the aluminum surface. This oxide layer is firmly attached to the surface, and stable (does
not react with the surrounding environment) to protect the inside.
1. Copper (Cu), raises strength and hardness, but decreases elongation (increase in length of stretch
when drawn). The most optimum Cu content in aluminum is between 4-6%.
4. Magnesium (Mg), increases aluminum strength and decreases the value of its ductility. Corrosion
resistance and weldability are also good.
5. Silicon (Si), causing the aluminum alloy can be heat treated to increase the hardness.
(Pure Aluminum) (Aluminum with Cu, Mn, Mg) (Alumunium with Cu)
3. Atoms or Elements
Pure aluminum has purity up to 99.96% and at least 99%. The impurities are in the form of Fe and Si
elements. Aluminum alloys have various content of atoms or major elements (major) and minor.
Major elements such as Mg, Mn, Zn, Cu, and Si while minor elements such as Cr, Ca, Pb, Ag, Fe, Sn,
Zr, Ti, Sn, and others. The major alloying elements in aluminum include:
1. Copper (Cu), raises strength and hardness, but decreases elongation (increase in length of stretch
when drawn). The most optimum Cu content in aluminum is between 4-6%.
4. Magnesium (Mg), increases aluminum strength and decreases the value of its ductility. Corrosion
resistance and weldability are also good.
5. Silicon (Si), causing the aluminum alloy can be heat treated to increase the hardness
4. Making way:
There are several processes that can be done to make pure aluminum and aluminum alloy, namely:
Aluminum is mined from bauxite seeds that are found on the surface of the earth. Bauxite mined for
industrial use has an aluminum content of 40-60%. After being mined bauxite seeds are milled and
smashed smoothly and evenly. Then the process of heating to reduce the water content. Further
bauxite undergoes a refining process.
The bauxite purification process is done by bayer method and the end result is alumina.
First of all bauxite is mixed with chemical solutions like caustic soda. The mixture is then pumped
into a press tube and then heated. The process is further screened and followed by the seeding
process to form a wet alumina deposit (hydrated alumina). Wet alumina is then washed and
continued by drying process by heating to 1200oC. The end result is alumina particles with chemical
f 3. Alumunium Smelting Process
Alumina produced from purification process still contains oxygen so that must be done next process
that is fusion. The alumina fusion is carried out by an electrolytic reduction process. This melting
process uses the Hall-Heroult method. Alumina is dissolved in a chemical solution called cryolite in a
furnace called a pot.
This pot has walls made of carbon. The outer part of the pot is made of steel. The flow of electricity
is given through anodes and cathodes. The reduction process requires carbon taken from the anode.
In this process required direct electric current of 50-150 kiloampere.
The electric current will electrolyze alumina into aluminum and oxygen reacts to form CO2
compounds. The liquid aluminum from the electrolysis proceeds down to the bottom of the pot and
is then streamed by the siphon principle to the crucible which is then transported to the holding
furnace.
The electricity needed to produce 1kg of aluminum is about 12-15 kWh. One kilogram of aluminum
is produced from 2kg of alumina and 1/2 kg of carbon. The reaction of alumina refining into
aluminum is as follows:
4. Aluminum Classification
1. Pure Alumunium
Aluminum is obtained in a liquid state through an electrolysis process, which generally achieves a
purity of 99.85% by weight. However, if the process of electrolysis further, it will get aluminum with
99.99% purity is achieved material with the number ninenya four.
Corrosion resistance changes according to purity, in general for 99.0% purity or above it can be used
in resistant air for many years. Al's electricity delivery, approximately 65% of the electricity
conductivity of copper, but its density is approximately one-third of copper making it possible to
expand its cross section. Therefore, it can be used for cables and in various forms. For example as
thin sheet (foil). In this case can be used Al with 99.0% purity. For reflectors that require high
reflectivity also for electrolytic coders used by Al with the number Nine four.
Aluminum series 1xxx compositions
Al, %
Designation Si,% Fe,% Cu,% Mn,% Mg,% Zn,% Ti,% Others,%
min
1050 0,25 0,4 0,05 0,05 0,05 0,05 0,03 0,03 99,5
1060 0,25 0,35 0,05 0,03 0,03 0,05 0,03 0,03 99,6
0.05-
1100 0.95 Si + Fe 0,05 - 0,1 - 0,15 99
0.2
2. Aluminum alloy
Aluminum alloys are grouped in various standards by various countries in the world. However, the
most famous and perfect classification is the American Aluminum Association (AA) standard based
on the previous standard of Alcoa (Alumunium Company of America).
These alloys can be heat treated especially those containing (2.5-5%) Cu. From this series the famous
series 2017 known as "duralimin" contains 4% Cu, 0.5% Mg, 0.5% Mn on standard composition. This
Mg alloy is improved on the standard composition of Al, 4.5% Cu, 1.5% Mg, 0.5% Mn, named the
2024 alloy called Duralumin Super. Alloys that have Cu have poor corrosion resistance, so when a
special corrosion resistance is required the surface is coated with a pure Al or a corrosion resistant Al
alloy called an alkad plate. These alloys are widely used for tools that work at high temperatures eg
in the piston and cylinder head combustion motors.
Aluminium series 2xxx compositions
Pb=0.4,
2011 0.4 max 5.0-6.0 - - - -
Bi=0.4
V=0.1,
2219 0. 2 max 5.6-6.8 0.2-0.4 - - 0.02-0.1
Zr=0.18
V=0.1,
2319 0. 2 max 5.6-6.8 0.2-0.4 - - 0.1-0.2
Zr=0.18
Mn is an element that strengthens Al without reducing corrosion resistance and is used to make
corrosion resistant alloys. In the phase diagram, Al-Mn is in equilibrium with a solid solution Al is
Al6Mn (25.3%). Actually the Al-1,2% Mn and Al-1,2% Mn-1.0% Mg alloys are named alloys 3003 and
3004 which are used as alloys without heat treatment. The alloys in this series can not be hardened
by heat treatment. The 3003 series with 1.2% Mn is easily formed, corrosion resistant, and
(weldability) is good. Widely used for pipes and oil tanks.
Al-Si Alloys are very well aquatic, which have excellent surfaces, no hot grinding, and are excellent
for cast alloys. In addition, this alloy has good corrosion resistance, is very light, very small expansion
coefficient, and as a good conductor of heat and electricity. Because it has good advantages, this
alloy is very widely used. But in this case the modification is not necessary. The properties of the
silumin are greatly improved by heat treatment and slightly improved by alloying elements.
Commonly alloyed with 0.15-0.4% Mn and 0.5% Mg. The soluble and diluent treated mixture is
called gamma silumin and is simply called a beta silumin. Alloys that require heat treatment plus Mg
also Cu and Ni to provide hardness during heat, this material is commonly used for piston motor.
The very low thermal expansion coefficients of Si make the thermal coefficients of the alloys also low
when more Si is added. Al-Si hypereutectic alloys have been developed to 29% Si to soften the Si
primary grains. The smoothing process will be more effective with the addition of P by Cu-P alloy or
addition of phosphor chloride (PCl5) to achieve the presentation of 0.001% P, achievable primary
refinement and homogenization. Al-Si alloys are widely used as welding electrodes that mainly
contain 5% Si.
The alloy is non heat treatable. The 4032 series alloy containing 12.5% Si is easy to forge and has a
very low heat expansion coefficient used for the forged pistons.
In a single phase Al-Mg binary alloy present in equilibrium with an Al solid solution is a solid solution
which is an intermediate compound of Al3Mg2 metal. The unit cell is a hexagonal arrangement (eph)
but there is also a ccc face unit cell (fcc) complex. The eutetic point is 450ºC, 35% Mg and the solid
solubility limit at the eutectic temperature is 17.4% which decreases at the regular temperature to
about 1.9% Mg, so the aging ability can be expected.
Al-Mg alloys have excellent corrosion resistance called hydrinalium. Alloys with 2-3% Mg can be
easily forged, extruded and extruded. Al-Mg Alloys are generally non-heat tretable. Series 5052 with
2.5% Mg is widely used for oil mixture and aircraft fuel. The 5052 series is commonly used as forged
material. The 5056 alloy is the strongest alloy after hardening by strain hardening when subjected to
high hardness. The annealed 5083 alloy is a strong and welded (4.5% Mg) strong intermediate (4.5%
Mg) mixture so widely used as an ingredient for LNG tanks. Series 5005 with 0.8% Mg is widely used
as an extrusion profile rod. Series 5050 with 1.2% Mg is used as oil and gas pipeline in vehicles.
The addition of a small amount of Mg to Al will cause aging hardening very rarely, but if it
simultaneously contains Si, it can be hardened by heat aging after the dissolution treatment. This is
because the M2Si compound behaves as a pure component and makes the balance of a pseudo-
binary system with Al. The alloys in this system have less strength than the other alloys used as
forged materials, but are very tough, excellent for forming, extrusion and in addition can be
strengthened by heat treatment after workmanship. The 6063 alloy is widely used as a construction
framework. Because the alloy has a good enough power without reducing the conductivity of
electricity it is used for power cables. In this case mixing with Cu, Fe, and Mn should be avoided as
they cause high electrical resistance. Magnesium and Silicon form the Mg2Si (Magnesium Silicide)
compound which gives high strength to this alloy after heat treatment process. Series 6053, 6061,
6063 has excellent corrosion-resistant properties than other heat treatable aluminum. The use of
6xxx aluminum series is widely used for piston motors and cylinder head motor del.
B 0.06%
6101 0.3-0.7 0.10 max. 0.03 max. 0.35-0.8 0.03 max.
max.
B 0.06%
6201 0.5-0.9 0.10 max. 0.03 max. 0.6-0.9 0.03 max.
max.
Zn 1.6-
6253 * 0.10 max. - 1.0-1.5 0.04-0.35
2.4%
Pb and Bi
6262 0.4-0.8 0.15-0.40 0.15 max. 0.8-1.2 0.04-0.14 0.4-0.7%
each
Aluminium menyebabkan keseimbangan biner semu dengan senyawa antar logam MgZn2 dan
kelarutannya menurun apabila temperaturnya turun. Telah diketahui sejak lama bahwa paduan
sistem ini dapat dibuat keras sekali dengan penuaian setelah perlakuan pelarutan. Tetapi sejak lama,
tidak dipakai sebab mempunyai sifat patah getas oleh retakan korosi tegangan. Di Jepang pada
permulaan tahun 1940, Iragashi dkk mengadakan studi dan berhasil dalam pengembangan suatu
paduan dengan penambahan kira-kira 0,3%Mn atau Cr, dimana bitur Kristal padat diperhalus, dan
mengubah bentuk presipitasi serta retakan korosi tegangan tidak terjadi. Pada saat itu paduan
tersebut dinamakan ESD, Duralumin, superekstra. Selama perang dunia ke II, di Amerika Serikat
dengan maksud yang hampir sama telah dikembangkan pula suatu paduan, yaitu suatu paduan yang
terdiri dari Al-5, 5%Zn-2,5%Mn-1,5%Cu-0,3%Cr-0,2%Mn, sekarang dinamakan paduan 7075. Paduan
ini mempunyai kekuatan tertinggi diantara paduan-paduan lainnya. Penggunaan paduan ini paling
besar adalah untuk konstruksi pesawat udara. Di samping itu penggunaannya menjadi lebih penting
sebagai bahan konstruksi.
a. Mechanical Properties
Power
The strength and hardness of aluminum are not so high. However, with the integration and heat
treatment can increase the strength and hardness. Most of the aluminum material is enhanced by a
mechanism of metal strengthening called precipitation hardening. In precipitation hardening there
must be two phases, the more numbered phases are called matrices and phases that are less
precipitate. The reinforcing mechanism includes three stages: solid solution treatment: heating to
the top of the solvus line to obtain a homogeneous solid phase solution, quenching: cooled rapidly
to maintain the homogeny solid phase microstructure in order to avoid diffusion, and aging: heated
to less temperature high order for the occurrence of alpha phase diffusion at a precipitate forming
distance. In addition, there are several ways of standardized hardness testing used to test metal
hardness, among others, testing Brinell, Rockwell, Vickers, Shore, and Meyer.
Modulus of Elasticity
Aluminum has a lower elastic modulus when compared to steel or iron, but in terms of strength to
weight ratio, aluminum is better. Elastic aluminum has a lower melting point and density. Under
diluted conditions can be processed in various ways. This allows the aluminum products to be
formed essentially close to the end of the product design.
Ductility (ductility)
The higher the purity of aluminum the higher the level of toughness.
Fatigue (Fatigue)
The aluminum material does not indicate the limit of fatigue, because aluminum will fail when
pressed.
Aluminum is 100% recycled material without downgrading of quality. Returning from aluminum,
smelting requires less energy, only about 5% of the energy required to produce the primary metal
initially required in the recycling process.
Reflectivity
Aluminum is a visible reflector of light as well as heat, and that together with low weight, makes it
ideal for reflector materials such as light furniture.
Kemurnian Al (%)
99,996 >99,0
Sifat-sifat
Kekuatan tarik
4,9 11,6 9,3 16,9
(kg/mm2)
Kekuatan mulur
1,3 11,0 3,5 14,8
(0,2%)(kg/mm2)
Kekerasan Brinell 17 27 23 44
Tensile strength Antara 230 sampai 570 MPa
Regangan 10-25%
b. Physical Properties
Kemurnian Al (%)
Sifat-sifat
99,996 >99,0
6106 Al MgSiMn