Copper and Magnesium Alloys Quiz

ME 435: Industrial Metallurgy

• Course offered by Mechanical and Mechatronics Engineering at Waterloo.
• Introduction to Industrial Metallurgy lecture date: September 10th, 2024.

Important Points

• Lecture slides, project assignments, and grades posted on LEARN (https://learn.uwaterloo.ca/login.asp).
• Accessibility issues: https://uwaterloo.ca/disability-services/.
• Questions welcome.
• In-person quizzes and final exams.
• Project submissions via Dropbox in LEARN.
• Course conduct and plagiarism policies.
• Scheduled breaks during lectures.

Course Outline

• Instructor: Professor Yimin Wu ([email protected]).
• Office: E7-3418.
• Extension: x40185.
• TA: Ms. Maryam Soleimani ([email protected]).
• Office: E3-3173.
• Lectures: Tuesday and Thursday, 10:00-11:20pm EDT, MC 4064.
• Tutorials/TA office hour: Friday, 1:00-2:00pm EDT, E3-3173

Grading

• 20% Midterm (October 22nd) - Aluminium alloys & other non-ferrous alloys.
• 35% Lab project (Progress Report due November 8th, Final Report due November 29th).
• 45% Final Exam (December 10th) - Covering all course content.

Introduction

• Metallurgy: The study of metals, intermetallic compounds, and alloys.
• Industrial Metallurgy: The practical application of metallurgical principles and manufacturing methods to produce useful parts with optimum properties.
• Material-processing-structure relationship a key component in understanding industrial metallurgy.

Course Objectives

• Introduce the main types of metals and alloys used for engineering purposes and their properties.
• Explain how alloying elements and processing parameters affect microstructures and material properties of alloys.
• Select appropriate metals/alloys for applications, considering desired part properties and service conditions.

Example

• Chef's knife design criteria: Inexpensive material, easy to process, hardness to hold sharp edge, resistance to rust/tarnishing (corrosion).
• Stainless steel types: Ferritic (BCC), Martensitic (BCT), Austenitic (FCC), Duplex (Ferrite + Austenite), Precipitation-hardening (semi-austenitic, martensitic).
• Martensite stainless steel requires a high Cr content (>12 wt%).
• Martensite formation methods: Heating the steel to produce austenite, followed by quenching.

Example - Additional Points

• General types of metals/materials: Ceramic / CerMet, Aluminum Alloy, Titanium Alloy, Steel, Stainless Steel.
• Lecture topics: Aluminium and its alloys, other Non-Ferrous Alloys (Mg, Cu, Ni, etc.), Ferrous Alloys (steel, stainless steel, tool steels, cast irons), Surface modification.
• Course project: Groups identify the materials and manufacturing methods for automotive engine parts (1 ferrous part, 1 non-ferrous part, 1 heat-treated sample). Analysis objectives include alloy composition, processing method, shaping of the part, heat treatments, surface modifications, and additional properties.
• Analysis techniques: Metallography, Scanning Electron Microscopy (SEM) with Energy Dispersive X-Ray Spectroscopy (EDS), Image Analysis, Heat Treatments, Hardness Testing (Rockwell, Vickers), Tensile Testing.
• Course Project: The objectives and analysis of the course project are clearly defined.

Course Project

• Identifying the material and manufacturing methods used to produce parts of an automotive engine.
• Each group select: 1 ferrous, 1 non-ferrous part, 1 heat-treated sample.
• Students work in groups of 3.
• Sign-up in class using the sign-up sheet.

Course Project Objectives

• Determine the alloy compositions for each selected part.
• Compare the components to commercially available alloys.
• Investigate the structure (phase or phases present) of the part.
• Outline the processing method used to make each part. Analysis techniques and equipment used includes: Metallography, Scanning Electron Microscopy (SEM) with Energy Dispersive X-Ray Spectroscopy (EDS), Image Analysis, Heat Treatments, Hardness Testing (Rockwell, Vickers), Tensile Testing.

Course Project Details for Analysis

• Analyze the alloy composition of each part (primary alloying elements and their relative amounts) and examine the structure of the part.

• Compare the components to commercially available alloys;

• Investigate the method used in making each selected part, including shaping, deformation processes (e.g., rolling, casting, machining), heat treatments (if any), and surface customizations (e.g., coatings, case-hardening).

• Analyze the specific characteristics of the modified surface (coating thickness, and composition).

• Identify additional properties or characteristics of the material and manufacturing method that make it the most suitable choice.

Example Questions

• Draw a schematic hardness vs. time curve showing underaged, peak-aged, and overaged conditions of aging.
• Explain the drop in hardness of overaged conditions.
• Two types of solid solution: interstitial and substitutional.
• The magnitude of solid solution strengthening depends on atom size difference, percentage of solutes, problem caused and natural aging.

Aluminum and Aluminum Alloys

• General characteristics: Good corrosion resistance, high electrical and thermal conductivities, high ductility and medium strength, low density (2.7 g/cm³).
• Applications: Containers & packaging, structural materials in architecture and transportation, electrical applications, radiators, cooking utensils.
• 1XXX - Pure Al with >99.00%.
• 2XXX - Al-Cu.
• 3XXX - Al-Mn.
• 4XXX - Al-Si.
• 5XXX - Al-Mg..
• 6XXX - Al-Mg-Si.
• 7XXX - Al-Zn-Mg; Other additional elements.
• Outline: Introduction to Al and its alloys, General characteristics & applications, Designations of Aluminum and its alloys (Materials designations & temper designations), Strengthening methods for Al Alloys (Solid solution strengthening, Precipitation Strengthening, Dispersion Strengthening, Strain hardening).
• Example: 6061-T6, 1100-O, 3003-H18 aluminum alloys.
• Different types of Al alloys: Cast alloys and Wrought Alloys
• Production methods (e.g., Ingot casting, Homogenization, Hot rolling, Cold rolling, Anneaing, Age-hardening).
• Temper designations: F (as fabricated), O (annealed), H (work-hardened), W (solution heat treated), T (heat treated with aging).
• Heat Treated temper designation types: T1, T2, T3, ..., T10.
• Tx5x designation (Stress Relieved)

Aluminum Alloy Designation

• Four-digit designation system, including a decimal point.
• Cast Al and Al alloys: a numerical designation, preceded by a serial letter, with a decimal point, 0 for cast products or 1 for ingots.

Fabrication of Al Alloys

• Detailed description regarding how Al alloys are fabricated.

Classification of Temper Designations

• F - As fabricated
• O - Annealed
• H - Work-hardened (HXX)
• W - Solution heat treated
• T - Heat treated (TX)

Heat-Treated Temper Designations

• T1, T2, T3, T4, T5, T6, T7, T8, T9, T10.

Examples - Additional Questions

• What is a 6061-T6 alloy? (Al-Mg-Si alloy that is solution-treated and artificially aged)
• What is a 1100-O alloy? (Commercially pure aluminum that is annealed)
• What is a 3003-H18 alloy? (Al-Mn alloy that is strain-hardened to full hardness)

Tx5x Designation

• Stress-relieved
• Tx51: stretch in tension
• Tx52: compression
• Tx54: combination of tension and compression
• Function to reduce warpage during machining, improve fatigue and stress-corrosion resistance

Strengthening Methods for Al alloys

• Solid solution strengthening
• Dispersion Strengthening
• Precipitation Strengthening
• Strain hardening

Solid Solution Strengthening

• Source of strengthening: Strain field interferes with dislocation movement.
• The magnitude of strengthening depends on atom size difference, percentage of solutes, problem caused (e.g., natural aging).

Other topics include

• Dispersion Strengthening
• Heat treatments involved in Al alloys.
• EBSD working mechanism I & II

Additional topics include

• Effects of precipitation
• Effective precipitates properties

Two types of solid solution:

• Interstitial: smaller atoms fill the spaces between larger atoms in the crystal lattice.
• Substitutional: atoms of similar size replace atoms of the same type in the crystal lattice.

Strain Hardening

• Steel strength increases with plastic deformation.
• Dislocation density increase resulting in higher yield strength
• Decreased grain size leading to increase in strength.

Cold Working

• Cold working increases strength (and reduces ductility)
• Grain structure also changes with cold working
• Anisotropic behaviour.

Annealing (O Temper)

• Deformed structure: Elongated grains, non-isotropic properties.
• Decreased ductility

Deep Drawing

• Beverage can strength is 70% due to strain hardening during fabrication

Questions

• Which strengthening mechanism cannot be achieved in commercially pure (1100) aluminium? (a) Solid solution hardening, (b) Precipitation hardening, (c) Strain hardening, (d) Dispersion hardening.

Classification of Some Topics

• Solid Solution: Coherent, Semi-coherent, Incoherent.
• Anneal: Recovery, Recrystallization, Grain growth.
• Heat treated temper designations
• Analysis techniques and equipment, such as Metallography, Scanning Electron Microscopy, Image Analysis, Heat Treatments, Hardness Testing (Rockwell, Vickers), Tensile Testing
• Effects of precipitates and dislocations
• Effective precipitation characteristics (small, hard, round, and a large amount; coherent and incoherent with matrix).
• Examples of precipitation hardening alloys, clustering during natural aging

For Other Topics, see following sections:

• 7xxx Precipitates
• Example questions (quiz)
• Other Sections: Aluminum alloys, Casting, Selection of Casting Process, Commercial Purity Alloys (1xxx), Aluminum-Manganese Alloys (3xxx), Aluminum-Silicon Alloys (4xxx), Aluminum-Magnesium Alloys (5xxx), Aluminum-Copper Alloys (2xxx), Nickel - Chromium-Molybdenum Steels (43xx),etc.., 6xxx Al Mg Si Alloy, 7xxx Al Zn, 7xxx Al-Zn alloy compositions and applications, 7xxx Al-Zn Alloy Properties, Al-Li Alloys, Al-Li Composition and Properties, CES 2011-EDU Pack , Non-Ferrous Alloys (Mg, Cu, Ni), etc...

Test your knowledge on copper and magnesium alloys in this quiz. Explore concepts related to dislocations, recrystallization, and alloy classifications. Perfect for students and professionals in metallurgy and materials science.