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By J. K. Edgar

For a number of years the production and use of super-purity aluminum (better than 99.99 pct) has been steadily increasing. High-grade lots of. such aluminum show certain outstanding characteristics not found in lower grades containing principally silicon, iron and copper as impurities. One such characteristic is the so-called "self annealing," that is, the re-crystallization of the heavily cold worked metal at room temperature.' Interest therefore is aroused as to the effects of the impurities. It is well known that the amounts of silicon and copper which occur in aluminum of better than 99.95 pct are completely soluble, at least at elevated temperatures (above 200°C). Iron, on the other hand, is known to be fairly insoluble in solid aluminum. Thus, a knowledge of the limits of this solubility would he of considerable use in studying the characteristics of the high purity metal. All investigators have agreed that iron has very low solubility in solid aluminum. Rosenhain, Archbutt and Hanson2 reported traces of an aluminum-iron phase in the "purest samples of aluminum obtainable." Gwyer and Phillips3 reported that an iron constituent was visible under the microscope in metal containing ".0088 per cent iron." Roth4 found that in the solid state the solubility of iron in high purity aluminum was 0.01, 0.01, 0.017 and 0.022 pct at 225, 320, 500 and 600°C respectively. Dix5 working with alloys containing less than 0.03 pct impurities, concluded from microscopic and chemical analyses of eutectic areas that the eutectic composition was close to 1.7 pct iron. Dix placed the eutectic temperature at 65s°C. Archer and Fink,6 using high purity aluminum-iron alloys, found that the hypoeutectic liquidus intersects the eutec-tic horizontal at 1.7 pct. This is in fair agreement with the investigation of the aluminum-iron system by Gwyer and Phillips who placed the eutectic at 1.89 pct iron with a freezing point of 653'C. Preparation and Chemical Analysis oP Alloys Electrolytically refined aluminum (99.991 pct aluminum) and a high purity alumi-num-iron alloy (11.45 Pet iron) were used in the preparation of the alloys for this investigation. To aid in controlling the iron content of the experimental alloys, an alloy of lower iron content was prepared first from these materials. The high purity aluminum was melted and heated to about 700°C in a plumbago crucible coated with alundum cement and the aluminum-iron alloy was then added. The alloy was thoroughly stirred, fluxed and skimmed and then chill-cast into notch bars. The aIlalyses of the three materials are given in Table I. The alloys for the determination of the solid solubility of iron in aluminum were prepared by melting 600 g total of the aluminum plus the required quantity of the aluminum-iron alloy (No. 92531). These

Jan 1, 1949

By W. R. Finlay, W. R. Jr. Hibbard

The key feature of the lattice coherency theory of precipitation hardening1 is the forced coherence between matrix and precipitate which elastically strains both lattices and is believed to be the major source of strengthening in precipitation hardening. In systems exhibiting age hardening, the atom movements leading to precipitation are not at all extensive and are such as to require the minimum amount of energy to produce the interface; that is, the new lattice forms in such a way as to be as nearly as possible a continuation of the old with a matched, coherent plane at the interface at least during the initiation of the precipitation. The crystallographic sequence whereby regions of the matrix change to the precipitate lattice usually can be resolved into a set of shearing operations.6'6 Conversely, the perhaps novel speculation is made that solution of a second phase is accompanied by shearing movements which are possibly the reverse of the precipitation shearing movements. A basic premise of the investigation reported in this paper is that precipitation and solution shearing movements constitute structural weaknesses which might cooperate with applied stresses to facilitate plastic deformation. Another basic premise of the investigation is that the application of hydrostatic pressure to a precipitation hardening system will significantly alter the degree of disregistry across the matrix-precipitate interface and thereby significantly affect the course of age hardening. Two binary precipitation hardening systems were investigated: rz pct zinc in aluminum which undergoes transformations, both precipitation and solution, by a simple crystallographic mechanism; and 4 pet copper in aluminum which undergoes a complex transformation in precipitating and dissolving a second phase. The effects of the application of uniaxial tensile creep stress during elevated temperature aging of both systems and of hydrostatic pressure during the elevated temperature aging of 12 pct aluminum-zinc were then investigated. Previous Investigations Van Wert in 1935,~ studied the effect of hydrostatic pressure on the room temperature age hardening of a few precipitation hardening systems. The latter were rather unfortunately selected since none is known to exhibit any marked volume change on aging and the majority were complex commercial alloys the precipitation mechanisms of which are not known. Jenkins, Bucknall and Jenkins~n,~ in 1944, applied tensile creep stresses to a complex copper. nickel-silicon alloy at various temperatures. The complexity of the alloy and the industrial objective of the work did not permit an appreciable addition to the theoretical understanding of either deformation or precipitation hardening.

Jan 1, 1949

By James W. Cameron

DESPITE the fact that, after oxygen and silicon, aluminum is the most abundant and widely distributed element in the earth's crust, it is, commercially, a modern metal. Attempts were made by Sir Humphrey Davy and other chemists to decompose alumina, the oxide, into its elements, but with unsatisfactory results, and it was not until 1827 that Wohler succeeded for the first time in isolating the metal in pure form. Some thirty years later, commercial production of aluminum was started in a plant near Alais, France, using a process developed by Deville which was a modification of that of Wohler. It was not, however, until around 1886 that possibilities of low-cost production were realized. Hall and Heroult discovered, independently, the now famous process for extraction of aluminum by the electrolysis of alumina (Al,O,) dissolved in fused cryolite. This discovery, with its subsequent effect in reducing the price of the metal, was perhaps the greatest single factor contributing to the remarkable growth of the aluminum industry. But only in the years following the Great War did aluminum begin to attain equal importance in many fields with other non-ferrous metals. Numerous factors, political and economic, in the past decade have had a profound effect on the industrial history of the metal. At present, systematic substitution of aluminum for other base-metals is proceeding at a rapid rate in such countries as Germany and Italy with a view towards 'economic self-sufficiency'. Quite naturally, ?the economic depression started extensive research and experiment in various industries in an attempt to improve efficiencies and lower costs. Partial answers have been found in the extended use of aluminum and its alloys. Even against the background of tremendous technological advance that has marked the past fifty years, the rise of the aluminum industry must necessarily stand out conspicuously.

Jan 1, 1939

By John D. Sullivan

MAJOR technical advances seldom occur in a single year, and this is especially true with aluminum and magnesium where marked improvements in metallurgical processes and products took place during the war years. Nevertheless, the light metals and alloys, particularly aluminum, are advancing in commercial importance and are finding their niche in industry. New applications during the year have resulted from a better over-all knowledge of properties, handling, etc., rather than from revolutionary new developments.

Jan 1, 1948

By John D. Sullivan

ALUMINUM and magnesium plants in the United States underwent enormous wartime expansion which made many wonder if ghost plants would result when industry swung back to a peacetime basis. Production capacity of primary aluminum ingots was stepped up from 150,000 tons annually to about 1,150,000 tons; magnesium production increased from 2500 tons in 1936 to nearly 200,000 in 1943, with a production capacity of some 300,000 tons. Not only was primary metal production enlarged but also the capacity of prime fabrications such as castings, forgings, extrusions, and sheets was correspondingly increased. In mid-December it was estimated that production of primary aluminum ingots in the United States in 1946 will be about 410,000 tons while consumption will be about 500,000, close to half of the wartime consumption. The 1946 estimated consumption of secondary aluminum is 200,000 tons. The critical shortage of soda ash is hindering production of primary metal, and the outlook for an early relief of this shortage is dark.

Jan 1, 1947

By George C. Heikes

ALTHOUGH the application of light metals in war materiel increased during the year, based on the number of uses, the trend in aluminum and magnesium production in 1944 was characterized by a sharp decline in the production of both metals accompanied by a further accumulation of large Government reserve stocks. Several primary reduction plants were curtailed to prevent building excessive inventories. By the end of the year, however, a lively revival of war production took place when resistance stiffened on the western front in Europe. Production of primary aluminum ingot was reduced from over 90,000 tons per month at the start of the year to 45.000 tons per month by the end of the year.

Jan 1, 1945

By Robert Archer

THE proper material of construction for a given purpose is that material which meets the requirements satisfactorily at the lowest ultimate cost. It is consistent with this principle that most aluminum castings are made of an alloy containing about 8 per cent. copper. This alloy possesses mechanical properties satisfactory for general engineering purposes together with manufacturing characteristics leading to the production of finished castings at low cost. It is to the aluminum industry what gray iron is to the iron and steel industry. Just as some services require "semi-steel," malleable castings or steel castings instead of gray iron, there is a certain and growing demand for aluminum castings of superior strength or ductility, or both. Since the beginning of the industry producers and others have sought to develop alloys or processes by which such castings could be made. Out of these efforts have emerged many alloy compositions and special processes, of which only a few have had sufficient merit to survive. It is the purpose of this paper to describe those which seem to the authors to offer the greatest promise for the production on a commercial scale of aluminum castings of superior mechanical properties, with special reference to heat-treated castings. The suitability of an alloy or process for actual manufacture is affected by so many factors that the problem of appraisal is not a simple one. Since this is such an important part of the whole subject it is proposed to discuss briefly some of the requirements. The final verdict is of course the result of commercial trial and experience. It will therefore, perhaps, be profitable to employ a somewhat historical method of treatment in discussing the subject of alloy development.

Jan 9, 1926

By Robert S. Archer

THE proper material of construction for a given purpose is that material which meets the requirements satisfactorily at the lowest ultirnatc cost. It is consistent with this principle that most aluminum castings are made of an alloy containing about 8 per cent. copper. This alloy possesses mechanical properties satisfactory for general engineering purposes together with manufacturing characteristics leading to the production of finished castings at low cost. It is to the aluminum industry what gray iron is to the iron and steel industry. Just as some services require "semi-steel," malleable castings or steel castings instead of gray iron, there is a certain and growing demand for aluminum castings of superior strength or ductility, or both. Since the beginning of .the industry producers and others have sought to develop alloys or processes by which such castings could be made. Out of these efforts have emerged many alloy compositions and special processes, of which only a few have had sufficient merit to survive. It is the purpose of this paper to describe those which seem to the authors to offer the greatest promise for the production on a commercial scale of aluminum castings of superior mechanical properties, with special reference to heat-treated castings. The suitability of an alloy or process for actual manufacture is affected by so many factors that the problem of appraisal is not a simple one. Since this is such an important part of the whole subject it is proposed to discuss briefly some of the requirements. The final verdict is of course the result of commercial trial and experience. It will therefore, perhaps, be profitable to employ a somewhat historical method of treatment in discussing the subject of alloy development. The alloys or processes to be used in the production of aluminum castings are to be considered from the standpoint of their effects on both the utility and the cost of the finished casting. Specific gravity and mechanical properties come under the first head, while the properties

Jan 1, 1927

By David C. Grant

During in situ uranium mining using ammonium bicarbonate lixiviant, the ammonium exchanges with cations on the ore's clay. Mter mining is complete, the ammonium may desorb into post-leach ground water. For the particular ore studied, other chemicals (i.e., uranium and selenium) which are mobilized during the leach process, have also been found in the post-leach ground water. Laboratory column tests, used to simulate the leaching process, have shown that aluminum chloride can rapidly remove ammonium from the ore and thus greatly reduce the subsequent ammonium leakage level into ground water. The aluminum chloride has also been found to reduce the leakage levels of uranium and selenium. In addition, the aluminum chloride treatment produces a rapid improvement in permeability.

Jan 1, 1982

By Sang-Beom Lee

For thermodynamic prediction, the deoxidation equilibrium of aluminum in Fe-36%Ni alloy was studied with a cold crucible under Ar gas atmosphere at 1773K. For the deoxidation reaction in liquid Fe-36%Ni base, i.e.: A12O3(s) = 2A1 + 3O The interaction parameters and the equilibrium constant between aluminum and oxygen in liquid Fe-36%Ni alloy are given in the following: eo Al = -3.8, roA1=0.9, eAl° = -6.4, rAl° = 700, rAIAIo = 3.1, roA1o = 833 within the composition range of [Al] < 1 mass%. The temperature dependence of the equilibrium constant was obtained in the range of 1773K < T < 1973K by using reported data and present results as follows: log KAo= 0.58-24463.7 / T The deoxidation equilibrium with aluminum in Fe-36%Ni could be thermodynamically well described in the range up [Al] < 1 mass% with first and second order interaction parameters as well as the equilibrium constant determined in this study.

Jan 1, 2002

By Dale A. Zuck

Recovery of aluminum metal from drosses? is a major factor in the recyclability success story enjoyed by the United States aluminum industry. Today&apos;s modern dross processor uses the latest technology to maximize metal recovery at the lowest cost while complying with all environmental laws and regulations. Most dross processors, however, pay little attention to the resulting saltcake, the end residual of dross recyCling, and rely on landfills for .disposition of this material.. The alternative is to recycle the saltcake, but the success of this technology is dependent on the development of reliable outlets for each of the saltcake constituents. This paper discusses the evolution of an aluminum dross oxide processing technology that ,produces an economically attractive source of alumina for the production of portland cement.

Jan 1, 1995

Leading Article from &quot;British Medical Journal,&quot; London, 4th, November, 1944.Assuming that silica exerts its injurious effect upon animal tissue through a slow transformation into silicic acid, Denny, Robson, and Irwin thought that if the solubility of siliceous material retained in the lungs could be suffciently reduced the usual fibrotic response could be diminished or prevented. They discovered that aluminum powder rendered siliceous material insoluble in vitro by coating the silica particle with a thin film of gelatinous hydrated alumina, which on drying formed crystalline alpha aluminum monohydrate. The presence of this adsorbed layer on the surface of the quartz was shown by staining it with aurin. That metallic aluminum dust produced no fibrosis in the lungs was demonstrated by dust-inhalation experiments on eight rabbits. Attempts were therefore made to prevent silicosis by mixing quartz with metallic aluminum dust.Animals exposed to quartz dust developed typical silicosis in about five months, but the addition of 1 per cent. aluminum powder prevented this even after exposure had been lengthened up to 22 months, provided the aluminum powder was of a particle size below 5. This year Crombie, Blaisdell and MacPherson have reported the treatment of 34 silicotic miners by the daily inhalation of fine aluminum powder freshly ground from small aluminum pellets in a specially constructed mill. Daily treatment began with five-minute inhalations, which were gradually increased to 30 minutes. Some of the men received 300 treatments, but the majority only 200. Out of the 34 cases thus treated clinical improvement was manifested by lessening or disappearance of shortness of breath, of cough, of pain in the chest, and of fatigue. In 15 cases the condition became stationary and remained so in spite of continuous employment in silica dust throughout the treatment. The progress of the disease was assessed by means of tests for respiratory function repeated at three-monthly intervals. Obviously this treatment cannot be regarded as a cure for silicosis, since it cannot restore lung tissue which has undergone fibrotic change; but Crombie and his colleagues believe that the inhalation of finely particulate aluminum powder offers every prospect of preventing the development of human silicosis.In view of these findings, it is surprising that repeated papers by Goralewski from Germany describe various types of lung disease attributed to aluminum dust, and press for them to be scheduled under the Workmen&apos;s Compensation Act in that country. Seven hundred workers were investigated. They were making, probably by a stamping process, aluminium powder containing about four milliards of particles of dust per grain, and are reported as complaining of dry cough with pain on breathing, shortness of breath, poor appetite, and gnawing abdominal pain. Spontaneous pneumothorax developed in four workers. No abnormal physical...

Jan 1, 1945

By G. M. Scamans

In the past ten years there has been considerable penetration of aluminum automotive body sheet (ABS) into automotive structures. The exponential increase in demand is resulting in major investments in heat treatment and finishing capacity across the globe. Line speed and tonnage throughput is limited by the continuous heat treatment (CHT) floater furnace rather than the cleaning and pretreatment section where electrolytic treatments that offer higher line speeds should come into favour and roll coating of pretreatment should predominate. The capacity limiting surface texturing pass will either be eliminated or moved to the finishing line or a dedicated mill. The key to making aluminum both embedded carbon and cost competitive with steel for more and more affordable classes of vehicles lies in recycling of both prompt scrap and, in the longer term, end of life vehicle scrap. For the first time scrap separation technology is available that can compete effectively with hand sorting and can sort aluminum shredded vehicle scrap into wrought and cast alloys and then into individual alloy groups. The challenge is to use more end of life scrap in alloy formulation whilst at the same time extending the property range in terms of both strength and formability.

Jan 1, 2015

By G. M. Scamans

In the past ten years there has been considerable penetration of aluminum automotive body sheet (ABS) into automotive structures. The exponential increase in demand is resulting in major investments in heat treatment and finishing capacity across the globe. Line speed and tonnage throughput is limited by the continuous heat treatment (CHT) floater furnace rather than the cleaning and pretreatment section where electrolytic treatments that offer higher line speeds should come into favour and roll coating of pretreatment should predominate. The capacity limiting surface texturing pass will either be eliminated or moved to the finishing line or a dedicated mill. The key to making aluminum both embedded carbon and cost competitive with steel for more and more affordable classes of vehicles lies in recycling of both prompt scrap and, in the longer term, end of life vehicle scrap. For the first time scrap separation technology is available that can compete effectively with hand sorting and can sort aluminum shredded vehicle scrap into wrought and cast alloys and then into individual alloy groups. The challenge is to use more end of life scrap in alloy formulation whilst at the same time extending the property range in terms of both strength and formability.

Jan 1, 2015

By PAUL P. ZElGLER

Rapid growth of the aluminum industry continued through 1948 with an acute shortage of the metal in all forms marking the year. Estimates based on shipments made during the first nine months indicate that, in 1948, the industry shipped more than two billion pounds of aluminum products or roughly four times the amount shipped in the greatest peacetime year prior to the war. The rapid expansion of the aluminum industry is particularly reflected in the production of sheet. Last year, the industry as a whole shipped an estimated 40 per cent more sheet than was produced in the peak war year of 1944.

Jan 1, 1949

By Richard Mcivor, Largo Albert

"Inco Limited has operated aluminum mine shaft conveyances since 1968. Aluminum conveyances are used where the hoisting in system requires lightweight conveyances to maintain the hoist rope safety factors and mine hoist rope pulls as dictated by government regulations. Inco Ltd. currently has 20 skips (including spares) operating in the Ontario Division mines. The main problems encountered are with galvanic corrosion between dissimilar metals and metal fatigue. This paper will highlight some of the problems encountered and illustrate methods utilized to overcome the problems and improve the conveyances performance.IntroductionAluminum mine shaft conveyances have been in use at Inco Limited&apos;s various Sudbury district mines since 1968. All of the conveyances currently in use are skips used for hoisting mine ore and rock. Inco had an aluminum quick change Kimberley-type skip and cage in operation at its Totten Mine in the early 1970s, but this mine is no longer in operation and no further comment will be made.The primary reason why aluminum conveyances are chosen over conventional steel conveyances is because of their light weight. Typically an aluminum conveyance will weigh about 60% to 70% of a steel conveyance of similar design. The lighter weight conveyances will allow higher payloads to be used and still maintain the statutory hoist rope factors of safety. It must be remembered that increasing the payload will increase the power required to raise the load and the hoist will have to have the necessary horsepower for the increased payload or the system will be overloaded.The front dump (Rola-chute) skips are of the bail-less design, i.e. the box structure also supports the load and has the shaft guide shoes attached directly to the side of the box structure. The Copper Cliff North Mine and South Mine skips have a joint in the centre of the conveyance and are installed in the shaft in two sections and connected with pins. This feature allows very long (42 ft) skips to be used in areas where a one-piece bail-type conveyance could not be installed. It is not practical to make sectionalized bail-type conveyances"

Jan 1, 1988

By Fabiola Alvarez, Ana E. Bote, Daniel Pasquevich

"The oxidation of aluminum and its alloys was extensively studied for improving the corrosion resistance in structural materials having high specific strengths. But this reaction involves the formation of a very thin barrier layer on the metallic pieces. Furthermore, the ·recent development of the directed melt oxidation process for producing metal-ceramic; composites has renewed the interest in the study of interaction between gases and metals. Oxidation experiments in the presence of different chlorine partial pressures and at different temperatures were performed in ·a thermogravimetric balance, and microstructures were analyzed by electronic microscopy and X-ray diffraction. The oxy-chlorination kinetics was determined and the oxide formed W(IS amorphous at temperatures below 600 °C and crystalline .at higher temperatures. The appropriate experimental conditions for the fastest completed oxidation was further determined.IntroductionThe use of fine powders for the manufacture of ceramic components has significant advantages. They include excellent sinterability; low sintering temperature and better microstructure leading to improved mechanical properties. The conventional method of producing fine oxide powders involves controlled precipitation and pirolysis of suitable salts. The main limitation of the high temperature decomposition route is the evolution of environmentally unacceptable and corrosive gases. Controlled precipitation of hydroxides from solutions of salts, followed by thermal treatment involves large volumes of solutions and the calcination step that can induce grain growth (1).Direct oxidation of aluminum metal for producing alumina powder requires high temperatures for the direct oxidation of molten Al alloys by a vapor phase oxidant process (2, 3) or high technological process like thermal plasma reactor ( 4).Oxidation of high purity aluminum (5, 6) below the melting temperature· is initially characterized by a nearly linear reaction rate, followed by a rate which decreases rapidly with further weight gain. However, the oxidation rate of an aluminummagnesium alloy is much faster and it does not conform to any common oxidation law, but it is nearly parabolic at temperatures between 200 and 400 °C, an nearly linear· above 400 °C."

Jan 1, 2000

By Philip D. Wilson

AS thin most important and vital component of an airplane aluminum hay rapidly become the heart and tome- of the war program. Its production ham increased amt will continue to increase, in comparison with its pre-war position further than that of any of lie other important critical metals except magnesium. Compared with the 1939 production of tons of primary ingot coming from four plants, all owned by the Aluminum Company of America the 1942 figures are more than three timer as large. Including, recoverable scrap and contracted ingot from Canada the 191,, supply of aluminum for the United States will be over siren times dial of 1939- A substantial part of this increase has been achieved during the past year as total production in 1941 was only some 307,500 tons. During 1942 six great new ingot plants sponsored and owned by the Government have come into production and three others are nearing completion.

Jan 1, 1943

By B. Arsenault

Aluminum coatings can provide galvanic cathodic protection for several metals and alloys, In order to be a suitable protective solution on structural components, the mechanical integrity of the component must be preserved, In particular, fatigue properties are a challenge for thermal-spray protective coatings on mechanical structures, To address the issue of the fatigue integrity of 7075 aluminum alloy with an arc-sprayed protective coating, different surface preparations prior to arc spraying were considered, In the present work, a feasibility study was performed using laser ablation as a surface-preparation technique before or during arc spraying of coatings, This was collaborative effort between the LERMPS laboratory in France, the National Research Council Canada and the Royal Military College of Canada, Both fatigue and adhesive properties of aluminum coatings were evaluated in relation to substrate-surface-preparation techniques including laser ablation (Protal® process), grit blasting and shot peening. Results indicate that a combination of key conditions, including the use of nitrogen as the arc spray gas, shot peening, and proper laser energy density for ablation, provide high fatigue resistance of metallic coated 7075 alloy substrates. Specimens prepared under these conditions show a similar fatigue resistance to uncoated substrates.

Jan 1, 2005

By Turan Uysal, Ramazan Aydogmus, MURAT ERDEMOGLU

The paper investigates the effects of calcination for thermal activation and intensive milling for mechanical activation on aluminum recovery by acid leaching of pyrophyllite ore enriched via attrition scrubbing and froth flotation. The study compares these methods in terms of energy consumption and aluminum recovery, concluding that mechanical activation is more economical and environmentally friendly.

Nov 1, 2023