Separation of Aluminum from More Noble Elements in an Electrolysis Cell with Side-by-Side Geometry

Currently, recycled metal is diluted with primary metal to keep the concentration of alloying elements within specification. This will be more difficult in the future, when a larger proportion of the metal is made from scrap. Particularly, there is a need for a process that can remove elements more noble than aluminum from the scrap metal. While electrolytic refining in a three-layer cell (the Hoopes process) is a possibility; the present paper presents a simpler and more flexible electrolysis cell where the anode metal (alloy) and the cathode metal (purified metal) are placed side-by-side. The principle was demonstrated in a laboratory cell. The current efficiency was above 80 pct and the specific energy consumption was about 7 kWh/kg Al. The refining effect was very good, e.g., the copper content in the 7xxx alloy used was reduced from 2.1 wt pct to less than 20 ppm. An industrial version of the cell used in the present work is suggested. The principles and design are generic and can be used for other purposes than recycling aluminum.

Linking Spectrograph to Mechanical and Physical Properties of X7475 Experimental Alloys Produced from Recycling Beverage Cans for Bumper Beam Applications

The automobile industry intends to consume more aluminium alloys in an effort to reduce the greenhouse emissions through the cut in the weight of the passenger cars. Experimental X7475 aluminium alloy is a good candidate to achieve this mission. Past efforts targeted at exploring the aluminium for bumper beam applications and even the recovery of aluminium from recycled beverage can (RBC) were not with the aim of upgrading the 3xxx to a novel 7xxx alloy. The wt. % of Zn was 5.0, 4.5 and 4.0, while Mg was left at 1.50, 1.25 and 1.00 wt. % with Mn at a peak of 0.075, 0.050 average and a least wt. % of 0.025. Alloys were homogenized and taken through annealing (O), natural aging (T4) and artificial aging (T6). The effect of hardening phases such as MgZn2 (ICDD 034-0457) due to heat treatments on the physical and mechanical properties of the new X7475 alloys was investigated. Formation of precipitates affected the density and hardness of the alloys produced via stir casting route. A least hardness of 63.40 Hv was observed in alloy H with a density of 2.7264 g/cm3 while the maximum of 113.06 Hv was recorded against alloy C in as-cast (AC). The result has contributed to the database of experimental alloys with the possibilities of producing a new material from RBCs for bumper beam applications. Future investigation should employ design of experiment (DOE) in optimization of the heat treatment for better mechanical properties.

Thermo-Mechanical Treated High Strength AA-7xxx Aluminium Alloy by Cold and Cryo-Rolling Study their Mechanical Properties Corrosion and Microstructure Correlation

Thermo-mechanical treatment, in particular, cryo-rolling is a unique technique to produce super high strength AA-7xxx aluminium alloys with ultra-fine grained structure. In order to conduct the rolling at room temperature and cryo-temperature (liquid N2 (-190°C)), the AA-7xxx alloy ingot was rolled from 6mm to 1mm with 85% reduction in thickness. Optical microscopy, XRD, electron microscopy, hardness and tensile testing were conducted on the rolled alloy for understanding the phase changes and evaluating the mechanical properties. The alloy rolled at liquid nitrogen (LN2) exhibits very high strength with reasonable ductility. Corrosion behaviour of AA-7xxx series aluminium alloy various conditions in NaCl (3.5%) solution were investigated. Cold rolled and cryo rolled alloy exhibits better corrosion resistance than that of cast.

Effect of Ti Addition to Age Hardening Response of Al-10Zn-6MgxTi Alloy Produced by Squeeze Casting

This research focused on investigating the effects of Ti addition on the age hardening response of Al 7xxx alloy for Organic Rankine Cycle (ORC) turbine impeller application in power plant generators. Al-10Zn-6Mg wt. % alloys were produced by squeeze casting with 0.02, 0.05, and 0.25 wt. % Ti addition. As-cast samples were homogenized at 400 °C for 4 h. Solution treatment was conducted at 440 °C for 1 h, followed by quenching and ageing at 130 °C for 200 h. Age hardening result was observed using Rockwell B hardness measurement. Other characterizations included impact testing, STA, optical microscopy, and SEM-EDS. Results showed that the addition of Ti in all content variations increased the as-cast hardness due to the diminution of secondary dendrite arm spacing (SDAS) values of the alloy. Ageing at 130 °C strengthened the alloys, however the addition of Ti was not found to affect neither peak hardness nor impact values of the alloy. Identities of second phases formed during solidification were found to be T (Mg32(Al,Zn)49), β (Al8Mg5), and TiAl3, while precipitates produced during ageing were GP Zone, η′, and η (MgZn2).

Investigations on the Hot Stamping of AW-7921-T4 Alloy Sheet

AW-7xxx alloys have been nowadays considered for greater light weighting potential in automotive industry due to its higher strength compared to AW-5xxx and AW-6xxx alloys. However, due to their lower formability the forming processes are still in development. This paper investigates one such forming process called hot stamping. The investigation started by carrying out hot tensile testing of an AW-7xxx alloy, that is, AW-7921 at temperatures between 350°C and 475°C, to measure the strength and formability. Formability was found to improve with increasing temperature and was sensitive to the strain rate. Dynamic recovery is considered as usual reason for the formability improvement. However, examining the precipitation states of the as-received condition and after hot stamping using differential scanning calorimetry (DSC), the dissolution of precipitates was also believed to contribute to this increase in formability. Following solution heat treatment there was no precipitation during cooling across the cooling rates investigated (5–10°C/s). Samples taken from parts hot stamped at 10 and 20 mm s−1 had similar yield strengths. A 3-step paint baking heat treatment yielded a higher postpaint baking strength than a single step treatment.

DC Casting of Large Sized Ingot of a High Strength 7xxx Alloy under the Influence of Electromagnetic Field

Hot tearing and cold cracks are major defects during direct chill (DC) casting of large sized ingots of high strength aluminium alloys. In order to solve these problems, based on a low frequency electromagnetic casting (LFEC) process, a new technology, electromagnetic casting with the application of an air blade (EMA) was developed. In the present work, this new technology was used to prepare large sized AA7055 aluminium alloy ingots and the effects of the low frequency electromagnetic field and the air blade on macro-physical fields, microstructure and cracking are studied by numerical and experimental methods. The results show that applying an electromagnetic field can modify the flow direction, increase the velocity of melt flow and homogenize the distribution of temperature in the sump. Applying an air blade can homogenize the distribution of temperature and decrease the stress and strain in the solidified ingot. Furthermore, the microstructure of the ingot is refined remarkably and cracking is eliminated by simultaneously applying the electromagnetic field and the air blade during DC casting.

Microstructural Evolution of a New Aerospace 7XXX Alloy during Retrogression and Re-Ageing Treatment

RRA treatment was applied to a high-Zn, 7XXX alloy under development for aerospace applications. Microstructure of the alloy is studied at different stages of the 3-step ageing process, by Transmission Electron Microscopy, in order to understand the corresponding evolution of mechanical and corrosion properties. The Compression Yield Strength at the end of the high temperature step was found higher than at the end of the 1st step, contrary to the conventional RRA treatment. After re-ageing, the final CYS turned out significantly higher than at the T6 temper of the alloy, while the material remained sensitive to exfoliation corrosion.