Description
Book SynopsisAluminum: Technology, Industry, and Applications provides an overview of the processes, practices, and trends associated with the use of aluminum as an engineering material.
This resourceful and practical book includes chapters on mining and smelting, ingot and continuous casting, shape casting, hot and cold rolling, extrusion and drawing, forging, and secondary operations. It discusses the factors involved in the selection of product forms, alloy compositions, and temper designations with emphasis on manufacturability, component performance, sustainability, and cost.
The book also describes the role of aluminum in aerospace, automotive, trucking, rail, marine, packaging, appliance, and building and infrastructure applications, noting major advancements as well as challenges. It also includes content that traces the development of the aluminum industry from its beginnings to its current state, from the perspective of the individuals and organizations who shaped it.
It is for anyone working in or serving the aluminum industry and those who have interest in its past, present, and exciting future.
Table of Contents
- Chapter 1: Introduction—Aluminum as an Industrial Material
- Discovery of Aluminum
- The Washington Monument
- Origins of the Industry
- Evolution of the Aluminum Industry
- Chapter 2: Mining, Refining, Smelting, and Recycling
- Where Does Aluminum Come From?
- Refining—The Bayer Process
- Smelting
- Primary Aluminum
- Scrap and Recycling
- A Visit to the Aluminum Recycling Center
- Chapter 3: Strengthening and Heat Treatment of Aluminum
- Alloy Designation Systems
- Strengthening of Aluminum
- Crystal Structure and Ductility of Aluminum
- Alfred Wilm (1869—1973)
- Temper Designations
- Microstructure Changes during Annealing
- Chapter 4: Direct Chill Ingot and Continuous Casting Processes
- Melting and Alloying
- Recycling
- Molten Metal Treatment
- Control of Inclusions
- Ingot Grain Refining
- Direct Chill Casting
- Direct Chill Ingot Microstructure
- Continuous Casting Methods
- Continuous Casters: The Holy Grail for Sheet Production?
- Chapter 5: Aluminum Shape Casting
- What Is a Casting?
- Aluminum Shape-Casting Processes
- Sand-Mold Casting
- High-Pressure Die Casting
- Casting Alloys
- Al-Si Alloys
- Casting Quality and Performance
- Premium Castings
- Heat Treatment of Cast Products
- Chapter 6: Production of Aluminum Rolled Products
- Ingot Preparation
- Ingot Preheating and/or Homogenization
- Hot Rolling
- Aluminum Rolling Mills
- Plate Production
- Cold Rolling of Sheet and Foil
- Finishing Operations
- Lithographic Sheet
- Thick Heat-Treated Plate
- Chapter 7: Production of Aluminum Extrusion and Wire Drawing
- Extrusion Process
- Extrusion Alloys and Process
- Hollows and Tubes
- Cold-Finished Rod and Bar
- Free-Machining Alloys and Products
- Weldable 6xxx and 7xxx High Strength Structural Alloys
- Secondary Operations
- Production of Wire Products
- Chapter 8: Aluminum Forging
- What Is Forging?
- Types of Forging Processes
- Forging Equipment
- Forging Process
- Forging Alloys
- Forged Products
- Chapter 9: Product, Alloy, and Temper Selection
- Introduction to Alloy and Product Selection
- Important Physical Properties
- Mechanical Properties
- Aluminum Corrosion
- Water Staining of Aluminum
- Chapter 10: Customer Manufacturing Processes
- Formability
- Surface Treatments
- Room Temperature Joining
- Elevated Temperature Joining
- Machining
- Chapter 11: Aluminum in Aircraft and Space Applications
- Commercial Aircraft
- Modern Aircraft Manufacturing
- Aerospace Alloys
- Military Aircraft
- Aluminum in Space
- Chapter 12: Aluminum in Light Vehicles
- Aluminum Shaped Castings
- The Story of the Vega Aluminum Engine
- Automotive Aluminum Rolled Products
- Ford F150
- Automotive Aluminum Extruded Products
- Chapter 13: Aluminum in Ground Transportation
- Early Uses of Aluminum in Ground
- Transportation
- Trucks
- UPS Truck Tour with Driver
- Buses—School, City, and Long Distance
- Railroad Freight Applications
- Subways and Light Rail
- Passenger High-Speed Railroad Applications
- Aluminum in Military Vehicles
- Chapter 14: Aluminum in Marine Transportation
- Small Boats
- Alloys for Shipbuilding
- Aluminum Ships
- SS United States
- Chapter 15: Aluminum Packaging Products
- Foil Packaging Products
- Coffee Capsules, Pouches, and Packets
- Semirigid Containers
- Beverage and Food Cans
- Brief History of the Aluminum Can
- Can Metallurgy
- What Can Go Wrong in Can Making?
- Impact Extruded Containers
- Aluminum Closures
- Chapter 16: Aluminum Building Products
- Early Use and Development
- Extruded Products
- Rolled Products
- Cast Products
- Chapter 17: Aluminum in Household Goods and Appliances
- Cookware
- Surface Finishes on Aluminum
- Consumer Electronics and TVs
- Apple and Aluminum
- Home Interiors
- Ladders and Other Tools
- Luggage and Briefcases
- Outdoor Furniture
- Aluminum in Art
- Art and Architecture
- Chapter 18: Aluminum in Infrastructure
- Electrical Conductors
- Roads and Bridges
- Saguenay River Bridge at Arvida
- Highway Signs, Traffic Signals, and License Plates
- Railroad and Highway Crossings
- Solar Energy Generation
- Agriculture and Industrial Applications
- Chapter 19: Aluminum in Sports and Recreation
- Water Sports
- Baseball
- Easton Sports
- Hockey, Tennis, and Racquet Sports
- Cricket
- Track and Field
- Snowmobiles, Jet Skis, and Golf Carts
- Bicycles
- Sports Wheelchairs
- Motorcycles
- Travel Trailers and Recreational Vehicles
- Camping Equipment
- Chapter 20: Aluminum and Its Importance for Sustainability
- Prospects for the Future
- Primary Production
- Current State of Recycling
- Decarbonizing Aluminum Production
- What's Next for Recycling?
- Appendix 1
- Wrought Aluminum Alloys
- Appendix 2
- Aluminum Casting Alloys
- Appendix 3
- Aluminum Alloy Heat-Treatable Alloy Temper Designations and Product Forms
