Aluminum Alloy is an alloy that consists primarily of aluminum. Other common elements included in the alloy include silicon, copper, magnesium, manganese, nickel, and zinc. Aluminum is one of the most commonly used metals in the world. Its cost and formability makes it a versatile choice for a variety of industrial applications.
There are several different grades of aluminum alloy with different uses and properties. The most common aluminum alloy is grade 1100, which contains 99% pure aluminum and is the most common grade of aluminum sheet sold. However, it has the lowest strength of all the commercial grades. This alloy is available in various tempers and is most often supplied in round bars. It is also extremely ductile.
These grades are used in many industries. For example, Grade 1101 is more expensive and stronger than Grade 1100, but it still retains the formability and low cost of that material. This grade is widely used in gas lines, heat exchangers, fasteners, and mailboxes. However, it is slightly less malleable than its predecessor and requires additional heat treatment to become fully machineable.
A common aluminum alloy used for manufacturing is grade 6061. This grade offers better corrosion resistance than the other grades of aluminum alloy in the 300 series. It also offers superior heat welding properties. For this reason, it is the best choice for products with high humidity or high wear. In addition, this grade is ideal for furniture with noticeable moldings. It also has excellent rust resistance and is suitable for use in sticky conditions.
Aluminum alloy is a highly versatile metal. It is a very good conductor of heat and electricity. For example, the electrical grade of aluminum has a conductivity of 62%, and the mechanical grade of aluminum has a conductivity of 204%. Furthermore, it is easy to work with and can be shaped using a variety of forming processes. Its properties make it useful for a wide range of applications, from utensils to storage tanks and the construction industry.
The formability of aluminum alloys is an important property in many applications. Formability is the property that limits the plastic deformation capability of a material and is influenced by its material properties, process parameters, and strain bounding criteria. It is also influenced by the geometry of the part being formed and the deformation process. Formability can be assessed by performing simulation tests.
Formability can be assessed in various ways, including by using a Forming Limit Diagram (FLD). This method is widely used because it provides reliable information about the fracture limit. Metallic formability is also affected by the crystallographic texture of the material. Several attempts have been made to correlate the different texture components with the forming capacity of the material.
The formability of aluminum alloy sheet metal is greatly improved when it is shaped using hot forming. Research at the University focuses on forming aluminum alloys at high temperatures and using finite element modeling. The results show that a combination of these methods results in a high degree of formability.
Another method to assess the formability of aluminum alloys is by performing stamping tests. In this method, an aluminum alloy sheet that is 3mm thick is used. It has a T6 temper and is considered to have high strength. However, the material has low formability at ambient temperature and therefore requires high temperatures during the stamping process.
In metal forming, the term ‘formability’ refers to the ability of a material to undergo deformation without developing undesirable conditions. This chapter discusses the physics behind the property and explains the origin of several major defects. Examples of such defects are wrinkling, necking, orange peel, grain coarsening, and mechanical fibering.