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Charge Calculation For Al-Si Alloys

The document discusses the chemical composition of 6063 aluminum alloy and plans to create three new alloys - Alloy A, B, and C - with varying amounts of copper, magnesium, silicon, iron, and manganese. It provides the chemical composition limits of 6063 aluminum alloy and the targeted compositions for each new alloy. It then calculates the amounts of aluminum-copper and aluminum-silicon master alloys that would need to be added to a 3000g batch of 6063 alloy to produce Alloy A with 4% copper and 6% silicon, Alloy B with 1.5% copper and 12% silicon, and Alloy C with 5% copper and 18% silicon when melted in a pit furnace.

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1K views2 pages

Charge Calculation For Al-Si Alloys

The document discusses the chemical composition of 6063 aluminum alloy and plans to create three new alloys - Alloy A, B, and C - with varying amounts of copper, magnesium, silicon, iron, and manganese. It provides the chemical composition limits of 6063 aluminum alloy and the targeted compositions for each new alloy. It then calculates the amounts of aluminum-copper and aluminum-silicon master alloys that would need to be added to a 3000g batch of 6063 alloy to produce Alloy A with 4% copper and 6% silicon, Alloy B with 1.5% copper and 12% silicon, and Alloy C with 5% copper and 18% silicon when melted in a pit furnace.

Uploaded by

hari
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© © All Rights Reserved
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Base Metal

6063 Aluminum wrought alloy is purchased from H.H.Metals, Delhi with the following
chemical composition limits.
Equivalent
Alloy
(AA)

Copper Magnesium Silicon

Iron

Manganese

Others

0.6

0.3

0.4

Remarks

U.S.A
6063

0.1

0.4-0.9

0.3-0.7

Aluminium
97.4%

Table 1.Chemical composition limit (per cent)


The composition of the three required alloys planning for casting using pit furnace from
6063 Al-alloy is the following.
Type

Copper

Magnesium

Silicon

Iron

Manganese

Alloy A

0.9

0.6

0.3

Alloy B

1.5

0.9

12

0.6

0.3

Alloy C

0.9

18

0.6

0.3

Remarks
Aluminium
88.2%
Aluminium
84.7%
Aluminium
75.2%

Table 2. Composition of the materials planned for casting.


Proportioning of the charge
The chemical composition of the base metal from which the required alloys are
planning to cast is given in Table (1) and the required alloys to be casted have the
respective constituent elements as shown in Table (2). For calculating the charge, the
melting loss of the limit must be taken into account and this depends on the design and
type of melting unit, melting techniques, the method of refining, etc. A simplified
calculation of the charge for Alloy A, Alloy B and Alloy C melting in a pit furnace is
considered which is given below.

Assume the following charge components: Primary aluminum ingot (6063 alloy)
and hardeners Al-50%Si, Al-50%Cu.
Charge calculation for Alloy A, Alloy B & Alloy C (Assuming for 3Kg):

Composition
(in %)
Composition
in gram (A)

Al

Cu

Mg

Si

Fe

Mn

Total

97.4

0.1

0.9

0.7

0.6

0.3

100

2922

27

21

18

3000

Table 3. Weight of constitutive elements in 3Kg of 6063 alloy.


It is clear from the table 3. that 3Kg of 6063 alloy contains 35 grams of Silicon. So, for
increasing the silicon upto 6%, 12% & 18% composition we have to add master alloy Al50%Si to 6063 alloy. Similarly for increasing the copper upto 4%, 1.5% & 5%
composition we have to add master alloy Al-50%Cu to 6063. The amount required can be
found out by trial and error method as follows.
Al-12%Si-1.5%Cu alloy (Alloy 336)
100 grams of Al-50%Cu master alloy and 920 grams of Al-50%Si master alloy is
required to add in 3000grams of 6063 Al alloy for attaining the above composition levels
in the alloy as justified below by calculations.
% Increase in Cu by the above additions of master alloy = (3+50)/(3100+920)= 1.32%
% Increase in Si by the above additions of master alloy = (21+460)/(3100+920)= 11.96%
Al-18%Si alloy (Alloy 390)
550 grams of Al-50%Cu master alloy and 1930 grams of Al-50%Si master alloy is
required to add in 3000grams of 6063 Al alloy for attaining the above composition levels
in the alloy as justified below by calculations.
% Increase in Cu by the above additions of master alloy = (3+275)/(3550+1930)= 5.07%
% Increase in Si by the above additions of master alloy = (21+965)/(3550+1930)=
17.99%

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