aluminium technologies

1.12.2015
# Name Date Hours Presentation title
1 Cenk Eken 15 Aralık 10:50-11:20 Ultrasonic processing of aluminium melts

2 Murat Teke 11:30-12:00 Assesment of melt quality via K-mold method

3 Alper Güneren 22 Aralık 09:30-10:00 Friction stir processing of aluminium alloys

4 Haluk Erdemir 10:10-10:40 Additive manufacturing of aluminium alloys

5 Gazican Özkan 10:50-11:20 Squeeze casting of aluminium alloys

6 Mehmet Yasak 11:30-12:00 High integrity casting processes

7 Erkut Özer 29 Aralık 09:30-10:00 Casting of hypereutectic Al-Si alloys and their applications

8 Serhan Köktaş 10:10-10:40 Rheocasting of aluminium alloys and their applications

9 Kürşat Kambur 10:50-11:20 Severe plastic deformation processing of aluminium alloys

10 Engin Kılınç 11:30-12:00

11 Mehmet Ağılkaya 5 Ocak 09:30-10:00 Steel vs aluminium for automotive applications

12 Emre Baran 10:10-10:40 Production of aluminium foams

13 Berkay Oral 10:50-11:20 FSW of automotive aluminium

14 İzzet N. Demir 11:30-12:00 Casting of Al-Mg based foundry alloys and their applications
production routes
of wrought
aluminium alloys
(semi) continuous casting
direct chill (DC) casting
round section – billet  extrusion  profiles
slab – ingot  hot/cold rolling  sheet/foil

semi-continuous casting

Twin roll casting (TRC)  cold rolling  sheet/foil

Twin belt casting (TBC)  hot/cold rolling  sheet
continuous casting
Direct Chill (DC) casting
● DC casting was invented in the early 1930s (VAW-
Germany and Alcoa-USA).
● Today it is the premier process for producing
aluminium shapes suitable for subsequent
processing in extrusion, hot/cold rolling operations.
● Around ten million tons/year of aluminium is DC
cast worldwide.
● The process is also used to cast copper, zinc and
magnesium.)
DC casting
● DC casting of aluminium provides the link between
liquid metal, as obtained from reduction cells or
from scrap melting, and the semi-fabricator.
Products include:
● large rectangular sections known as rolling blocks,
rolling ingots or slab (typically ≈ 500 x 1500-2000
mm in section) which are used by rolling mills for
plate, sheet or foil production.
● Large circular section ingots (typically 150-400mm
dia) known as billets which are used by extruders
for various extrudates-profiles
DC casting/circular sections
DC casting/rectangular sections
DC casting/shaped sections
DC casting/rectangular sections
DC casting/rectangular sections
DC casting
● A furnace, or more often multiple furnaces, contain
the liquid metal allowing it to be alloyed.
● The furnace tilts, or a drain or plug hole is opened,
initiating a flow of metal along the launder.
● In-line treatment is usually employed to remove
dissolved hydrogen, alkali metals and solid
impurities prior to entering the casting station.
Basic layout of a typical vertical
direct chill casting
installation
DC casting
Alloyed and refined liquid metal is supplied to the
caster. Distribution can be by separate launders to
each mould with individual flow control or by a
flooded table,
where the moulds
are mounted in a
common water
jacket and the
metal flows
through a
refractory pan
mounted on top.
DC casting/circular sections

The casting
speed
depends on
alloy and size

It is typically in the 1-3

mm/s range.
DC casting
● DC casting produces ingots of uniform cross
section, initially by containment of the liquid
metal in a cooled mould and then by direct cooling
of the casting.
● the cooling medium is water, both for the mould
cooling (primary cooling) and the direct or
secondary cooling.
● The solid moves out of the mould, liquid is fed
into the mould opening and is contained by the
water cooled mould.
Surface
formation
during DC
casting
The direct chill
water spray
cools the ingot
as it emerges,
extracting
enough heat for the solid
shell to form above the
spray inside the mould and
contain the liquid.
DC casting
● At the start of casting, the open ended metal
mould has to be plugged with a starting head or
“dummy” block to contain the liquid and allow the
cast to proceed.
● Metal is poured into the water cooled mould,
freezing onto the starting head.
● After a delay, the starting head is lowered into a
pit.
● casting stops when the bottom of the pit is
reached.
Horizontal DC casting

Water Molten
chilled aluminium
mould
Water spray
Secondary cooling

Extrusion
log

In the horizontal version, a flying saw primary cooling

cuts the ingot to length as it emerges
and casting can be fully continuous.
DC casting alloys
● All wrought alloys may be DC cast.
● Circular sections, known as rounds or billets, up to
1.1 m diameter, are usually sent to extrusion
operations but can be used to supply forging
presses.
● 6000 alloys are used for most extrusions, although
high Si foundry alloys, high conductivity 1000 series
(3000 and 5000) and high strength 2000 and 7000
series alloys can also be DC cast.
● Remelt ingots, both pure and alloyed, in small
rectangular sections (eg. 150 x 50 mm) or large T
sections (500 x 1200 mm), can be produced.
Surface temperature of DC cast ingots

impact point

distance
Effect of Casting Variables
● if one increases casting speed, heat input increases,
leading to increased temperature gradients and
greater diffusive heat flow, which balances the
increased heat input.
● Similarly, a consequence of larger ingot size is higher
heat input and a longer diffusion path. In practice,
casting speed is reduced as diameter increases.
● The casting temperature has a small effect on the
heat flow as the specific heat of the liquid is only
~4-5% of the total heat input.
● Latent heat accounts for about 35% of the heat input
and specific heat of the solid the remainder.
Effect of Casting Variables
● Since the specific and latent heats for the various
aluminium alloys are very similar, variation in
temperature distribution from alloy to alloy is
due to changes in thermal conductivity.
● As alloy content increases, thermal conductivity
decreases, the pool depth increases and
temperature gradients increase.
● Alloy content also determines the liquidus and
solidus temperatures, ie. the freezing range.
Solidification
● Under the influence of the temperature distribution,
solid forms where the liquid temperature goes below
the liquidus for a given alloy.
● TiB2 grain refiner is added to provide nucleation sites
for the formation of solid alpha aluminium crystals,
giving a very fine equiaxed structure.
● If casting is performed without grain refiner, the
classical grain structure of a columnar exterior and
equiaxed centre results.
● The smaller equiaxed grain size prevents cracking at
normal casting speeds.
Solidification
● In addition to the level of grain refiner, cooling rate
also determines the fineness of microstructural
features such as dendrite arm spacing (DAS), grain
size and intermetallic particle size.
● The cooling rate decreases from surface to centre as
the distance from the water spray increases.
● This gives rise to a variation in microstructure from
the surface to the centre which is particularly
apparent with larger castings.
● In many cases, this variation is not important.
● However, for some AlFe alloys it causes a change in
intermetallic particle phase producing a fir tree
structure.
Solidification
● This in turn causes anodising streak defects.
● The volume fraction, shape and size of
intermetallics will also vary due to cooling rate
variation from edge to centre.
● Very little can be done about this variation as it is
a function of the size and thermal diffusivity of the
ingot.
Solidification
Composition is the controlling factor for
microstructure.
Apart from composition,
ingot dimension
thermal conductivity
are the main
parameters
affecting cooling
rate and refinement
of microstructure.

Fine equiaxed structure

of a grain refined DC casting
Solidification

Measured grain size showing

coarse microstructural zone in
DC cast 3004 alloy.
Grain structure of a non
grain refined 178 mm diameter billet
Macrosegregation
● In larger DC castings, significant compositional
variation is found.
● Elements that form eutectics with aluminium rise
in concentration away from the edge of the
casting, with the centre being depleted.
● Elements that form peritectics with aluminium
show a reverse trend.
● This composition difference is likely to give rise to
a variation in properties across the section when
extruded or rolled.
Macrosegregation
Hot-Top Casting
● Insulation placed at the top of the mould was
introduced to control the location of the initial
contact point of the liquid against the mould.
● In this way, the liquid metal contact point was
fixed at a point below the insulation and was
independent of the metal level used.
● This minimizes reheating and improves surface
quality.
● Modern hot top moulds are similar in principle,
with a refractory header inserted into the top of
the mould.
DC casting/circular sections
Liquid metal
Hot top mould
Primary cooling
sıvı

liquid+solid Water jets

Secondary cooling
solid ingot

Casting speed
Simple hot top mould formed by
addition of thin insulating paper to
an
open
top
mould
Air Assisted Hot-Top

Gas pressurised
hot top process
DC casting
Electromagnetic Casting (EMC)
● The electromagnetic casting mould uses an
inductor coil through which a high frequency
(typically a few kHz) current is passed.
● The currents induced in the liquid metal interact
with the magnetic field of the coil.
● This produces a restraining force on the liquid
which acts against the metallostatic head pushing
the metal away from the mould.
● Lack of contact between liquid and mould
eliminates mould cooling and the problem of
reheating, producing very good surface
microstructures.
Electromagnetic casting
extrusion
extrusion
● The extrusion process involves a preheated billet
being squeezed through an opening in a steel die
forming the cross-section of the extrusion or
profile.
● This may be a simple or an intricate form and the
cross-section may be solid or hollow.
● The most widely-used extrusion alloys are 6xxx
series, being the easiest to extrude in very
complex cross-sectional shapes.
● Materials with a higher alloy content are more
difficult to extrude and are therefore not
available in complex shapes.
extrusion
● The extrusion process gives designers and users
unique opportunities:
● Cross-sections of profiles with all kinds of special
functions – such as grooves, joining details,
stiffeners – which reduce fabrication and
installation costs as compared to rolled steel
products
● Extrusion costs are relatively low.
● Extrusion is therefore already beneficial for small
production series
extrusion
Aluminium extrusion
● aluminium takes full advantage of the extrusion
process.
● Other metals can be extruded but few with the ease
of aluminium and its alloys.
● Aluminium’s high strength-to-weight ratio, and its
ability to be extruded into any shape – no matter
how complex, with tight tolerances, make it an ideal
material for design applications which require
maximum versatility from a cross-sectional area.
● Aluminium extrusions are also highly cost effective
since they need virtually no machining or
maintenance.
Aluminium extrusion
● Aluminium extrusions are produced by heating
aluminium billets to approximately 500°C and
forcing the hot metal through a steel die.
● As the extruded section emerges it is cooled and
cut to the desired length.
● Heat treatment is then used to optimise the
material’s inherent mechanical properties.
● Computer aided design and manufacture is used to
reduce design time, improve tolerances, and
control each stage of the process more accurately.
Benefits of extrusion
Less fabrication: there is greater design potential
because intricate shapes may be extruded, reducing the
need to manufacture component parts for future
assembly. Some shapes achievable by extrusion are
unattainable by any other process.
Low prototype costs: the cost of tooling aluminium
extrusions is low compared to that of roll forming,
casting, forging and moulding of competing materials.
Great structural efficiency: optimum structural
efficiency is possible, as, by using extrusions, metal can
be placed where it adds strength and omitted where it is
not needed.
Benefits of extrusion
Less weight: extruded aluminium is lightweight yet strong
and durable. Differences in properties between aluminium
and competing materials can result in aluminium structures
being up to half the weight of equivalent structures made
from other heavy materials that are not so readily
fabricated.
A wide range of attractive, corrosion-resistant finishes:
can be achieved through powder or electrophoretic coating;
designers can specify virtually any colour they wish. Natural
silver or colour anodized films are also available.
Less maintenance: aluminium is a naturally durable metal
and the surface finishing described above further enhances
durability.
Extrusion alloys
6xxx extrusion alloys
Role of Mg and Si
● 6XXX series alloys are typical heat-treatable
aluminium alloys which gain their strength from
thermal processing rather than mechanical
deformation.
● The key elements of these alloys are Mg and Si
which combine to form the Mg2Si precipitates.
● These precipitates occur in several forms which
may be divided into the following 3 categories.
6xxx extrusion alloys
Role of Mg and Si
●  (beta double prime) Mg2Si, the smallest type of
Mg2Si precipitate that is rod-shaped and
contributes most to mechanical properties when
densely dispersed.
●  (beta prime) Mg2Si: a larger version of rod-
shaped precipitate that grows from  category.
● The  precipitates have a negligible contribution
to mechanical properties.
●  (beta) Mg2Si: the largest Mg2Si precipitate that is
cube-like in shape and due to its size, contributes
nothing to mechanical properties.
6xxx extrusion alloys
● Most 6XXX alloys are designed to have either
balanced Mg and Si levels or an excess of Si.
● The diagonal line in the next Figure is for a balanced
composition, assuming that the Fe content in these
alloys is %0.16.
● Excess Si alloys are preferred over excess Mg alloys,
because, excess Mg does not add to the final
mechanical properties of the product.
● Excess Mg increases the flow stress of the alloy and
makes it difficult to extrude.
● Excess Si aids the artificial ageing response and so
increases the strength of the final product.
Extrusion alloys
● Hardening by Mg2Si precipitation
● Hardness increases with the increase in the
amount of Mg2Si!
● Fe content must be limited to improve the
surface quality (particularly in the case of
high extrusion speeds!)
● Mn and/or Cr is also added to the alloy in
the relatively higher strength 6061 and
6082 alloys to control recrystallization!
Extrusion alloys
Excess Mg Excess Si
Mg % 1.4
Medium strength AA 6082
1.2
AA 6061
1.0 AA 6063
0.8

0.6

0.4
AA 6005 A
AA 6060
0.2
Low strength
0
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 Si %
Role of alloying elements
Iron
● Iron is also present in 6XXX alloys and combines with
Si and Al to form AlFeSi intermetallics.
● These intermetallics do not contribute to the
strength of the alloy but, if they are not correctly
processed, they will have a detrimental effect on
the extrudability of the alloy.
● Accurate control of Fe contents in 6XXX series alloys
is important for surface finishing applications.
● Different levels of Fe will cause variations in colour
response during anodising. Fe will also reduce
conductivity.
Role of alloying elements
Manganese
● Mn is used in a number of ways in 6XXX series alloys. Mn
helps to reduce the homogenization times by promoting the
transformation of -AlFeSi to -AlFeSi and
● Helps to prevent coarse grain growth during post extrusion
heat treatments of medium strength alloys such as 6061 and
6082.
● Another benefit is that the fracture toughness can be
improved by additions of Mn as it helps to prevent the
nucleation of Si at the grain boundaries which embrittles
the material.
● In higher strength 6XXX seris alloys with significant Mn
additions (e.g. > %0.10), the detrimental effects of Mn are
an increase in flow stress of the billet which decreases
extrudability, as well as increasing quench sensitivity.
Role of alloying elements
Copper
● Cu additions may improve conductivity and
machinability of the extruded alloy
● counteracts the detrimental effect of room
temperature storage on the mechanical properties
of artificially aged high strength alloys,
particularly 6061.
● The corrosion resistance of 6XXX series alloys is
lowered by the presence of Cu once the level
exceeds %0.2.
Role of alloying elements
Chromium
● Cr acts in much the same way as Mn but its effect
on quench sensitivity is more pronounced than
Mn.

Zinc
● Zn is not known to have any detrimental effect on
the mechanical properties of 6XXX alloys.
● However, in amounts greater tha %0.03 Zn may
cause a differential effect known as “spangle”
during the anodising process.
Role of alloying elements
Extrusion processing cycle
melting DC casting homogenization preheating

Extrusion cooling ageing

stretching
anodising
cutting
painting
storing
fabrication
forming
Extrusion processing cycle
Thermomechanical process
casting
Homogenization
soaking
cool-down : cooling rate is critical
Pre heating
Extrusion
quenching ageing (T5)

solutionizing
ageing (T6)
DC casting
Quality characteristics of cast
billet
● Minimum surface segregation;
● Shell zone as shallow as possible (<200 m)
● Section must be free of inclusions and porosity!
● Uniform structure across the section:
● Minimum segregation
● Fine and equiaxed grain structure, uniform
across the section (<200 m)
● Uniform distribution of intermetallic
compound particles
Cast billet
Thermal cycle of 6XXX series alloys
● 6XXX alloys obtain the maximum strength from the
following heat treatment cycles:
● Solutionizing during extrusion or solution heat
treatment
● Followed by quenching at a rate that is alloy
dependent and
● Then precipitation age hardening
● Maxiumum mechanical properties cannot be
obtained without accurate temperature control
which regulates the Mg2Si characteristics
throughout the process.
Extrusion processing cycle
700 C

600 C
580 C
2-3 h
440-490 C
200 -500 C/h Forced air
0.5-1 min /water
quenching
(5 s
deformation 185 C
5-45 min
200 C/h zone 5h
induction/
gas
DC casting homogenization preheating extrusion cooling ageing
Cast 6XXX alloy billet
Extrusion process cycle
pre extrusion rapid
heating soak cool down Heating cooling
solvus
temperature

quenching
gas

Cast ingot time

Heat treatments are not independent! The process
must be designed with a consideration of their effect
on the subsequent steps!
 Homogenization anneal
soak: segregations must be eliminated/
transformation must be completed 
Cool down: neither too fast nor too slow/ optimum
 400C/st
600
temperature (C)

300 heating soak cool down

300 660 900

time (min)
homogenization
550 C Temperature 580 C
2h
Annealing time

8h
homogenization
● Marked improvements must be achieved in the as-cast
structure:
● Detrimental effects of Fe must be reduced by encouraging
 transformation
● To minimize dendritic segregation
● To modify Fe-bearing compound particles
● To solutionize Mg2Si phase during soaking and precipitation
of Mg2Si phase in a suitable form during the cool down.
● Precise T control to avoid incipient melting (<570C).
Homogenization anneal

Cooling of billets to room temperature after homogenization

is a critical operation!
Cooling is performed with forced air or with water mist in
batch operations. It is difficult to maintain rapid cooling and
control cooling rates!
New technology cool down
homogenization
The as-cast billet consists of a solid Al matrix
containing dissolved Mg and Si as well as a network
of -AlFeSi intermetallics located at the grain
boundaries
homogenization
For 6XXX alloys not containing additions of Mn, longer holding
times in the homogenization cycle would be necessary to
transform -AlFeSi to -AlFeSi.
Typically, a cycle would be 4 to 8 hours at 575 C, followed by
similar cooling for Mn containing alloys.
 homogenization
● Homogenization cycle is specifically designed to modify the
as-cast structure to one which can be extruded at high
speed while achieving excellent surface finish and optimum
mechanical properties.
● For low strength 6XXX alloys containing Mn, a typical
homogenization cycle consists of heating the billet to 575C,
holding for 2 to 4 hours and then cooling the billet at a
controlled rate through the critical range of 450C to 200C.
● This cooling practice avoids the formation of -Mg2Si and -
Mg2Si precipitates in the microstructure which are
detrimental to the final mechanical properties of the
extrusion.
● The actual cooling rate used is dependent on the type of the
alloy and the billet diameter.
homogenization
Homogenization cycle:
● Transforms hard, needle-like -AlFeSi
intermetallics (detrimental to extruded surface
finish) to more globular -AlFeSi intermetallics.
● Ensures an even distribution of chemical
elements in the alloy.
● Nucleates a large number of fine, evenly
dispersed  and -Mg2Si precipitates that are
readily dissolved during extrusion.
homogenization
Cool down

600C/h 200C/h
350C/h
preheating
● Preheating must be carried out below the solvus
temperature!
● Preheating must be quick and be synchronized
with the extrusion press operation.
● Induction heating must be preferred as it is quick
and as it offers precise temperature control.
● In the case of gas preheating, the process must be
performed so as to minimize the time elapsed
above 360 C.
● Mg2Si precipitates rapidly above 360 C. It may be
difficult to solutionize these coarse precipitates
solely with the frictional heating inside the press.
preheating
Pre-heating
● The purpose of pre-heating billets for extrusion is to
lower the flow stress of the alloy to allow extrusion at
maximum speed while maintaining an excellent
surface finish and mechanical properties.
● The preheat temperature used must be sufficient to
dissolve -Mg2Si precipitates during extrusion.
● This will ensure that optimum final mechanical
properties are obtained subsequently with proper
press quenching and artificial ageing.
● A typical preheat temperature for dilute 6XXX alloys is
450 C but this may vary depending on how difficult a
section is to extrude, the alloy type and the particular
mechanical properties/surface finish requirements.
Pre-heating
● Two common type of billet preheaters are gas fired,
tunnel type furnaces and electrical induction heaters.
● The latter type of preheating is very rapid with billets
reaching temperature for extrusion in a matter of
minutes.
● The rapid heat up rates in induction heating allow for
littletime for the post
homogenized microstructure
of the billets to change.
● The homogenized
microstructure
mainly contains -Mg2Si
precipitates and some Mg
and Si in solution.
Pre-heating
Rapid induction heating: 200C/hr

Gas preheating: 20C/hr

Delayed gas preheating: 10C/hr

Graph of preheat rates and zones of  and -Mg2Si formation.

Pre-heating
● Mg and Si retained in solution will increase the
hot flow stress of the billet thus decreasing
extrusion speeds.
● However, the rapid heat up through the range
200C-450C is beneficial because it avoids the
formation of coarse -Mg2Si precipitates.
● Coarse -Mg2Si precipitates are not readily
dissolved during extrusion and avoiding this
phase enables optimum mechanical properties to
be reached.
● When using gas preheating the situation is almost
reversed.
Pre-heating
The slower heat-up allows the homogenized
microstructure to change so that Mg and Si may be
precipitated from
solution as  Mg2Si
which lowers the
hot flow stress of
the billet allowing
greater extrusion
speeds to be used.

Billet microstructure showing

coarse  Mg2Si formed during a
delay in gas preheating
Pre-heating
● The detrimental aspect of gas heating is the
possible reduction in final mechanical properties.
● Slower delayed preheating can coarsen the  Mg2Si
as the temperature approaches 400 C.
● Mg2Si begins to form at around 400 C.
● The coarse  Mg2Si requires higher exit
temperatures for dissolution and the  Mg2Si will
not dissolve during extrusion.
● The reduced amount of Mg and Si in solution will
result in less than optimum mechanical properties
after artificial ageing.
Direct extrusion process
extrusion
Manufacturing tubes via extrusion
Direct extrusion process
● Aluminium billets are heated to 450-500 C,
depending on alloy, extrusion shape and
extrusion ratio) and loaded into a pre-heated
container (420-470 C).
● A hydraulic ram pushes the billet through the die
aperture at pressures up to 680 MPa.
● The hot metal flows through the die to produce a
continuous extrudate with a cross-section
identical to the die aperture.
● The shapes may vary from complex hollows to
simple solids.
Factors affecting extrusion process
Press capacity
For maximum press productivity,
an extrusion press is operated
close to the maximum
running pressure which
usually corresponds to
maximum speed.

The solid line is the boundary between sufficient and

İnsufficient pressure to extrude through a given die over a
range of extrusion speeds and billet temperatures.
Factors affecting extrusion process
● This boundary may be moved to the left by using
soft (dilute) alloys or by utilising more available
pressure in order to maximise productivity.
● Harder alloys, higher extrusion ratios, or more
complex shapes will move the boundary to the
right.
● This will expand field A and reduce the extrusion
speeds (and productivity) obtained for a
particular press capacity (pressure).
● Using higher billet temperatures may compensate
for the reduction in extrusion speed but other
variables may limit the temperature increase.
Factors affecting extrusion process

Soft alloys

poor
surface

Surface finish
Factors affecting extrusion process
Surface finish
● Complex shapes, high extrusion ratios and hard alloys
move this boundary to the left reducing the extent of
field B (extrusion possible).
● This shift may also correspond to the surface
deterioration such as surface tearing, pick-up and
melting in some extrusions.
● These factors reduce the extrusion speeds and billet
temperatures that can be used before the surface
finish breaks down.
● Coarse Mg2Si particles formed either due to slow post
homogenization cooling or slow preheat, also move
the surface finish boundary to the left (large field C).
Factors affecting extrusion process
Mechanical properties
● Mechanical properties also impose some limits on the
extrusion process.
● The new boundary moves to the right by using billet
with coarse -Mg2Si precipitates, extrusion of thick
cross-sections and where higher mechanical property
levels are required.
● Extrusion speeds and billet temperatures must
therefore be increased for the extrusion to satisfy final
mechanical property requirements.
● This is to say the energy supplied to the billet to
dissolve Mg2Si must be increased.
Factors affecting extrusion process
Billet containing  and fine  Mg2Si, thin cross-section
extrusions and lower mechanical property requirements all
move the boundary to the left. Constraints on extrusion
speed and
billet
temperature
requirements
are reduced
and final
mechanical
properties are
more easily
attained.
Extrusion operation window
The combination of the press capacity (available
pressure) surface finish and final mechanical
properties
act as the
boundaries of
the operating
window
for a quality
product.
Extrusion operation window
● Where these boundaries are located depends on
actual product requirements for surface finish
and specific mechanical property limits.
● These boundaries also highlight where maximum
press productivity can be achieved.
● Extrusion speed and billet temperatures are
limited to within these boundaries.
● Other variables, such as alloy type, extrusion
ratio/shape and final extrusion properties, may
enlarge or reduce the size of the operating
window.
Press quenching/cooling
● Post-extrusion cooling rates must be fast enough
to retain Mg and Si in solid solution so that
mechanical properties are maximized by their
precipitation during subsequent age hardening.
● Cooling rates are determined by section size and
cooling type such as still air, fans, water mists or
water baths.
Press quenching/cooling
Schematic illustration of various cooling rates and
areas for precipitation of coarse Mg2Si.
Extrusion T

Log TIME
Typical cooling rates required
for some 6XXX alloys
Heat treatment of 6XXX alloys

Mg2Si wt%
solutionizing
● The material is heated above the solvus line in
the phase diagram and is held inside the single
phase region until all secondary phases are
solutionized.
● Mg2Si in 6XXX alloys (and Al2Cu preipitates in
2XXX alloys) is completely solutionized by the
end of solution soak.
● Solution heat treatment temperature is between
500-550°C so as to avoid both the melting and
eutectic temperatures.
Cooling-quenching
● Once the billet is solutionized, it is cooled to room
temperature rapidly enough to retain the Mg and Si in
solution.
● Hence, a supersaturated matrix is obtained.
● Quenching may be employed after a solution heat
treatment as well as after a high temperature forming
operation.
● For instance, the press exit temperature is often
higher than the solvus temperature and the extrudate
may be quenched right after extrusion.
● This quenching may be performed in a water tank as
well as with a fan.
precipitation
● There must be a fine distribution of Mg2Si
precipitates (actually ) to achieve high
hardness values!
● Formation of coarse Mg2Si precipitates before or
during extrusion will lead to low hardness levels.
● Formation of such coarse precipitates is
inevitable if the material is held between 230 C
and the solvus temperature, 500 C, too long.
Precipitation in Al-Mg-Si system
soft hardness  peak hardness overaged
solid coherent partially incoherent
solution zones coherent precipitates
precipitates
   (Mg2Si)
zones rods plates

Al atoms Mg/Si atoms

Artificial ageing
● The solutionized and quenched material is not
stable and is anxious to undergo precipitation.
● Mg and Si in solution is precipitated in forms so as
to maximize hardness.
● Room temperature natural ageing: hardness
increases in a marked fashion shortly after the
solution heat treatment and quenching with time
spent at room temperature.
● This hardness increase is prominent in the first
couple of hours but is markedly lower than the
hardness that can be achieved with an artificial
ageing treatment.
Natural ageing
● The material undergoes ageing-precipitation if
held at room temperature after the solution heat
treatment.
● The precipitation hardening that occurs under
these circumstances is prominent within the first
couple of hours after quenching. It slows down
with time and stops completely.
● The hardening thus obtained is much lower than
that obtained with artificial ageing.
Artificial ageing
● Precipitates that form during artificial ageing are
coherent with the matrix for a maximum hardness.
● In other words, the crystal structure of the
precipitates is the same weith that of the matrix.
● This leads to coherency stresses at the precipitate-
matrix interface and limits the mobility of the
dislocations producing high hardness.
● The coherency deterorates as the precipitates
grow and they finally form another phase.
● The coherency stresses are gradually reduced and
the matrix starts to soften.
Precipitation in Al-Mg-Si system
Solution
%100  solid solution
heat
retained upon cooling
treatment
temperature

Fine dispersion of
precipitates within grain
(retained upon cooling
Precipitation
heat treatment

Equilibrium structure:
time
coarse -Mg2Si
precipitates at 
grain boundaries
Precipitation in Al-Cu system
Solution %100  katı eriyiği
%100  solid solution
heat Hızlı soğutma ile oda
retained upon cooling
treatment sıcaklığında korunmuş
temperature

Fine dispersion of
Artificial Tane içlerinde
precipitates within grain
ageing:/precipit küçük çökeltiler
(retained upon cooling
ation heat
treatment

Equilibrium structure:
time
coarse -CuAl2
precipitates at 
grain boundaries
Precipitation in Al-Mg-Si/Al-Cu
systems

Peak hardness/optimum
precipitate size and
Hardness/strengtht

Supersaturated disitribution
solid solution

Over aged/
Under aged/ Coarse precipitates
Fine not developed
precipitates

Ageing time