Preface

Aluminum is the second most plentiful element on the earth and it became a competition in 19th century. The huge demand of aluminum is projected to get 70 million tons, over 30 millions being obtained from recycled scrap. The scope of aluminum ranges from household to space vehicles. Dramatic advances in casting,welding,forming and eco friendly methods of production have made aluminum and aluminum alloys highly attractive candidate for automotive and aerospace industry, because of their wide range of attributes such as high strength, resistance to corrosion, low density, high reflectively, high ductility and proven reliability. The developments in the last two decades have been revolutionary and well documented both for wrought, heat treatable and non-heat treatable alloys. New developments in methods of casting, forming, welding, environmental degradation, grain refinement and particle size at nano and micro scale have made big impact on their demand for space and automotive industry.

Despite serious competition from composites, aluminum alloys are still the king in these industries, as exemplified by 777 Airbus. Aluminium is a very versatile metal and can be cast in any form, stamped, forged, machine, brazed and resin bonded.

Substantial evidence has been gathered on formability which affects the structural integrity of the components. The demand on quality and integrity of welding is increasing on military and commercial aircraft. This includes improved toughness, lower weight and increased resistance to corrosion fatigue. The progress made in welding, analysis of different techniques and their impact on micro structural characteristics has been discussed in several chapters in the hinder the section "welding, casting and forming". Ambriz Richardo has discussed this topic whereas Saravana Kumar has provided valued information on tailored blanks and deep drawing behavior of aluminum alloys. Because of high plastic strain, levels, rigid strength requirements and high quality controls are required for forming processes ranging from single to multiple stage because of increasingly dynamic and competitive market demands which includes outstanding toughness and a high resistance to corrosion fatigue. Various casting process such as direct chill casting, rotary die equal channel angular processing, counter gravity casting and centrifugal casting is described by Aremo Bolaji, Watazu Akira and others have shown new dimensions in the field of casting. Dramatic changes in surface treatment have proved highly effective in the life cycle of aluminum alloys as shown by Shoja Razavi Reza, Wierzbinska Malgorzata, Lopez-Cellajas Regulo, Metikas Theodore and Morwka-Nowotnik Grazyna have added new data to new information. Improvements in surface topography and stability are only achieved successfully by combining electrochemistry, microstructures and the role of micro/nano particles new methods of surface modifications are described by Akbarzadeh Abbas, Timelli Giulio and Kornev Vladimir. Corrosion is a serious thread to aluminum alloys and aluminum based metal matrix composites reinforced by silicon carbide. A brief mechanism of corrosion of composited is given by Zaki Ahmad. Environmental damages such as corrosion fatigue in aluminum alloys and their mechanism have been described by Ghazali Mariam and Eichlseder Wilfried. The principle behind the chapters in book was an analysis of the procedures such as casting, forming, welding and environmental degradation which have a strong bearing on the integrity of aerospace structures and automotive. The authors have addressed the problems of grain refinement, micro segragation, casting defects, crack growth, weld defects to show to what levels the aluminum alloys have been technically elevated. The chapters were selected on a rigid criteria of which novelty and new approaches were the main pillars.

Preface XI

**Dr. Zaki Ahmad (Professor Emeritus)**

King Fahd University of Petroleum and Minerals, Dhahran

C. Eng, UK, FIMMM, UK

Saudi Arabia

I would like to finish this preface by the famous saying of Albert Einstein "Any fool can make things bigger, but it takes a genius to make the things smaller". I hope this

small book would prove an asset in pursuit of knowledge on aluminum alloys.

I hope the book would be very useful for practicing engineers, technicians, senior students and all those interested in aluminum alloys in particular the technical staff of aerospace, automotive and defense industry. Chapters on casting, welding and others could be used to support their textbook at a graduate level. This book is profusely illustrated to make the concepts clear to the readers.

While editing the book I had the problems of shifting from one country other which prolonged my editing work for which I apologize.

I thank Mr. Mishaal Ahmed (my grandson), Manzar Ahmed, Intesar Ahmed, Shamsujehan, Huma Sabir and Abida Sultana, they provided me with the mental support for the work not the least, the spirit of my beloved dead son Intekhab Ahmed drove me through very hard times while reviewing the chapters.

I am very grateful to KFUPM who gave me the moral support. I am specially indebted to Dr Faleh Al Sulaiman vice rector of technology at KFUPM, Dr Nasir Aqeeli, Mr Faheemuddin and Mr Abdul Aleem of M.E department of KFUPM. I also thanks Dr M. Budair rector of Al-Jouf University for his moral support.

In the end I thank the Al Mighty to give me the moral courage to undertake the responsibility. I am grateful to InTech publisher for giving me the honor of being the chief editor of this book.

I would like to finish this preface by the famous saying of Albert Einstein "Any fool can make things bigger, but it takes a genius to make the things smaller". I hope this small book would prove an asset in pursuit of knowledge on aluminum alloys.

X Preface

the main pillars.

chief editor of this book.

dimensions in the field of casting. Dramatic changes in surface treatment have proved highly effective in the life cycle of aluminum alloys as shown by Shoja Razavi Reza, Wierzbinska Malgorzata, Lopez-Cellajas Regulo, Metikas Theodore and Morwka-Nowotnik Grazyna have added new data to new information. Improvements in surface topography and stability are only achieved successfully by combining electrochemistry, microstructures and the role of micro/nano particles new methods of surface modifications are described by Akbarzadeh Abbas, Timelli Giulio and Kornev Vladimir. Corrosion is a serious thread to aluminum alloys and aluminum based metal matrix composites reinforced by silicon carbide. A brief mechanism of corrosion of composited is given by Zaki Ahmad. Environmental damages such as corrosion fatigue in aluminum alloys and their mechanism have been described by Ghazali Mariam and Eichlseder Wilfried. The principle behind the chapters in book was an analysis of the procedures such as casting, forming, welding and environmental degradation which have a strong bearing on the integrity of aerospace structures and automotive. The authors have addressed the problems of grain refinement, micro segragation, casting defects, crack growth, weld defects to show to what levels the aluminum alloys have been technically elevated. The chapters were selected on a rigid criteria of which novelty and new approaches were

I hope the book would be very useful for practicing engineers, technicians, senior students and all those interested in aluminum alloys in particular the technical staff of aerospace, automotive and defense industry. Chapters on casting, welding and others could be used to support their textbook at a graduate level. This book is profusely

While editing the book I had the problems of shifting from one country other which

I thank Mr. Mishaal Ahmed (my grandson), Manzar Ahmed, Intesar Ahmed, Shamsujehan, Huma Sabir and Abida Sultana, they provided me with the mental support for the work not the least, the spirit of my beloved dead son Intekhab Ahmed

I am very grateful to KFUPM who gave me the moral support. I am specially indebted to Dr Faleh Al Sulaiman vice rector of technology at KFUPM, Dr Nasir Aqeeli, Mr Faheemuddin and Mr Abdul Aleem of M.E department of KFUPM. I also thanks Dr

In the end I thank the Al Mighty to give me the moral courage to undertake the responsibility. I am grateful to InTech publisher for giving me the honor of being the

illustrated to make the concepts clear to the readers.

prolonged my editing work for which I apologize.

drove me through very hard times while reviewing the chapters.

M. Budair rector of Al-Jouf University for his moral support.

**Dr. Zaki Ahmad (Professor Emeritus)**

C. Eng, UK, FIMMM, UK King Fahd University of Petroleum and Minerals, Dhahran Saudi Arabia

**Part 1** 

**Casting and Forming of Aluminium Alloys** 
