What is Aluminium? It is a chemical element, which is found naturally on Earth. It is the most abundant metal on our planet, as it makes up roughly 8% of the crust on the surface. It is very versatile, making it the second most used metal after steel in various ways such as in automobiles manufacturing and buildings. Centuries after industrial production of aluminum started, its demand globally has rapidly skyrocketed to about 29 million tons annually, where approximately 22 million tons is virgin aluminium. In comparison, 7 million tons are reused aluminum from scrap metal. Worth noting, aluminium is of the metals used in engineering since it has a strength to weight ratio that is greater to that of steel.
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Properties and advantages of aluminium
The advantages of using aluminium are associated with its remarkable properties as follows:
• Resistance to corrosion
When aluminium gets exposed to air and humid conditions, a layer of oxide skin is formed to protect the aluminium surface from extreme oxidation. This self-protecting oxide layer gives aluminium the resistance it has against deterioration, resistant against weathering even to the industrial atmosphere that facilitates weathering. Anodizing treatments can further be used to enhance the resistance of the oxide layer on surfaces.
Aluminium conducts heat and electricity excellently. The thermal conductivity of aluminium is about 50 to 60 percent that of copper, making it very applicable in large scale production of cooking utensils. Thermal conductivity relates to transfer from one medium to another; thus, aluminium heat exchangers used in the chemical, food, and aircraft industries. Aluminum's high conductivity (1350) is about 62 percent of the International Annealed Copper Standard (IACS) makes it effective for use and electrical conductor and has about a third of the specific gravity of copper.
Smooth aluminium has high reflectivity on the electromagnetic spectrum from the radio waves and into the infrared and thermal range. It bounces about 80% of light and 90% of the heat that strikes its surface. This high reflectivity gives aluminium a decorated appearance and makes it effective for use against radiation of light and heat in applications such as roofing and automotive heat shields.
The nontoxic nature of aluminium was discovered centuries ago in its first industrial use. This characteristic makes it suitable for use in cooking utensils without having harmful effects on the human body. It also facilitates its use in foil wrapping for food products in the processing industry.
The recycling of aluminium is unmatched. Notably, there is a significance difference in properties between recycled and virgin aluminium. About 5% of the energy used in producing virgin aluminum is needed to recycle aluminium. Currently, approximately 60% of aluminium is recycled towards the end of its life cycle.
For most of its applications, aluminium does not need a protective coating. Finishing techniques such as sandblasting, polishing, and wire brushing serve most of the finishing needs, and, in most cases, the surface finish used is adequate without the need for further finishing. Where pure aluminium or additional protection is needed, a wide range of surface finishes such as paint, chemical, and electrochemical techniques are applied.
Pure aluminium for commercial use has a tensile strength of 90MPa, making it very useful for structural materials. Working on it through processes such as cold rolling makes is stronger. Further increase in strength is made by alloying it with elements such as copper, manganese, and silicon at measured percentages. Alloys are much stronger and can be further strengthened through heat treatment.
The strength to weight ratio of aluminium is much higher than of constructional steel. This feature makes it suitable for designing and constructing strong and lightweight structures with many advantages for structures that move, such as ships, vehicles, and aircraft.
The ease of fabrication of aluminium is one of its most important features due to its lower degree of workability using any casting methods. Aluminium can be fabricated into the desired thickness from foil, which is thinner than paper to aluminum wires to be rolled, aluminum sheets that can be roll-formed, stamped, and drawn. Essentially, the speed and ease with which aluminium is machined contribute significantly to the low cost of producing aluminium parts. Aluminium metal can be turned, milled, and bored at high speed, which machines are capable coupled with its flexible nature.
Aluminium is malleable, meaning that it can be drawn into wires without breaking. However, its ductility lower than that of copper. Aluminium also has a low density and melting point. In molten form, aluminium can be cast in several ways due to its flexibility to produce desired products such as sheets, foils, tubes, and rods.
Aluminium and its alloys have proven to be useful in cold temperatures. Unlike other metals such as steel, which become brittle upon exposure to low temperatures, aluminium, and its alloys become stronger. Not only does the strength increase at low temperatures but also its tensile, yield, and impact measurements. Moreover, the corrosion resistance of aluminum increases at these conditions, making it suitable for use in cold and ice regions without accelerated breakdown due to the existence of moisture.
Aluminium, even when rolled like a foil, is 0.007mm thick and is sufficiently impermeable and does not emit smell or taste. Its is also non-toxic and coupled with its odorless and impermeable features makes it ideal for packaging products such as pharmaceuticals and foods.
Aluminium does not attract magnets and thus referred to as paramagnetic in layman’s language. This feature makes it ideal for shielding in antennas and computer disks.
Aluminium is a good absorber of sound, making it ideal for constructing roof ceilings and shock absorbers in automobiles. Aluminum foam, its porosity, material composition, thickness, and various types of treatment make it permeable to sound and shock.
Sources and further reading
Aluminium Alloy - General Information - Introduction to Aluminium and its alloys. Aalco.co.uk. Retrieved 27 May 2020, from http://www.aalco.co.uk/datasheets/Aluminium-Alloy_Introduction-to-Aluminium-and-its-alloys_9.ashx.
Asminternational.org. (2020). Key Characteristics of Aluminum. Asminternational.org. Retrieved 27 May 2020, from https://www.asminternational.org/documents/10192/3456792/06787G_Sample.pdf/c4151917-99fc-46e8-a310-d5578d0af160.
DJUKANOVIC, G. (2016). Aluminium alloys in shipbuilding – a fast growing trend. Aluminiuminsider.com. Retrieved 27 May 2020, from https://aluminiuminsider.com/aluminium-alloys-in-shipbuilding-a-fast-growing-trend/.
Aluminum offers a unique blend of benefits for manufactured metal nameplates and other industrial applications. In general, it is a relatively light metal, with a strong resistance to heat and corrosion. It is also reasonably malleable, with good thermal conductivity.
Aluminum as a Design Consideration
Design decisions are sometimes based on hasty assumptions and simplistic comparisons of aluminum and steel.
Yes, aluminum is more flexible, formable, and lightweight.
Yes, steel offers superior strength, durability, and resistance to corrosion.
Any assessment that stops here, however, is shortsighted.
To fully understand of the value of aluminum in industrial settings, we need to discuss:
aluminum alloys
anodized aluminum
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Cost-Benefit Analysis of Aluminum
The use of aluminum in industrial environments has steadily increased over time, and its price has remained less volatile than steel and other metals.
Of course, design engineers need to look beyond initial material costs to consider lifespan and the expense of maintenance, repair, and replacement.
These cost considerations depend on a broad range of aluminum features and benefits.
Important Features and Benefits of Aluminum
Strength and Durability: Many aluminum grades provide high strength and durability. There is no denying, however, that steel offers more strength than even the strongest aluminum alloys.
Temperature Resistance: Aluminum is resistant to elevated temperatures. Interestingly, its tensile strength increases at lower temperatures.
Weight: Aluminum is approximately one-third the weight of steel. This feature reduces unnecessary weight without sacrificing load capacity.
Thermal Conductivity: Aluminum has one of the highest levels of thermal conductivity (among common metals). This feature makes aluminum an excellent choice when heat dissipation or distribution is needed.
Formability: The malleability of aluminum allows for designs that are more intricate and complex, without the risk of cracking. This versatility makes aluminum suitable for products ranging from industrial nameplates to aerospace components.
Corrosion Resistance: Aluminum is a reliable metal that offers durability and resistance to corrosion and high temperatures, making it suitable for outdoor environments.
Fabrication Options: Aluminum offers great flexibility for a range of fabrication options: chemical etching, digital printing, embossing, laser marking, and screen printing. Finishing options are also expansive: anodization, multiple clear- and color-finish coatings, brushing, and polishing.
Aesthetic Appeal: The silverish white appearance of aluminum, along with its ability to support more precise design, imaging and color stability, make it an ideal choice when environments call for a blend of durability and aesthetics.
Aluminum Alloys
Aluminum alloys give design engineers a wide allowance for design flexibility.
Following is an overview of a handful of aluminum alloys:
Aluminum alloy 1100 is commercially pure aluminum that offers excellent corrosion resistance, high thermal conductivity, and good malleability. While this formability allows for more intricate design, it also offers less strength than some other aluminum alloys.
Aluminum alloy 1145 is a commercially pure aluminum alloy that provides high formability, good electrical conductivity, and corrosion resistance.
Aluminum alloy 5005 contains magnesium, which increases overall strength. Alloy 5005 also features low density, excellent thermal conductivity, and increased corrosion resistance in high-alkaline marine environments.
Aluminum alloy 5005 is an ideal choice for anodization, an electrochemical process that creates a thin oxide coating as a natural extension of raw aluminum. The resulting layer significantly increases hardness, durability, and resistance to corrosion.
Anodized aluminum is three times as hard as standard aluminum, yet it maintains a 60% weight reduction in comparison to steel. And, unlike a painted or applied protective coat, the newly formed anodized layer forms a nearly foolproof resistance to chipping, flaking or peeling.
Aluminum alloy 5052 offers exceptional corrosion resistance to seawater, salt spray, and other corrosive agents. It is a great option for marine and aerospace applications.
Aluminum alloy 6061 is relatively flexible and simple to process. Because it is an ideal grade for machining, aluminum alloy 6061 is a good choice for complicated designs and stringent specifications.
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