Alcoa Aluminum: Rolled Products

Dr. J. Daniel Bryant

Technical Fellow, Alcoa Technical Center (Pittsburgh, Pennsylvania)

1

March 18, 2015

2

Alcoa covers every stage of aluminum production

and is a leader in major end markets O

pera

tio

ns

Upstream (41%) Bauxite mining

Alumina refining

Aluminum smelting

Aluminum recycling

Downstream (26%) Fastening Systems

Super-alloy castings

Wheel & Transportation

Building & Construction

Forgings & Extrusions

Midstream (33%) Aluminum Sheet & Plate

Aluminum Can Stock

Primary

Aluminum

Automotive

Transportation

Packaging

Building/

Construction

Aerospace

Industrial

Oil & Gas

Consumer

Electronics

$7.5bn $6.1bn $4.8bn

Alcoa Global Packaging (AGP)

Aero, Transportation & Industrial (ATI)

China & Consumer Electronics (CRP)

Global Rolled Products

– a global business spread across 5 continents

North

America

Europe Russia

Middle

East

Australia

Latin

America

Market-facing Global Business Units… …with a Global footprint

China

Product Lines:

• Can (Beverage & Food)

• Specialty Foil

• Industrial

Product Lines:

• Commercial Aerospace

• Auto Body & Brazing

• Industrial

• Commercial Transportation

Product Lines:

• Can (Beverage)

• Brazing

• Commercial Transportation

• Consumer Electronics

3

GRP business unit structure and operating locations

Research Directions at Alcoa Technical Center in Sheet and Plate Products:

1. Improve Process Efficiency:

• improve conversion (secondary processing) efficiency

• reduce scrap (improve recovery –planned and unplanned)

• improve output (ROC)

• reduce labor content per kg

2. Improve Sustainability

• reduce effluent (solids, volatiles, etc.)

• reduction in greenhouse gas generation

• improve recycling

3. Introduce Improved Products

• superior process performance (for our processes)

• superior process performance (for our customers’ processes)

• superior service performance (for their customers)

4

Alcoa Technical Center:

Our Role in Global Rolled Products

The fundamentals: What is rolling?

….a process in which

a material is passed

between two parallel

rotating rolls, causing

the material to be

reduced in thickness

and increased in length

If there is no lateral spreading of the sheet, i.e. ew = 0,

(usually when w >>t) then et = -el and we call this plane strain

If there is any spread in the width direction

(ew 0) it is no longer plane strain

Sheet and Plate Manufacturing

Example: Davenport Works - 65 Years Serving Our Customers

• Began production in 1948

• $716M in Total Assets

• 132 acres under roof

• 2,300 employees

• 110 alloys, 8,000 specs

• 1,100 global customer locations

Operations:

• Metal Purification

• Casting

• Rolling, Stretching

• Sawing/Machining

• Heat Treatable & Non-Heat Treatable

• Sheet & Plate

Diversified Product Base:

• Aerospace and Defense

Sheet & Plate

• Automotive Sheet

• Industrial Sheet & Plate

• Commercial Transportation

6

Sheet and Plate Manufacturing at Davenport Works

• Ships 500 million lbs/yr. or 1.3 M lbs. a day of finished product

• Produces plate products up to 220” wide and 110 feet long

• Three reversing hot mills, 220” wide, 160” wide, 144” wide

• 100” 5 stand hot mill

• Two 100” cold mills

• 86” wide continuous heat treat line

• New 88” wider continuous heat treat line (exclusively for automotive)

• Two vertical heat treat lines

7

Sheet and Plate Manufacturing

Theme:

Understanding the metallurgical thinking and microstructural changes as we

follow aluminum through the processing flowpath....

8

Sheet and Plate Manufacturing: Ingot

9

Multiple ingots are cast at a

single composition using

direct chill (DC) casting

To remove “liquated” layer and provide a flat surface

for rolling, ingots are scalped prior to homogenization

10

250 microns

Solidifies as dendritic grains

(also known as: cells/crystals)

Constituent

Particles

Non-uniform tinting

within grains is due to

the non-uniform distribution

of elements such as Mg, Mn, etc.

Tracking the Metallurgical Evolution: As-Cast Microstructure

11

Tracking the Metallurgical Evolution: As-Cast Microstructure

50mm

Si - much of it combines with Mg

to form Mg2Si particles.

(these appear dark as-polished)

Fe - very low solubility in solid Al

It tends to form Al3Fe and Al12Fe3Si2

type particles in the last stages

of solidification – these are constituents

Aluminum Matrix -

has Mg, Mn*, Cu, etc.

dissolved within it -

usually not uniformly

distributed

* Mn, like Fe, is also has low

solubility in solid Al - but is

unable to partition into

liquid during solidification

and gets trapped in solid.

Will come out during ingot

homogenization as dispersoids

Constituent Particles

5182 Can End Stock

12

Mn, although highly

insoluble in Al

was trapped in solid

during solidification

During the long thermal

exposure during

ingot homogenization, Mn

is able to diffuse and

form discrete dispersoids

of Al6(Mn,Fe)

...and perhaps also some

Al12(Mn,Fe)3Si2

Tracking the Metallurgical Evolution: After Homogenization

3104 Can Stock

4-high

work rolls

backup roll

backup roll

2-high

reversing

2-high

5-stand tandem mill

slab

Load = Pressure x Area

Load = Pressure x (WxL)

So, Load a L

… and a smaller work roll diameter

therefore results in lower loads

What is the advantage of a

smaller work roll diameter?

L1 L2

Sheet and Plate Manufacturing: Hot Rolling

220-in. Hot Reversing Mill - Davenport

Sheet and Plate Manufacturing: Hot Rolling

Sheet and Plate Manufacturing: Hot Rolling

15

Ingots are rolled down to progressively

thinner gauges in reversing mills.

Deforming becomes more plane strain

(the sheet maintains its width and gets

progressively longer) as rolling proceeds.

Rolled plate seen on the run-out table to

the right...

5-Stand Hot Continuous Mill used for rolling to sheet thicknesses (“hot band”)

Sheet and Plate Manufacturing: Hot Rolling

17

Coil After Exit from Hot Continuous Mill

Sheet and Plate Manufacturing: After Continuous Hot Rolling

Hot rolled coils, with gauges in

the 2mm to 8 mm range, are

now either given an anneal

treatment or are passed

directly to cold rolling to

reduce the gauge and modify

the crystallographic texture

18

Unannealed hot rolled microstructure

Hot rolled products can be

come off the mill fully

recrystallized, partially

recrystallized or

unrecrystallized, depending

on the alloy, the reduction

schedules and the rolling

temperature.

When recrystallization occurs

the elongated, strained hot

rolled grains are replaced by

a new set of low aspect ratio,

strain-free grains

Hot rolled product, therefore,

can be either self-annealed

or unannealed

A batch anneal (also called

an hot line anneal or

intermediate anneal) can be

imposed to complete

recrystallization, if so

desired...

Tracking the Metallurgical Evolution: Annealing after Hot Rolling

Partially annealed hot rolled microstructure

Fully annealed hot rolled microstructure Partially annealed hot rolled microstructure

19

Tracking the Metallurgical Evolution: Cold Rolling and Annealing

Path 1 Path 2 Path 3 Path 4

Cold Roll 50% Cold Roll 33% Anneal Cold

Roll

60%+

Anneal Anneal

Cold Roll 20% Cold Roll 40% Cold Roll 60%

Anneal

33 mm 18 mm 13 mm 10 mm

As-Hot Rolled 5xxx...

Yield Strength

88 MPa

Yield Strength

101 MPa

Yield Strength

91 MPa

Yield Strength

105 MPa

20

Crystallographic Texture: Controlling Anisotropy

After exiting the hot continuous mill, the

strip recrystallizes….

new grains

nucleate among

hot deformed

grains

grains grow grains impinge fully recrystallized

Some/many of the

recrystallized grains

are of the cube

orientation….

When the cube faces of face

centered cubic crystal structure

of Al is lays in the sheet plane

& FCC edges are parallel to

rolling direction, we have

cube texture

RD

21

The cube texture from hot rolling imparts ‘0-90o’ earing

tendencies to the recrystallized strip….

0 90 180 270 360

0-90o earing of cube texture

100% cube texture

50% cube + 50% random

100% random

Heig

ht of C

up (

arb

itra

ry u

nits)

angle from rolling direction, degrees

Crystallographic Texture and Earing

22

The cold rolling texture causes ears to be

formed at all locations ~45o from RD

(actually closer to 48o)….

0 45 90 135 180 225 270 315 360

45o earing of rolling texture

Heig

ht of C

up (

arb

itra

ry u

nits)

angle from rolling direction, degrees

Crystallographic Texture and Earing

Rolli

ng D

irection

Rolli

ng D

irection

23

So, the secret to low earing is to product the right amount of cube texture in the hot

rolling process to balance with the texture subsequently introduced in cold rolling to

final gauge….

0-90o earing of cube texture

Heig

ht of C

up (

arb

itra

ry u

nits)

0 45 90 135 180 225 270 315 360

well balanced earing

Heig

ht of C

up (

arb

itra

ry u

nits)

angle from rolling direction, degrees

So while zero earing is only possible with random textures, earing can be

reduced by balancing crystallographic textures introduced in different steps in

the rolling process...

0 45 90 135 180 225 270 315 360

45o earing of rolling texture

Heig

ht

of

Cup

(arb

itra

ry u

nits)

angle f rom rolling direction, degrees

+ =

Crystallographic Texture and Earing

24

Real World Example:

Aluminum Can Stock

AA3104

0 45 90 135 180 225 270 315 360

Heig

ht of C

up (

arb

itra

ry u

nits)

angle from rolling direction, degrees

Crystallographic Texture and Earing

0 45 90 135 180 225 270 315 360H

eig

ht of C

up (

arb

itra

ry u

nits)

angle from rolling direction, degrees

Real World Example:

Aluminum End Stock

AA5182

25

Crystallographic Texture

Control is Important for

Manufacturability:

Forming

Hemming

Isotropy in Properties

But it is also Important for

Service Performance:

Surface Appearance

Aluminum Automotive Bodysheet

Alcoa Automotive Engineering

2002B

Inner sheet aluminum release after Analyses

Crystallographic Texture In Automotive Sheet

26

Crystallographic Texture: Automotive Bodysheet

Surface appearance in

aluminum autobody sheet

can be compromised by

bands of cube oriented

grains that are remnants

from the hot rolling

process. These “ridging” or

“roping” lines are a cause

for rejection....

27 August 2007

1 in 3 trucks in North

America ride on Alcoa

Wheels

Examples of Alcoa Products Used on Commercial Vehicles

Typical Steel truck wheel weighs 35 kg

versus typical aluminum truck wheel

weighs 21 kg (roughly 40% savings)

28

Trailers

• 95% of gasoline tankers are aluminum in the US

• Powered Bulk haul trailers with pressurized

material movement are normally aluminum in the US

• Dump truck boxes in aluminum are common

29

Use Alloy Key Attributes

Chassis, Trailer Frames 6061-T6 extrusion Strength, fatigue*

Side Sheets 3004, 5052-H291 Painted, durability

Roof 3003-H1x Wide width

Fuel Tanks 5052-O Impact resistance*

Compressed Air 5083, 5754, 5154 Impact resistance*

Wheels 6061-T6 Fatigue, surface, wear

Cab Sheets 6022, 6111-T4, 5182-O Formability

Bumpers 6061, 5xxx Surface, strength

Trim Various 3xxx, 5xxx Good surface

Application of Aluminum in Commercial Transportation

30

Precipitation Strengthening: High Strength Aerospace Alloys

Aluminum Alloys for Aerospace

Alcoa “invented “ aluminum alloy development...

First recorded alloy 1100 (2S) developed in 1888

3003 (3S) followed in 1906

First important heat treated alloy was 2017 (1916), followed by 2025

(1921), and 2014 (1928)

2024 appeared in 1932 and is still a workhorse alloy for aerospace

First important high strength alloy was 7075 (1942)

large majority of commercially important aerospace alloys developed by

Alcoa

…and we have been innovating ever since

Important aerospace alloys developed by Alcoa:

2014, 2017, 2024, 2124, 2219, 2519, 2524, 2026, 2624, 2090,

2099, 2060, 2055

6061, 6013

7075, 7175, 7475, 7178, 7050, 7150, 7055, 7085, 7255

Important tempers developed by Alcoa

T73, T76, T74, T77

Aluminum Alloys for Aerospace

1910 1920 1930 1940 1950 1960 1970 1980 1990 2000

Spar &

Thick

Product

Upper Wing

Fuselage

Lower

Wing

Military &

Space

Unialloy

7050-T7451 7085-T7651

A380

2017-T4 2024-T3

DC3

2090-T83

2097

2195-T8M4

Space Shuttle

2324-T39

757/767

2624-T39

2026-T3511

7075-T651

B29

7178-T651

707

7075-T7351

7075-T7651

L1011

7150-T651

757/767

7150-T6151

A310/MD11

7055-T7751

777

7150-T7751 7255-T7951

A380

2524-T3

777

6013-T651

A380

2005

2099-T83 A380

7085-T7652

2060-T8E30

C919

7055-

T76511

7085-T7451

2624-T351

A340-500/600

Alcoa Aluminum Aerospace Alloy Development History

2020-T651

A5

2099-T86

787

7085-T7452

F-35

7085-T7452

787

7475-T7351

2010

2040-T6

F-35

2099-T81 A380

34

The product of aging of Al-

Cu-Li Alloys: strengthening

precipitates...

Precipitation Strengthening: High Strength Aerospace Alloys

3rd Generation Al-Li alloys have been developed by optimizing alloy

composition, TMP and tempering for a good balance of:

Density

Strength and toughness balance

Low anisotropy of mechanical properties

Fatigue crack growth resistance

Corrosion resistance

Thermal stability

Manufacturability

Attractive applications are being identified for lower wing, upper wing,

fuselage, thick sections of civil transport in addition to military and space

applications

3rd Generation Al-Li Alloys

36

1. Manufacture of Rolled Aluminum Products is a Multi-Step Operation

• Ingot Casting

• Homogenization

• Scalping

• Hot Rolling

• Intermediate Annealing

• Cold Rolling

• Heat Treatment (coil annealing, continuous heat treatment, aging)

2. Thermo-Mechanical Processing is used to Control Product Gauge, Properties and

Anisotropy

• Strength

• Toughness

• Corrosion Resistance

• Surface Appearance

• Crystallographic Texture

3. The Microstructural Evolution through the Process Guides Metallurgical Decisions

Summary