Monthly Archives: October 2011

6063 aluminium alloy Uses

6063 aluminium alloy uses

Uses
6063 aluminium alloy is used for architectural fabrication, window and door frames, pipe and tubing, and aluminium furniture.

Welding
6063 aluminium alloy is highly weldable, using tungsten inert gas welding. Typically, after welding, the properties near the weld are those of 6063-0, a loss of strength of up to 30%. The material can be re-heat-treated to restore a higher temper for the whole piece.

Extrusions
6063 is widely used in the production of extrusions – long constant-cross-section structural shapes produced by pushing metal through a shaped die. These include “L” and “U” shaped channels and angles.

Aluminium

Aluminium

Aluminium or aluminum  is a silvery white member of the boron group of chemical elements. It has the symbol Al and its atomic number is 13. It is not soluble in water under normal circumstances. Aluminium is the most abundant metal in the Earth’s crust, and the third most abundant element, after oxygen and silicon. It makes up about 8% by weight of the Earth’s solid surface. Aluminium is too reactive chemically to occur in nature as a free metal. Instead, it is found combined in over 270 different minerals.The chief source of aluminium is bauxite ore.

Aluminium is remarkable for the metal’s low density and for its ability to resist corrosion due to the phenomenon of passivation. Structural components made from aluminium and its alloys are vital to the aerospace industry and are very important in other areas of transportation and building. Its reactive nature makes it useful as a catalyst or additive in chemical mixtures, including ammonium nitrate explosives, to enhance blast power.

Despite its prevalence in the environment, aluminium salts are not known to be used by any form of life. Also in keeping with the element’s abundance, it is well tolerated by plants in soils (in which it is a major component), and to a lesser extent, by animals as a component of plant materials in the diet (which often contain traces of dust and soil). Soluble aluminium salts have some demonstrated toxicity to animals if delivered in quantity by unnatural routes, such as injection. Controversy still exists about aluminium’s possible long-term toxicity to humans from larger ingested amounts.

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6063 aluminium alloy Mechanical properties

6063 aluminum alloy mechanical properties

The mechanical properties of 6063 aluminium alloy depend greatly on the temper, or heat treatment, of the material.

6063-O
Un-heat-treated 6063 has maximum tensile strength no more than 19,000 psi (131 Mpa), and no specified maximum yield strength. The material has elongation (stretch before ultimate failure) of 18%.

6063-T1
T1 temper 6063 has an ultimate tensile strength of at least 17,000 psi (117 MPa) in thicknesses up to 0.5-inch (13 mm), and 16,000 psi (110 MPa) from 0.5 to 1.0-inch (25 mm) thick, and yield strength of at least 9,000 psi (62 MPa) in thickness up to 0.5-inch (13 mm) and 8,000 psi (55 MPa) from 0.5 to 1.0-inch (25 mm) thick. It has elongation of 12%.

6063-T4
T4 temper 6063 has an ultimate tensile strength of at least 19,000 psi (131 MPa) in thicknesses up to 0.5-inch (13 mm), and 18,000 psi (124 MPa) from 0.5 to 1.0-inch (25 mm) thick, and yield strength of at least 10,000 psi (69 MPa) up to 0.5-inch (13 mm) and 9,000 psi (62 MPa) from 0.5 to 1.0-inch (25 mm). It has elongation of 14%.

6063-T5
T5 temper 6063 has an ultimate tensile strength of at least 22,000 psi (152 MPa) in thicknesses up to 0.5-inch (13 mm), and 21,000 psi (145 MPa) from 0.5 to 1.0-inch (25 mm) thick, and yield strength of at least 16,000 psi (110 MPa) up to 0.5-inch (13 mm) and 15,000 psi (103 MPa) (from 0.5 to 1.0-inch (25 mm). It has elongation of 8%.

6063-T6
T6 temper 6063 has an ultimate tensile strength of at least 30,000 psi (207 MPa) and yield strength of at least 25,000 psi (172 MPa). In thicknesses of 0.124-inch (3.1 mm) or less, it has elongation of 8% or more; in thicker sections, it has elongation of 10%.

Other tempers
6063 is also produced in tempers T52, T53, T54, T55, and T832, with various improved properties.

Aluminum extrusion process

Aluminum extrusion process

Extrusion is defined as the process of shaping material, such as aluminum, by forcing it to flow through a shaped opening in a die. Extruded material emerges as an elongated piece with the same profile as the die opening.
The first step is to choose the desired shape and color. Think of the shape as the die which will be used and the color as the temper and alloy needed. Next, the billet is inserted into the holding chamber and pressure is applied to the handle, which forces billet through the shape.

Press size determines how large of an extrusion can be produced. Extrusion size is measured by its longest cross-sectional dimension. The most important factor in the extrusion process is temperature. Temperature is most critical because it gives aluminum desired characteristics such as hardness and finish.

The steps in the extrusion process are as follows:

1. Billets must be heated to approximately 800-925 ¢X F.

2. After a billet reaches the desired temperature, it is transferred to the loader where a thin film of smut or lubricant is added to the billet and to the ram.

3. The billet is transferred to the cradle.

4. The ram applies pressure to the dummy block which, in turn, pushes the billet until it is inside the container.

5. Under pressure the billet is crushed against the die, becoming shorter and wider until it has full contact with the container walls. While the aluminum is pushed through the die, liquid nitrogen flows around some sections of the die to cool it. This increases the life of the die and creates an inert atmosphere which keeps oxides from forming on the shape being extruded.

6. As a result of the pressure added to the billet, the soft but solid metal begins to squeeze through the die opening.

As an extrusion exits the press, the temperature is taken with a True Temperature Technology (3T) instrument mounted on the press platen. The 3T records exit temperature of the aluminum extrusion. The main purpose of knowing the temperature is to maintain maximum press speeds. The target exit temperature for an extrusion is dependent upon the alloy. For example, the target exit temperature for the alloys 6063, 6463, 6063A, and 6101 is 930¢X F (minimum).

7.Extrusions are pushed out of the die to the leadout table and the puller, which guides metal down the run-out table during extrusion. While being pulled, the extrusion is cooled by a series of fans along the entire length of the run-out and cooling table.

8. When the extrusion reaches a desired length, the extrusion is cut with a profile saw or a shear.

10.Metal is transferred (via belt or walking beams systems) from the run-out table to the cooling table.

11. After the aluminum has cooled and moved along the cooling table, it is then moved to the stretcher. Stretching straightens the extrusions and performs ‘work hardening’ (molecular re-alignment which gives aluminum increased hardness and improved strength).

12.The next step is sawing. After extrusions have been stretched they are transferred to a saw table and cut to specific lengths.