Professional Documents
Culture Documents
in Europe
means Added Value ?
Gary Mahon
gary.mahon@innovaltec.com
Scope
Fatigue 9 Pick-up 9
Other Scratches
50
0.06 Mn
40 50
30 0.03 Mn 0.03 Mn
20 0.06 Mn 25
0.09 Mn Pick-up
10
OK
0 0
0.40 0.45 0.50 0.55 0.60 0.65 0.40 0.45 0.50 0.55 0.60 0.65
wt.% Si wt.% Si
Brassard et al
Alcan
ET’04
N-Tec
1400
1200
CLEAN
(High Flow Rate)
Increasing Inclusion
Weight (g)
1000 Content
800
600
High
400 Inclusion
Content
200 (Low Flow Rate)
0
0 30 60 90 120 150
Time (s)
Aluminium
N-Tec
Inclusion band
Defect Mapping
Degasser
Transfer
Launder
Smelter
Casting
Holder
Filter grains
Melter
Filter
Wide Inclusion Band
Many Inclusions
Al4C3
(TiV)B2
Al Borocarbides
Al2O3 films & particles
MgO films & particles
Spinel films & particles
AlN
Refractory particles
Fe Mn oxides
Bone ash
Note this is not a comprehensive list
Detailed Metallography
Root-cause analysis
250 µm
Grain Structure
Al MgO
O
Water
Mg
C
Ca
Si S
10 µm Cl Ca
EDX spectrum
© Innoval Technology Ltd
IP07-047, Slide 10
Evaluation of Billet Quality – Intermetallics
25
p
Alpha: 46 %
20
Beta: 54 %
App. Conc. Fe+Mn
Alpha Standard
15
Beta Standard
10
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
App. Conc. Si
100
Bottom Middle Top
95
90
% alpha 85
80
75
70
65
60
55
50
Red superimposed image of Mg2Si Edge Mid radius Center Edge Mid radius Center Edge Mid radius Center
16000
Other
14000
Consumer Durables
Old scrap (thousand tonnes)
12000 Engineering
Packaging
10000
Building
8000 Other Transport
Automotive
6000
4000
2000
0
1950 1960 1970 1980 1990 2000 2003 2004 2010 2020
Feeding DC Caster
Centre Edge
Mg-Alloy AZ91D
LM25 (Al-10.3Si-0.3Cu-0.16Mn)
300 8 12
Yield UTS Elongation
7 MC
250 10
HPDC
Elongation (%)
6
Yield, UTS (MPa)
200
Elongation (%)
8
5
150 4 6
3
100 4
2
50 2
1
0 0 0
100%Scrap 50%Scrap Primary 0.4 0.6 0.8 1 1.2
Fe Content (wt.%)
EU Framework 7
Collaborative and International
50% funding
University Education
EU is continuing to invest in producing a high number of science and
engineering graduates.
Design
Die Coatings
New Profiles &
Cost Reduction to enable
Processes penetration into new markets
New Finishing
High Strength Aerospace Alloys Operations
Alloys
Weldable medium strength
6000-series Alloys
Product Differentiation
Metal Matrix Composites
Technically demanding
products
Realisation that investment in world class equipment does not on its own give
world class products.
Many examples in aluminium rolling mills and extrusion plants.
¾ Return on investments taking longer than planned
¾ Cannot match quality of world-class products
¾ Need expertise that equipment suppliers do not possess
gary.mahon@innovaltec.com