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Al-Azhar University
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ABSTRACT:
The paper examines the solution heat treatment of an extruded 6063 aluminum alloy using
eddy current testing (as a NDT tool). The study shows that the strength and fracture resistance
of this metal alloy can be influenced to an appreciable extent by the solution heat treatment
used in this investigation and can be detected by applying the non-destructive techniques by
relating it to the relative electrical conductivity.
AA 6063 alloy was casted using direct shell technique, and then being extruded to obtain high
strength (T4) condition, specimens were Solution Treated (S.T) at 550o C for 3 hours, then
quenched in fresh water, followed by artificial aging for different times and temperatures.
That treatment leads to microstructures evolution and so different states. The material alloy
under investigation record high strength at specified limits which are (120 o C for 10 h aging
time and 180 o C for 6 h that called (T6) condition. where after that limit the strength
decreased. Applying ECNDT technique lead to produce a profile look like that profile results
from hardness and tensile results, so characterization of such properties can be carried on
using ECNDT, and that satisfy aim of work.
As all engineering industrial applications subjected to loads that can considered at the elastic
region so fabricated extensometer was manufactured to represent that loads and measure the
relative conductivity; it can be noticed that the relative electrical conductivity being increased
slightly and so we can see that as displacement increases the relative electrical conductivity
increased.
1. INTRODUCTION
A variety of mechanical properties could be changed during alloy working; these changes can
affect the engineering projects, resulting in expensive repairs. One key component for
ensuring such mechanical properties changes is inspection and monitoring for detection and
characterization of the properties. In-service inspection of alloy can be carried out using eddy
current (EC) bobbin coils, which are adequate for the detection of such changes. [1]
Aluminum is a very light metal with a specific weight of 2.7 kg m-3, about a third that of steel.
Pure, untreated aluminum is a soft metal with insufficient strength for most engineering
applications. Its strength can be adapted to the application required by modifying the
composition of its alloys and by various thermal and mechanical treatments. [2]
Alloys in the 6xxx series contain silicon and magnesium approximately in the proportions
required for the formation of magnesium silicates (Mg2Si), thus making them heat treatable.
Although they are not as strong as most 2xxx and 7xxx alloys, 6xxx series alloys have good
formability, Weldability, machinability, and corrosion resistance with medium strength.
Alloys in this heat treatable group may be formed in the T4 temper (solution heat treated but
not precipitation heat treated) and strengthened after forming to full T6 (solution heat treated
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plus precipitation heat treated). Uses of Al-Mg-Si alloys include architectural applications,
bicycle frames, transportation equipment, bridge railings, and welded structures. [3]
Aluminum alloys are extensively used as structural materials in the nuclear industry such as
in fuel cladding and reactor cores because of their good corrosion resistance and very low
capture cross-section for fast and thermal neutrons. In the past, the choice of a particular alloy
for use as a structural material was based on the measured properties of the un-irradiated
material. [4]
The ability to control the working stresses level in mechanical components and structures is
an important factor in engineering industries. Evaluation and monitoring of the stress state of
these elements is time consuming, because of the conventional techniques involved. [5]
D.E.Esezobor, S. O. Adeosun [6], examined the solution heat treatment of an extruded 6063
aluminum alloy. The study shows that the strength and fracture resistance of this metal alloy
can be influenced to an appreciable extent by the solution heat treatment used in this
investigation.The ultimate tensile strength (UTS) increases as the solution time increases
from 6 to 20 hours for treatment temperature of 90o C. The maximum UTS (198.8MPa and
188.6 MPa) occur at 120o C and 150o C respectively at the solution holding time of 10 hours.
While, at 120o C and 10 hrs. the UTS are relatively the same as the as-received specimen,
though the latter exhibits a higher fracture stress. Annealing at 470 o C results to lower UTS
value (114.3MPa) and poor fracture resistance (522MPa). [6]
2. EXPERIMENTAL PROCEDURES
2.1 Material
The material used in this study is 6063 aluminum alloy with the chemical composition shown in
Table I. The specimens used in this experiment having dimensions of [30*35] and thickness of 8 mm.
2
Table I. Chemical Composition of Aluminum Alloy 6063
(Weight Percent)
Al 98.9 % Mg 0.457 % Si 0.411 % Fe 0.158 %
Pb 0.0014 % Cu 0.0002 % Cr 0.0008 % Ti 0.012 %
Sn 0.0010 % Mn 0.037 % Ni 0.0037 % Ag 0.0001 %
Sr 0.0001 % V 0.011 % Zn 0.0010 % B 0.0024 %
Be 0.0005 % Bi 0.0010 % Ca 0.0007 % Cd 0.0001 %
Co 0.0010 % Li 0.0001 % Na 0.0006 % P 0.0051 %
2.2 Casting:
The alloy under investigation was direct shell casted, homogenized at 525°± 10° C followed with
formation under extruation to obtain T4 condition.
Using (EQUOTIP2) made in Switzerland, and taking BHN for the heat treated and as received
specimen.
- The specimens were grinded and polished using emery papers, starting at 600 till final polishing
stage, followed with suitable etching.
- A licka optical microscope was used to investigate the microstructure evolution
3
2.6 Non-Destructive Testing (NDT) Instruments:
The measurements of attenuation were carried out using the Elotest B1&B2 “SDM” (Eddy Current
Testing) instrument with bobbin probe. Eddy current test is a method for the inspection of metallic part,
in this technique the probe which is excited with an alternative current, induces eddy current in the part
under inspection.
2-7 Extensometer (stress application at elastic region)
Some tensile specimens were stretched within the elastic limit with different displacement values. Start
at zero till about 2mm. the corresponding loads were estimated from load- displacement diagram.
The extensometer was calibrated due to the tensile machine used; it found that every two loops are
equal to 0.2543 mm displacement. The extensometer was designed and fabricated for testing purposes;
geometry of fabricated extensometer used is shown in figure 2.
170° C 180° C
200° C 220° C
Fig.3 the microstructure evolution for different aged specimens at 6h (aging time)
The microstructures of the specimens show that the structure was changed and that due to formation of
precipitates, this precipitates strength the structure and made it harder.
4
The following states were recorded at same aging time (6 h) and different aging temperatures:
- The precipitates were dissolved by solution treating of samples at 550° C for 3 h.
- The precipitates start to grow with increasing aging temperature where its density increased
at 120° C reaching maximum in segregation and density at 180° C and then decrease with increasing
temperature that refer to that high temperatures after that limit start to dissolve precipitates.
- Precipitates were found on the grain boundaries and that make grains more strength, increasing aging
temperature make such precipitates depilates.
- EDX of such states was carried to show phases and precipitates formed to ensure variation and
determine precipitates nature. Where the following figures show such assay.
3.2. EDX (precipitates analysis)
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Fig.7 EDX for aged (200- 6h) specimen
6
BHN Poly. (BHN)
85
75
65
BHN
55
45
35
as cast
BH 120-2h
BH 120-4h
BH 120-6h
BH 120-8h
BH 170-2h
BH 170-4h
BH 170-6h
BH 170-8h
BH 180-2h
BH 180-4h
BH 180-6h
BH 180-8h
BH 200-2h
BH 200-4h
BH 200-6h
BH 200-8h
BH 220-2h
BH 220-4h
BH 220-6h
BH 220-8h
Extruded spec.
BH 120-10h
BH 170-10h
BH 180-10h
BH 200-10h
BH 220-10h
ST
200
175
150
125
100
As Cast
120-10h
220-8h
120-2h
120-4h
120-6h
120-8h
170-2h
170-4h
170-6h
170-8h
180-2h
180-4h
180-6h
180-8h
200-2h
200-4h
200-6h
200-8h
220-2h
220-4h
220-6h
170-10h
180-10h
200-10h
220-10h
S.T
ext. spec.
Aging Time-Temperature
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realtive electrical conductivity relative elec.conductivity Poly. (relative elec.conductivity)
10
8
6
4
2
0
rolled
120-2H
120-4H
120-6H
120-8H
170-2H
170-4H
170-6H
170-8H
180-2H
180-4H
180-6H
180-8H
200-2H
200-4H
200-6H
200-8H
220-2H
220-4H
220-6H
220-8H
120-10H
170-10H
180-10H
200-10H
220-10H
as cast
S.T
Checking the hardness profile and compare it with the obtained conductivity values we see that the two
curves are typical in that at maximum hardness value the highest electrical conductivity was achieved
and that can be seen at fig.12.
The two curves can be noted that are same in the behavior so by animation we can detect that the two
results are same and by calibration of the alloy used in industrial plans to the standard and then using
eddy current techniques, we can obtain the harness profile due to variable times and temperatures
which (in service).As the hardness increased the electrical conductivity increased and as decreased it
was decreased. So that the hardness profile is look like the conductivity profile.
These results can satisfy the aim of the research as we can detect the change of mechanical properties
by using a NDT technique.
75
realtive elec. cond. --- BHN
60
45
30
15
0
220-2H
rolled
120-2H
120-4H
120-6H
120-8H
170-2H
170-4H
170-6H
170-8H
180-2H
180-4H
180-6H
180-8H
200-2H
200-4H
200-6H
200-8H
220-4H
220-6H
220-8H
120-10H
170-10H
180-10H
200-10H
220-10H
as cast
S.T
Fig.12 The conductivity profile vs. hardness for the different aging conditions.
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3.5. Extensometer (stress application in elastic region)
Using the fabricated extensometer to detect change in relative electrical conductivity due to change in
displacement due to yield stress, Using the Elotest B2, with specifying following standards:
¥= 0°, ƒ= 104 KHZ, ƪ = 38 dB, and encoding the aluminum as standard, the following results were
obtained. Fig.13, show that the relative electrical conductivity being increased slightly and so we can
see that as displacement increases the relative electrical conductivity increase and that refer to particles
elongation due to tension that make conductivity more active.
4
3.5
3
2.5
2
1.5
1
0.5
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4
displacement (mm)
That can be applied in the field by applying eddy current testing at the beginning of the project and
obtaining the result (which is considered as a default), periodically in service inspection should be
carried on and so any alteration can be recorded, relating this alteration with the displacement can give
a good imagination of displacement happen.
4. CONCLUSIONS
- This work has studied the material characteristics (taking AA 6063) using a NDT technique
(which is ECNDT).
- To obtain the highest mechanical properties of AA 6063, artificial aging is carried on to a
specified limit which is (aging temperature of 120° C at 10h and 180° C and at 6 h). Where
after that limit precipitates start to dissolve and values being decreased.
- Measuring relative conductivity of the alloy under investigation lead to obtain a profile which
like that represent the hardness and tensile profiles, and satisfy aim of work.
- As all engineering industrial applications subjected to loads that can considered at the elastic
region so fabricated extensometer was manufactured to represent that loads and measure the
relative conductivity; it can be noticed that the relative electrical conductivity being increased
slightly and so we can see that as displacement increases the relative electrical conductivity
increased.
- That can be applied in the field by applying eddy current testing at the beginning of the project
and obtaining the result (which is considered as a default), periodically in service inspection
should be carried on and so any alteration can be recorded, relating this alteration with the
displacement can give a good imagination of displacement happen.
- Detecting the mechanical behavior of the alloy by using eddy current testing is the important
step as it gives the chance for detection of mechanical properties during in service.
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REFERENCES
[1] L.Obrutsky, B.Lepine,J.Lu, R.Cassidy and J. Carter, “Eddy current technology for heat exchanger
and steam generator tube inspection", published by Atomic Energy of Canada Limited, Chalk River
Laboratories, Chalk River, Ontario, Canada, p.1, 2004.
[2] S. H. Avner, “Introduction to Physical Metallurgy", published by Mc Craw-hill Inc. NY, p.361,
364, 1964.
[3] “Properties and selection nonferrous alloys and special- purpose material", ASM handbook,
formerly tenth edition, Vol.2, p. 3-15, 32, 37-40, 44-57, 1991.
[6] D.E.Esezobor, S. O. Adeosun. “Improvement on the Strength of 6063 Aluminum Alloy by Means
of Solution Heat Treatment”, Material Science and Technology (MS&T), p.645-647, 2006.
[7] M. Zergoug, G.Kamel, N.Boucherou, “Mechanical Stress Analysis by Eddy Current Method”,
ECNDT, December 2006.and the Journal of American Science, Vol. 4, p.4, 2008.
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