COURSE UNIT TITLE

: ALUMINIUM TECHNOLOGIES

DEGREE PROGRAMMES

Description of Individual Course Units

Course Unit Code Course Unit Title Type Of Course D U L ECTS
MME 5059 ALUMINIUM TECHNOLOGIES ELECTIVE 3 0 0 8

Offered By

Graduate School of Natural and Applied Sciences

Level of Course Unit

Second Cycle Programmes (Master's Degree)

Course Coordinator

ASSOCIATE PROFESSOR ESRA DOKUMACI ALKAN

Offered to

M.Sc. Metallurgical and Material Engineering
Metallurgical and Material Engineering
Metallurgical and Material Engineering

Course Objective

The present course is intended to introduce the basic aluminium production technologies. This involves the primary production stage starting from bauxite mining to the production of alumina, which is then processed to commercial purity aluminium metal, as well as the secondary production regime where the commercial purity aluminium metal is first alloyed and then processed further to produce aluminium castings, aluminium forgings, aluminium sheet and foil and aluminium profiles. The production processes employed, the quality issues of industrial relevance and the applications of various shapes and alloys will all be discussed throughout the lectures.

Learning Outcomes of the Course Unit

1   To introduce the history of aluminium and the present state of this extraordinary metal and the impact it makes in our lives.
2   To introduce the primary and secondary aluminium production Technologies
3   To introduce the aluminium foundry as well as wrought alloys and their properties
4   To describe the applications of aluminium foundry and wrought alloys.
5   To underline the outstanding attributes of aluminium metal
6   To describe in detail the production processes employed by the aluminium industry here in Türkiye.
7   To describe the significance and the benefits of aluminium recycling and to outline the recycling Technologies employed at present.
8   To describe the quali,ty problems encountered in the production of aluminium castings, sheet, foil and profiles and the remedies and measures taken to couteract their negative impact

Mode of Delivery

Face -to- Face

Prerequisites and Co-requisites

None

Recomended Optional Programme Components

None

Course Contents

Week Subject Description
1 Brief history Why aluminium: attributes of the aluminium metal Primary production of aluminium Bauxite mining: where and how Production of alumina from bauxite: Bayer Process Production of aluminium metal from alumina: Hall-Heroult Process Commercial purity aluminium: higher purity aluminium (3N, 4N, 5N, 6N)
2 Secondary production Production flowcharts Shape casting Alloying: Effect of alloying elements Aluminium foundry alloys- alloy designations Melting aluminium Melting furnaces-gas fired-electric resistance-reverbatory-induction etc. Melt quality-melt treatment-fluxing; drossing; degassing; filtration; modification, grain refinement; fluidity
3 Applications of aluminium foundry alloys Heat treatment of aluminium foundry alloys
4 Wrought aluminium alloys Heat treatable vs non-heat treatable alloys Effect of alloying elements Wrought alloy designations semi-continuous casting process: Direct Chill casting to round ingot or to slab continuous casting processes: twin roll casting; twin belt casting; block casting to strip
5 DC casting-production of round ingot- homogenization-billet-pre-heating-extrusion-heat treatment-aluminium profiles DC casting-production of slab- scalping-homogenization-hot and cold rolling-aluminium sheet and plate
6 Twin roll-belt casting-production of reroll stock / coiled strip- cold Rolling to sheet and plate Sheet Rolling Foil Rolling (extreme/dark rolling); stack Rolling; characteristics of the foil Rolling process; how it is different from sheet Rolling; double rolling quality issues in the production of aluminium sheet mechanical properties; flatness of sheet; sheet anisotropy,
7 Midterm I.
8 Applications of aluminium foil Quality issues with aluminium foil-pinhole count; tears Packaging applications Converting applications; extrusion-lamination-printing etc.
9 Forging of aluminium alloys Process flow chart Types of aluminium forging stock-cast vs extruded Quality issues
10 Heat treatment of aluminium alloys Homogenization of coiled strip- DC cast ingots and slabs-soaking-cool down Pre-heating Interannealing in sheet processing-Softening-recrystallization Partial annealing-recovery Solution heat treatment Ageing heat treatment Temper designations: T4, T5, T6, T7 vs H1X,H2X, H3X, etc
11 Aluminium composites-cast composites Applications of aluminium composites Aluminium foam-production-properties of aluminium foam Aluminium powder metallurgy-rapid solidification processing of aluminium alloys
12 Midterm II.
13 Aluminium recycling economics impact of aluminium recycling on environment recycling Technologies state of aluminium recycling in TR
14 Metallography of aluminium alloys Typical aluminium foundry and wrought alloy microstructures Polishing aluminium alloys Etching aluminium alloys Bright-dark field metallography Coloured-barker practice for grain size Measurement of grain size and dendrite arm spacing

Recomended or Required Reading

Textbook(s): :
ASM Specialty Hanbook: Aluminum and Aluminum Alloys, Ed. Joseph R. Davis, ASM
Supplementary Book(s):
Materials: Training in Aluminium Application Technologies- TALAT lectures
Automotive manual-European Aluminium Association
Aluminium Association web site

Planned Learning Activities and Teaching Methods

formal education, exams and homework

Assessment Methods

SORTING NUMBER SHORT CODE LONG CODE FORMULA
1 MTE MIDTERM EXAM
2 ASG ASSIGNMENT
3 PRS 1 PRESENTATION 1
4 PRS 2 PRESENTATION 2
5 FIN FINAL EXAM
6 FCG FINAL COURSE GRADE MTE * 0.20 +ASG * 0.20 + PRS 1 * 0.15 + PRS 2 * 0.15 + FIN * 0.30
7 RST RESIT
8 FCGR FINAL COURSE GRADE (RESIT) MTE * 0.20 +ASG * 0.20 + PRS 1 * 0.15 + PRS 2 * 0.15 + RST * 0.30


Further Notes About Assessment Methods

None

Assessment Criteria

Mid-term, quiz and final exams: ÖÇ 1, ÖÇ 2, ÖÇ 3, ÖÇ 4, ÖÇ 5, ÖÇ 6, ÖÇ 7, ÖÇ 8
Homework and oral presentations: ÖÇ 2, ÖÇ 6, ÖÇ 7, ÖÇ 8

Language of Instruction

English

Course Policies and Rules

To be announced.

Contact Details for the Lecturer(s)

e-mail: esra.dokumaci@deu.edu.tr

Office Hours

Mondays: 11:30-12:15

Work Placement(s)

None

Workload Calculation

Activities Number Time (hours) Total Work Load (hours)
Lectures 14 3 42
Preparations before/after weekly lectures 14 2 28
Preparation for midterm exam 1 20 20
Preparation for final exam 1 30 30
Preparation for quiz etc. 0 0 0
Preparing assignments 1 20 20
Preparing presentations 2 25 50
Quiz etc. 0 0 0
Final 1 2 2
Midterm 1 2 2
TOTAL WORKLOAD (hours) 194

Contribution of Learning Outcomes to Programme Outcomes

PO/LOPO.1PO.2PO.3PO.4PO.5PO.6PO.7PO.8PO.9PO.10PO.11PO.12
LO.15
LO.25231
LO.35
LO.4523
LO.553
LO.6523
LO.75
LO.8511

CONTACT INFORMATION
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Phone: +90(232) 412 12 12 - Fax: +90 (232) 464 81 35

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