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2E14 Design of aluminium and stainless steel s tructures

2E14 Design of aluminium and stainless steel s tructures. František Wald. List of lessons. Aluminium structures HAZ softening Design of aluminium elements Design of aluminium connections Design beyond the elastic limit Aluminium advanced design Stainless steel structures

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2E14 Design of aluminium and stainless steel s tructures

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  1. 2E14Design of aluminium and stainless steelstructures František Wald

  2. List of lessons • Aluminium structures • HAZ softening • Design of aluminium elements • Design of aluminium connections • Design beyond the elastic limit • Aluminium advanced design • Stainless steel structures • Stainless steel material and material properties • Specialty in design of stainless steel structural elements • Connection design • Erection and installation of stainless steel structures • Stainless steel advanced design

  3. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Objectives of the lecture • Introduction to aluminium design • References • Examples • Material selection • Eurocodes for aluminium design

  4. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Advantages • Weight (2700 kg\m3) • Corrosion • Mon magnetic and low toxic • Fatigue, low ductility transaction temperature

  5. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Corosion

  6. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes References European recommendation for aluminium alloy structures, ECCS publication, No. 26, Brusel, 1978. Bulíček V.: Rules for design, production and erection,Směrnice pro navrhování, výrobu a montáž konstrukcí z hliníkových slitin, Technický zpravodaj r.11 č.4, Vítkovice, 1975. Mazzolani F. M.: Aluminium alloy structures (second edition), E & FN SPON, London, 1995. Mazzolani F. M.: Stability problems of aluminium alloys members, the ECCS methodology, v Structural Stability and design, Balkema, Rotterdam, 1995. Bulson P. S.: The new British design code for aluminium BS 8118, v Proceeding of the 5th International conference on aluminium weldments, INACO, Munich, 1992. Kosteas D.: European Recommendation for fatigue design of Aluminium Structures, v Proceeding of the 5th International conference on aluminium weldments, INACO, Munich, 1992. Bulson P.S.: Aluminium structural analysis: recent European advances, Elsevier, London, 1992, ISBN 1-85166-660-5. Educational program TALAT ww.eaa.net/eaa/education/TALAT

  7. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes History – Bridge Quebec 1947

  8. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes History – Bridge for airport terminal 1948

  9. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes History – Aluminium ship 1948

  10. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes History – Sceleton of car, Landover 1990

  11. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes History – Offshore helimodule, 1986 Helideck, Helihangar, Stairtowers and Support Structure

  12. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes History – Couch for subway 1992

  13. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Examples of application • Scaffolds • Platforms • Roofing • Mobil structures

  14. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Aluminium and its alloys • Pure Aluminium • Aluminium Alloys • Wroughtalloys • Casting alloys • Non-heat treatable alloys • Heattreatablealloys

  15. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Pure aluminium • Electrolyticsmelters • Cast into different shapes or forms suitable for manufacturing of semifinishedproducts • Level of purity a distinction is made between • commercial purity (99,5 - 99,8% aluminium) and • high purity (up to 99,98% aluminium)

  16. Alloying elements • Improve its strength(from 20 MPa to350 MPa) • Commonly used • Copper (Cu) • Magnesium (Mg) • Zinc (Zn) • Silicon (Si) • Manganese (Mn) • Otheralloyingelements • bismuth (Bi), boron (B), chromium (Cr), lithium (Li), iron (Fe), lead (Pb), nickel (Ni), titanium (Ti), zirconium (Zr), strontium (Sr) andsodium(Na) • in small quantities to achieve special metallurgical effects or properties,e.g. grain refining, machinability etc.

  17. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Adding lithium (Li) • Quantities of 3 to 5% • Improves the elastic modulus • Decreases the density. • Structural aluminium-lithiumalloys • restricted to aerospace applications • special care and attentionat • casting, • fabrication, • use • scrap recycling stages

  18. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Heat treatable and not treatable alloys

  19. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Heat treatment

  20. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes The nature of heat treatment • Heating for a prescribed period • at a prescribed temperature, then cooling rapidly fromthis temperature, • usually by quenching (solution heat-treatment). • Ageing • spontaneously at ordinary temperatures (natural ageing) • by heatingfor a prescribed period at a prescribed low temperature (artificial ageing). Theapplication of both solution heat-treatment and artificial ageing is often termed “fullheattreatment“

  21. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Solution treatmentHeating, quenching, artificial ageing, re-heat treatment • Heating Specified temperature rangeand heating length. Alloying constituentstend to diffuse from the core into the aluminium cladding. Castaluminium alloys need to be solution heat-treated for longerperiods than wrought aluminium alloys. • Quenching Plate, extrusions and strip may be discharged from a furnace horizontally andquenched by water sprays to minimise distortion. Distortion can alsobe reduced by decreasing the cooling rate using hot water or oil as a quenching mediumand this is often helpful with castings and forgings.

  22. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Solution treatmentHeating, quenching, artificial ageing, re-heat treatment • Artificialageing Hardening canbe accelerated by heating the solution heat-treated alloy in therange 100 - 200 °C for a suitable period. Maximum strength is generally achieved by prolonged ageing at low temperature ratherthan by rapid ageing at high temperature. • Re-heattreatment Alloys which have been incorrectly heat-treatedcan be re-solution treated and then precipitation treatedagain to enable optimum properties to be achieved. Clad material should not be re-heat treated.

  23. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Heat treatment • Non heat treatable (Non-age hardening) alloys • AlMg • AlMn • AlMgMn • AlSiCu • AlSi • Heat treatable (Age hardening) alloys • AlMgSi (6000 series) • AlZnMg(Cu) (7000 series) • AlCuMg (2000 series) • AlLi (8000 series)

  24. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Four digitalloy designation system • The first digit indicates the alloy group as follows: • The second digit indicates modifications of the original alloy or impuritylimits. • The last two digits identify the aluminium alloy or indicate the aluminiumpurity. • A letter used as a prefix indicates an experimental alloy. • A letter used as a suffix indicates national variations.

  25. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes The first digit indicates the alloy group • Al. 99,00 % purity and above 1xxx • Copper (Cu) 2xxx • Manganese (Mn) 3xxx • Silicon (Si) 4xxx • Magnesium (Mg) 5xxx • Magnesium and Silicon (MgSi) 6xxx • Zinc (Zn) 7xxx • Other element (eg. Li, Fe) 8xxx • Unused series 9xxx

  26. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Classification examples of commonly used alloys Int. reg. record EN 573 ISO 1050A Al 99,5 1070A Al 99,7 2017A AlCu4MgSi 3103 AlMn1 5052 AlMg2,5 5454 AlMg2,7Mn 5083 AlMg4,5Mn 6060 AlMgSi 6063 AlMg0,5Si 6082 AlSiMgMn 7020 AlZn4,5Mg1

  27. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Temper Designation F as-fabricated Fabricated products without special control O annealed Wrought products which are annealed to obtain the lowest strengthtemper H strainhardened Wrought products which have been cold worked W solutionheattreated Unstable temper applicable only to alloys which spontaneously age at roomtemperature T thermally treated to produce stable tempers other than F, O, and H Products which are thermally treated, with or without supplementarystrain hardening. The T is always followed by one or more digits.

  28. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes H-temper - strain hardened H1 strainhardenedonly The number following this designation indicates the degree of strainhardening . H2 strain hardened and partially annealed Applies to products that are strain hardened more than the desired finalamount and then reduced in strength to the desired level by partialannealing. H3 strain hardened and stabilized Applies to products which are strain hardened and whose mechanicalproperties are stabilized by a low temperature thermal treatment whichresults in slightly lower tensile strength and improved ductility. Thisdesignation is applicable only to those alloys which, unless stabilized,gradually age-soften at room temperature.

  29. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes H-temper - strain hardened Three-digit H temper designation H111 to products strain hardened less thanthe amount required for a controlled H11 H112 acquire some temper fromshaping processes H311 to products which are strain hardened less thanthe amount required for a controlled H31 temper. H321 toproducts which are strain-hardened less thanthe amount required for a controlled H32 temper H323/H343 to products which are specially

  30. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes T temper - thermally treated T4 solution heat treated and naturally aged to a substantiallytable condition to products which are not cold worked aftersolution heat treatment, or in which the effect of cold work in flattering orstraightening T5 cooled from an elevated temperature shaping process andthen artificially aged to products which are not cold worked aftercooling from an elevated temperature shaping process, or in which the effectof cold work in flattering or straightening T6 solution heat treated and then artificially aged toproducts which are not cold worked after solution heat treatment, or inwhich the effect of cold work in flattering or straightening may not berecognized in mechanical property limits.

  31. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Assessment 1 • What are the advantages of aluminium structures? • What is nature of heat treatment? • How is indicated the heat treatment?

  32. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Aluminium productsforstructuralapplications • Extrusions • Theextrusionprocess • Directextrusion • Indirectandhydrostaticextrusion • Extrusionsforstructuralapplications • Sheet and plate • Thecoldrollingprocess • Hotrolling • Alloysforrolledproducts • Casting alloys

  33. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Processing aluminium alloys

  34. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Wrought alloys • For fabrication by hot and cold formingprocesses • rolling, forging and extrusion. • Principalaloying elements • Magnesiumstrengthening element • added up to 5% by weight. • Zinc, copper and/or silicon + magnesium • very high strength alloys specialheat treatments. • Lead and bismuth • The machinability is increased by adding. • Copper and/or nickel,manganese or iron • Hightemperature strength properties

  35. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Casting alloys • For the fabrication of cast parts • High fluidity in theliquid state • Good resistance to hot cracking during solidification. • Castability • addition of silicon (7 to 13% Si) • the silicon content furtherup to 25% reduces the thermal expansion down to levels of iron and steel

  36. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Extrusion process • At temperatures400° - 500° C • using a pre-heated billet • Direct Extrusion • Indirect and HydrostaticExtrusions • Extrusion alloys • 6000-series (AlMgSi), and the • Extrusionspeed for the 6063 alloy • between20 and 70 m/min.

  37. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Extrusion process

  38. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Extrusion - examples • AlMn- 3000-series for drawn tubes • due to very high formability • excellent dimensional tolerance abilities • 2000-series or the 7000 series • trength performance • noweldability (Cu alloys) • potential danger of stress corrosion (Zn alloys). • AlMgSi6000-serie • majority of extrusions good overall performance i.e. • relativelyeasy to extrude • medium to high strength in the T6 condition • good corrosion resistance in marine and industrial environments • good weldability by all welding methods • good availability on the market, both as standard and special sections 6082(AlMgSi1Mn) T6 In Europenormal

  39. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Sections • Extrusion • Extrusion • Extrusion • Casting • Cold forming • Hot rolling

  40. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Sections • Extrusion • Extrusion • Extrusion • Casting • Cold forming • Hot rolling

  41. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Extrusion • Bulbs • Stiffners • Locks

  42. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Extrusion – preparation for welding

  43. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Extrusion - thicknesses

  44. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Extrusion – reccomended shapes

  45. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Hot rolling • Thick sheetings

  46. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Hot rolling • Non heat treatable alloys • 5052 (AlMg2.5) • 5083 (AlMg4.5Mn) • 5054 (AlMg2.7Mn) • Heat treatable alloys • 6082 (AlMgSi1) • 7020 (AlZn4.5Mg1)

  47. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Reverze hot rolling • Thin sheetings

  48. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Casting Alloys for Structural Applications • The typical alloys AlSiMg, AlSiCu, AlMg, AlCuTi and AlZnMg, • AlSi-alloys are preferred with respect to castability. • Sand casting • produced by pouring molten metal into a sand mold and allowing it tosolidify. • Permanent mold casting • produced by feeding molten metal by force of gravity or lowpressure into a mold constructed of durable material (iron or steel), and allowing it tosolidify. • Die casting • produced by injecting molten metal under high pressure into a metal moldor die and allowing it to solidify.

  49. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Advanced sheetings • Thin sheetings

  50. Objectives Introduction Examples of structures Structural alloys Designation system Assessment 1 Products Assessment 2 Material selection Eurocodes Assessment 2 Summary Notes Sandwitch panels - priciple • Thin sheetings

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