This article will provide you with everything you need to know about aluminum 1100 and its use.
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Aluminum 1100 is the softest among aluminum alloys, making it highly malleable and suitable for a variety of industrial and household applications. It can be both cold and hot worked, but is most commonly shaped through methods such as spinning, stamping, forging, and drawing. As a member of the 1000 series, Aluminum 1100 consists of 99% aluminum, with the remaining 1% comprising elements like copper, iron, magnesium, manganese, silicon, titanium, vanadium, and zinc. Its softness leads to gradual work hardening, which facilitates easier forming and shaping.
Aluminum 1100's excellent workability makes it ideal for crafting complex and intricate shapes. It is commonly used in the food industry and chemical processing due to its properties. Notably, Aluminum 1100 boasts the highest thermal conductivity among aluminum alloys and also exhibits strong electrical conductivity. Additionally, its exceptional resistance to corrosion and bright, polished finish make it a popular choice for decorative applications.
Aluminum 1100 is available in sheets, plates, wire, and foil of various thicknesses.
As with all types of aluminum, aluminum 1100 comes in different forms, which are categorized by the changes in the types of alloys that are added and their aluminum content. The key feature of all forms of aluminum 1100 is the purity of its aluminum content, a factor that makes it so formable and workable.
Aluminum 1100 is the purest of the aluminum alloys, with a composition of 99% aluminum. The remaining 1% consists of trace amounts of various other elements. When hard-tempered, Alloy 1100 exhibits exceptional machinability. Despite its softness and relatively low strength, it is widely used due to its excellent formability.
Of the various aluminum alloys, aluminum 1100 is ideal for cold working due to its easy formability and can be shaped and formed using all of the different forming methods including bending, drawing, and spinning. The easy formability of aluminum 1100 makes it possible to manufacture it into several shapes, which include billets, coils, sheets, ingots, and foil that are formed from melting raw aluminum and casting it. Unlike other aluminum alloys, the softness and pliability of aluminum 1100 makes it possible to have it rolled for the production of different products.
| Properties of Aluminum 1100 | |||
|---|---|---|---|
| Properties | Conditions | ||
| T (°C) | Treatment | ||
| Density (x1000 kg/m2) | 2.71 | 25 | |
| Poisson's Ratio | 0.33 | 25 | |
| Elastic Modulus (GPa) | 70-80 | 25 | |
| Tensile Strength (MPa) | 110 | 25 | H12 |
| Yield Strength (MPa) | 105 | ||
| Elongation (%) | 12 | ||
| Reduction in Area (%) | |||
| Hardness (HB500) | 28 | 25 | H12 |
| Shear Strength (MPa) | 69 | 25 | H12 |
| Fatigue Strength | 41 | 25 | H12 |
| Thermal Expansion (10-6/°C) | 23.6 | 25 | |
| Thermal Conductivity (W/m-k) | 218 | 25 | H18 |
| Electric Resistivity (10-9 0-m) | 30 | 25 | H18 |
Aluminum alloy 1145 contains slightly more aluminum than alloy 1100, with a composition of 99.45%. This higher aluminum content enhances its conductivity compared to 1100. Aluminum 1145 is also similar to aluminum 1235, which is often used as a substitute due to its greater availability.
Aluminum 1145 is commonly used as cold-rolled foil for packaging food, pharmaceuticals, medical devices, and cosmetics. In the construction industry, it serves in thermal, hydro, and sound insulation applications due to its reflective properties, which help reflect sound waves back into the environment.
| Elements in Aluminum 1145 | |
|---|---|
| Elements | Content (%) |
| Aluminum, Al | 99.45 (m) |
| Copper, Cu | 0.05 |
| Manganese, Mn | 0.05 |
| Magnesium, Mg | 0.05 |
| Zinc, Zn | 0.05 |
| Titanium, Ti | 0.05 |
| Silicon, Si + Iron, Fe | Remainder |
| Specifications in Aluminum 1145 | |
|---|---|
| Specifications | |
| ASTM Standards | B209 |
| Finish | Standard Finishes |
| QQA Standards | 1876 |
| Temper | Standard Tempers |
| Thickness | 0.0005 to 0.064 in |
| Width | 0.375 to 60 in |
| Density | 2.6-2.9 g/cm3 |
| Elastic Modulus | 70-80 GPa |
| Poisson's Ratio | 0.33 |
Aluminum 1199 has the highest purity of aluminum with an aluminum content of 99.99%. Its low density has led to its extensive use in the aerospace industry. The purity and resistance to corrosion of aluminum 1199 has made it an ideal aluminum for use in the food and chemical industries as cookware and pressure vessels. The abundance of aluminum 1199 has made it less expensive than other metals and is the reason for its wide use. All aluminum alloys possess some level of resistance to corrosion. This is especially true for aluminum 1199. Its high aluminum content gives it exceptional electrical and thermal conductivity, which makes it ideal for use in the manufacture of conductors, capacitors, heat exchangers, and equipment for chemical production.
| Elements in Aluminum 1199 | |
|---|---|
| Elements | Content (%) |
| Aluminum, Al | 99.99 min |
| Silicon, Si | 0.006 max |
| Magnesium, Mg | 0.006 max |
| Zinc, Zn | 0.006 max |
| Iron, Fe | 0.006 max |
| Copper, Cu | 0.006 max |
| Gallium, Ga | 0.005 max |
| Vanadium, Va | 0.005 max |
| Manganese, Mn | 0.002 max |
| Remainder (each) | 0.002 (each) |
| Properties of Aluminum 1199 | ||
|---|---|---|
| Properties | Metric | Imperial |
| Tensile strength | 115 MPa | 16700 psi |
| Yield strength | 110 MPa | 16000 psi |
| Poisson's ratio | 0.33 | 0.33 |
| Elastic modulus | 62 GPa | 8990 ksi |
| Shear modulus | 25 GPa | 3630 ksi |
| Elongation at break (@tickness 1.60 mm/0.0630 in) | 5% | 5% |
| Shear strength | 74 MPa | 10700 psi |
| Hardness, Brinell (@load 500kg with 10.0mm ball) | 31 | 31 |
| Thermal Conductivity | 25°C | |
Aluminum 1100-H14 is considered a commercial-grade aluminum alloy known for its excellent formability, high thermal and electrical conductivity, weldability, and exceptional corrosion resistance. Like other forms of aluminum 1100, it is soft with low hardness.
The "H14" designation in aluminum 1100-H14 indicates the level of strain hardening it has undergone. The "H1" signifies that the aluminum has been strain-hardened only through cold working, while the "4" denotes that the alloy is half-hard. The hardness scale for strain-hardened aluminum ranges from 2 (quarter hard) to 8 (fully hard), with 4 representing half-hard.
In the 1xxx series of aluminum alloys, strain hardening is categorized into four types. H1 indicates strain hardening only, while other categories involve strain hardening combined with annealing, stabilizing, or oven curing with a coating. These designations describe the tempering processes for aluminum alloys, but it's important to note that none of the 1xxx series alloys are heat treatable.
| Elements in Aluminum 1100-H14 | ||
|---|---|---|
| Element | Value | Condition |
| Aluminum | 99.00% | H14 |
| Copper | 0.05 - 0.2% | H14 |
| Manganese | 0.05% | H14 |
| Zinc | 0.10% | H14 |
| Mechanical Properties of Aluminum 1100-H14 | ||
|---|---|---|
| Mechanical Properties | Value | Condition |
| Bending Fatigue Strength | 50.0 MPa | H14 |
| Elastic modulus | 69.0 GPa | H14 |
| Hardness, Brinell | 32.0 [-] | H14 |
| Plane-Strain Fracture Toughness | 22.0 35.0 MPa.√m | |
| Poisson's ratio | 0.33 [-] | |
| Shear modulus | 25.9 GPa | |
| Tensile strength | 110.0 - 145.0 MPa | H14 |
| Density | 2.71 g/cm3 | |
Aluminum compounds are present in materials such as clay and bauxite, a sedimentary rock known for its high aluminum oxide content, which ranges from 45% to 60%. The extraction of aluminum from bauxite involves separating impurities like sand, iron, and other metals from the aluminum oxide, a process that is both lengthy and complex.
Bauxite deposits can vary from hard rock to soft dirt, which affects their ease of mining. Over 70% of the world's aluminum is extracted from bauxite mines in just three countries, with smaller amounts mined in eight other countries. A significant environmental concern in the mining and extraction process is the generation of red mud, a byproduct that poses major ecological challenges.
The extraction of aluminum, known as alumina production, was developed by Austrian chemist Karl Josef Bayer in the late 1880s and is referred to as the Bayer process. This method involves a four-step procedure where bauxite is heated and treated with chemicals under pressure to remove impurities and dissolve the aluminum oxide.
Two distinct processes are used to extract aluminum from bauxite. The first is the Bayer process, which extracts aluminum oxide, or alumina, from bauxite. The second is the Hall-Héroult process, invented in 1886, which is a smelting method used to produce pure aluminum from the alumina.
To prepare bauxite for extraction, it is first ground and crushed into fine particles, which are then mixed with a sodium hydroxide solution to create a slurry. This slurry is pumped into a high-pressure tank known as a digester. Inside the digester, the slurry is exposed to steam and pressure, causing the sodium hydroxide to react with the alumina to form sodium aluminate. The impurities from the bauxite remain suspended in the mixture as red mud.
The mixture from the digester is then transferred through a series of pressurized tanks, known as blow-off tanks, where it is released to atmospheric pressure. During the clarification stage, red mud is separated from the sodium aluminate using cyclones, often referred to as sand traps. Finer residues are settled using thickeners, and the solids in the thickener are removed with cloth filters. The filtered residue is washed, combined, and discarded. The final clarified mixture is cooled using heat exchangers, which improves the saturation level of the dissolved alumina.
The sodium aluminate from the clarification process is pumped into tall precipitation tanks to separate the alumina. To accelerate this separation, aluminum hydroxide crystals from previous batches are added to the mixture. These added crystals serve as seed crystals, promoting the formation of larger agglomerates. The resulting aluminum hydroxide crystals, which are of the desired size, settle at the bottom of the tanks. They are then filtered and washed. The entire precipitation process can take several days.
The agglomerates from the precipitation process are placed in rotary kilns and subjected to calcination at temperatures exceeding 960°C (1750°F). This high-temperature treatment removes water from the hydrated alumina, leaving behind a fine, dry, white powder known as alumina. Calcination removes the chemically bound water, resulting in anhydrous alumina. Once calcined, the alumina is ready for the Hall-Héroult process, which is used to produce pure aluminum, including aluminum 1100.
The Hall-Héroult process, an electrochemical method developed by Charles Hall and Paul Héroult, is used to extract pure aluminum from alumina. This intricate electrolysis procedure requires precise calculations, including the concentration of alumina and the anode-cathode distance. The process takes place in an iron tank equipped with a heat insulator and a sloping floor to allow the molten aluminum to be collected and removed.
In the process, carbon anodes are immersed in a molten solution of aluminum trioxide and sodium hexafluoroaluminate (cryolite). The tank's iron lining is coated with carbon, which acts as the cathode for the electrolysis. Aluminum ions in the solution are attracted to the cathode lining. At a temperature of approximately 950°C (1742°F), the aluminum deposited on the cathode lining melts and collects at the bottom of the tank. To ensure the process runs smoothly, alumina is continuously fed into the tank to maintain an adequate concentration for effective dissolution.
The Hall-Héroult process results in the rapid production of most of the world’s aluminum. It is an energy-intensive method that requires substantial amounts of electrical power to sustain the electrolytic reaction needed for aluminum production. Consequently, the cost of electricity constitutes a major portion of aluminum production expenses. Despite this, the process is favored for its ability to produce high-quality aluminum with a purity level of 99.99%.
However, a significant drawback of the Hall-Héroult process is the substantial carbon dioxide emissions it generates. During electrolysis, the carbon anodes attract oxygen, leading to the production of CO2 as a byproduct. Controlling these emissions and preventing their release into the atmosphere remains a persistent challenge for aluminum producers.
The aluminum from the smelting process is mixed in a furnace with other metals to form aluminum alloys, which have properties and characteristics that meet the specific needs of various applications. Fluxing is used to purify the metal before it is formed into ingots or poured into molds. The newly produced metal is shipped to producers for forging, casting, cold working, drawing, rolling, and other machining processes.
Aluminum 1100 is directly formed into ingots or billets for shipping right after the smelting process, as it does not require mixing with any additional alloys.
Aluminum 1100, one of the most widely used aluminum alloys, is transformed into various products through several cold working processes. After smelting, the sheets, ingots, and billets of aluminum 1100 are typically shaped by drawing, spinning, stamping, forging, and rolling, although it can also be hot worked if needed.
Cold working can significantly enhance the strength of aluminum 1100 by increasing the number of dislocations, or defects, within the metal's atomic structure. As the number of dislocations rises due to cold working, the metal's strength improves. At room temperature, aluminum 1100 has a yield strength of approximately 4 ksi (30 MPa). After cold working, its yield strength can increase to about 24 ksi (165 MPa).
Rolling aluminum transforms slabs into usable forms, such as aluminum cans and containers for takeout food. The process begins with a slab or billet of aluminum 1100, which hardens and strengthens during rolling. A roller mill applies force to the top and bottom of the slab, gradually reducing its thickness to the desired level.
After rolling, aluminum is classified based on its thickness. If the thickness is 0.25 inches (6.3 mm) or more, the material is classified as plate, which is often used in aerospace applications for wing structures and other components. Thicknesses between 0.008 inches (0.2 mm) and 0.25 inches (6.3 mm) are classified as aluminum sheet, making it a versatile form used in various applications. Rolled aluminum that reaches a thickness as thin as 0.008 inches (0.2 mm) is classified as foil, commonly used for packaging and insulation materials.
The extrusion process involves pushing an aluminum billet through a die under high pressure to form a specific shape. Although aluminum 1100 is not commonly used in extrusion, its high formability makes it well-suited for creating intricate and unique profiles. During extrusion, the billet is heated to soften the aluminum, facilitating its passage through the die. Because aluminum 1100 is relatively soft, it requires less heating compared to other alloys to achieve successful extrusion.
Spinning, or spin forming, is a process where a disc or tube of aluminum is rotated at high speed on a lathe. A form block is positioned on the lathe, and a properly sized disc of aluminum is clamped against this block with a pressure pad. As the aluminum disc and form block spin, force is applied to the workpiece, causing it to conform to the shape of the block. This force can be applied using one or multiple tools to ensure a smooth, wrinkle-free final product.
Aluminum spinning is typically used for low to medium volume production due to the time required for the process. It is often preferred over stamping when tooling costs for stamping dies are prohibitive or when producing shapes that cannot be easily achieved with stamping. This method provides versatility for creating complex shapes and detailed designs.
Annealing is a heat treatment process that enhances the properties and formability of aluminum 1100. In this process, aluminum 1100 is heated to a specific temperature and then cooled slowly. Annealing helps to relieve internal stresses, increase ductility, and improve the metal's workability. The process can be categorized into three types: homogenization, recrystallization, and heterogenization.
Annealing enhances the formability of aluminum 1100 beyond its typical limits. While various work hardening methods can shape and deform aluminum, they can eventually lead to the metal's grain structure becoming too stressed, causing breaking, cracking, or warping. To address these issues, aluminum 1100 is subjected to annealing, a heat treatment process that resets the grain structure and allows for further shaping and manipulation.
The forging process for aluminum is similar to the forging processes for other metals, which includes the use of pressure using a press or hammers. The process of forging requires several steps in order to reach the appropriate tolerance for the completed part. Although forging is a force and pressure method, it still requires proper planning and preparation.
The forging process of aluminum 1100 begins with selecting the appropriately sized slab or billet, which must be cleaned to remove any debris or impurities. After cleaning, the billet is heated to soften the aluminum, making it easier to shape. This heating is precisely controlled to ensure the aluminum 1100 reaches the correct temperature for forging. For aluminum 1100, the forging temperature is relatively low, ranging between 371°C and 510°C (700°F and 950°F).
During forging, force is applied using either a press or hammer. The process includes upsetting, drawing out, and finishing. Upsetting is used to widen and shorten the billet's end, while drawing out stretches the workpiece to the desired length. Finally, finishing refines the shape and removes excess material.
Forging exerts significant stress on the aluminum, necessitating controlled cooling to room temperature to prevent thermal shock. As the size of the workpieces increases, the cooling time extends accordingly.
The final step in forging involves machining the product, which includes drilling holes, cutting off waste, polishing, and coating. Proper machining is crucial for ensuring the quality and performance of the finished part, resulting in a precisely produced component.
Several processes can be used to weld aluminum, including stick welding, though it is generally not recommended due to its messiness. The most common methods for welding aluminum are tungsten inert gas (TIG) welding and metal inert gas (MIG) welding. Other techniques include laser welding, resistance welding, and shielded arc welding.
TIG welding uses alternating current (AC) and argon gas as the shielding gas. The filler material is manually fed into the weld pool and does not require a feeding wire. This method is known for its cleanliness and minimal contamination. MIG welding, on the other hand, is faster and uses a spool gun or other feeding mechanism to supply welding wire. However, MIG welding can potentially contaminate the weld, so it's crucial to ensure that both the base material and filler are clean, dry, and adequately shielded.
Despite the challenges associated with welding aluminum 1100, it remains widely used across various industries due to its lightweight, conductivity, corrosion resistance, recyclability, and attractive appearance.
Aluminum 1100 is used to produce a wide range of products thanks to its favorable properties, ease of workability, and machinability. The sheets, slabs, billets, and plates of aluminum 1100, cast or rolled during production, are sent to manufacturers who use various processes to create marketable products. Its versatility makes aluminum 1100 popular in both industrial applications and home products.
Aluminum 1100 is commonly used in radiator manufacturing due to its excellent heat dissipation properties. Its versatility allows it to be formed and shaped to meet various design requirements. Radiator fins, which must be thin yet durable, benefit from aluminum 1100's ability to rapidly dissipate heat thanks to their thin profile and the material's inherent thermal conductivity.
Aluminum 1100 is used to manufacture pots, pans, cooking tools, and other cookware because of its excellent heat conductivity and resistance to corrosion. Its key feature is its ability to distribute heat evenly across the entire surface of a pot or kettle, ensuring that food is cooked uniformly.
Aluminum 1100 is frequently used as a roofing material for commercial, industrial, and residential buildings. The thickness of aluminum 1100 roofing varies by application: residential roofing typically ranges from 0.030 inches to 0.032 inches, while commercial roofing can be as thick as 0.063 inches. Aluminum 1100 roofing is suitable for various environments, including coastal areas, hurricane-prone regions, heavy snowfall zones, and high-temperature locations.
One of the most recognizable uses of aluminum 1100 is in aluminum cans, which are ubiquitous. Concerns about aluminum's environmental impact have been raised due to the widespread use of these cans. However, advancements in technology and efforts by manufacturers have shown that aluminum 1100 is among the easiest forms of aluminum to recycle and repurpose.
The production of aluminum cans is a rapidly growing industry due to their effectiveness in preserving beverages until opened. Aluminum cans are stackable, cost-effective, quick to fill, printable, and make efficient use of shelf space.
The brief list of aluminum 1100 products provided here is just a small sample of its many applications. Aluminum 1100 is used in a variety of items, including heat exchangers, electrical conductors, reflective surfaces, chemical processing equipment, signage, aircraft components, heat shields, soundproofing materials, and decorative pieces. Its numerous benefits and superior qualities make aluminum 1100 an ideal material for a wide range of products.
Aluminum has become a key material in the manufacturing of many modern products, particularly with the surge in popularity of cellphones, laptops, tablets, and other handheld devices. Its resilience, longevity, lightweight nature, and strength make aluminum an ideal choice for producing contemporary appliances.
When exposed to air, aluminum forms a thin oxide layer on its surface that protects the metal from corrosion. If this oxide layer is damaged, it quickly repairs itself when exposed to oxygen. This self-healing property is a major advantage of aluminum alloys. When stored in stable environments without significant temperature fluctuations or moisture, aluminum 1100 can last indefinitely without requiring additional surface treatment.
Aluminum is widely used in heat sinks due to its thermal conductivity, although it's not as high as copper's. The choice of aluminum over copper is attributed to its lightweight nature, versatility, lower cost, and ease of forming and shaping. Aluminum 1100 stands out with its exceptionally high thermal conductivity among aluminum alloys, making it the preferred choice for applications requiring both strength and efficient heat dissipation.
Aluminum 1100's low density makes it incredibly lightweight, which is a significant advantage over other metals in applications demanding strength, durability, and reduced weight. Its lightweight nature, combined with other beneficial properties, makes aluminum 1100 ideal for modern products where ease of handling and convenience are essential.
While reflectivity might not always be the foremost feature of aluminum 1100, its mirror-like finish provides notable photometric qualities and light control. This reflectivity makes aluminum 1100 particularly effective for signs, enhancing visibility at night. Beyond street signs, its reflective properties are utilized in advanced scientific instruments, including those used for sterilization.
Modern industrial practices emphasize sustainability, focusing on preserving and protecting the environment through efficient use of resources. Aluminum 1100 plays a crucial role in these efforts due to its high recyclability. When its useful life ends, aluminum 1100 is sent to recycling facilities where it is processed and reused, contributing significantly to environmental conservation and sustainability.
The high purity of aluminum 1100 gives it an attractive appearance, making it popular in architectural applications to accentuate building features. Its light weight not only enhances the aesthetic of structures but also provides additional benefits such as sun protection and insulation. Aluminum 1100's appealing look and functional qualities make it a valuable choice for both visual and practical applications.
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