Aluminium Alloys – The Link to
Energy and Sustainability
Adjunct Professor Malcolm J Couper
Monash University, Chongqing University

ALMA Forum, November 20188@95:5@9$=;/1>>5:3>195I>





8@95:5@9$=;/1>>5:3
$=;0@/?$1=2;=9-:/1:1=3D5:$=;0@/?>"'%"&$#%'
"%,&&)
!!&#"&%("'
G(&H$&,'*'"( E;5K4@7& %A;@EA@
5.=@2> *52)@A33G%A9@6
6:2;?6<;.9%.@2>6.9? <@%.@2>6.9?.;12?64;)20<;1
16@6<;  GFF8DIADF;#8<@8?4@@*J9AD7 BB   !<:GD8 ==><D6:.@2B.9A2?3<>@522;2>4E0<;?A:216;=><1A0@6<;:.;A3.0@A>2 A?2.;116?=<?.9<33<A>09.??2?<3=><1A0@?
';?-8$=59-=D:1=3D&@<<8D(FA8?<>><A@FA@EA9A<>8CG<H4>8@F  "1;

-AGD68<84 AD: &8K1AD>7 @8D:K-F4F<EF<6E8@95:5@9 &918?5:3?-=31?5:3>?1</4-:315:1225/51:/D 195>>5;:>,<A.<@FAQE,8@8I> O68DF<9<87>AI64D5A@7<AJ<784>G?<@<G?P
>6A4QE$@8DF@A78.86;@A>A:K8 : 68D?8FE
BB>8QE"D88@(4D=8F<@:+GE;9AD-?8>F8D,8FDA9<FE(6<*6;@<)A?@.6;./9212B29<=:2;@>2=<>@ 5E1>< 2920@>606@E 5E1>< 2;2>4E
 .9?<;<@2?@526:=<>@.;02<3I8FF45>8 .< 6A@F4<@<@: 7D4<@8764F;A7868>>78E<:@E!;2>@.;<12@205;<9<462? )%*205;60.9-<>86;4><A= :1=3D1225/51:/D5:9-:@2-/?@=5:3*B8D4F<@:4@;K7D4G><6
BD8EE

8B8@7<@:A@F;8BDA7G6F ?4@G946FGD84@74EEA6<4F878@8D:K>AEE8E64@584
E<:@<9<64@F=><=<>@6<; A9F;88@8D:K6A@EG?87F;DAG:;AGF4BDA7G6FO><986K6>8P
The Materials – Energy – Carbon Triangle:
Engineering solutions to problems of energy andsustainability (e.g. light-weighting) often require moreenergy intensive and carbon intensive materials
For Improved Materials:
Knowledge ofProcessing-Structure-Properties-Applications
is required

Progress on Aluminium
Lightweighting and Recycling1:1=-8-8@95:5@9 28;B/4-=?

,89<@8DE+D<?4DK+DA7G68DE,8?8>F8DE

:31:1=-8
%1918?1=> 2110B=;@34?
<=;/1>>1>:1B>/=-<;=;80>/=-<B5?4B1880125:10
/;9<;>5?5;:>13/-:>
%125:1=>21102;@:0=51>
;80>/=-<!AG@7D<8E,A>><@:(<>>E

JFDG78DE(4@G946FGD8DEA9
!<@<E;87+DA7G6FE

M
GDAB84@>G?<@<G? EEA6<4F<A@
4@7*D:4@<E4F<A@ A9 GDAB84@>G?<@<G?
,89<@8DE4@7,8?8>F8DE)22.9?<<6; 2>@>.: "'% A4I  ==  A><=2.;)0>.=):29@6;4+;6@
%<129H >.:2C<>83<>:2@.939<C?

/E8

>20E096;4 C<>91 .9A:6;6A: <>4
A>>86F<A@4EF<@:>>AK-6D4B
1DAG:;F>>AK-6D4B

1DAG:;F>>AK-6D4B.D84F?8@F8@95:5@9$=;/1>>5:3B5?4%1/;A1=D;2"1B&/=-<F-5=/=-2?-88;D>
>6A4B>4F8BDA7G6F<A@;FFBE III KAGFG58 6A? I4F6;HK2(F(F3-/L+DA7G6F<A@GE8E@8IE6D4BBD<?4DK<@:AF)8IE6D4B4>>AK6A?BAE<F<A@
64@58<78@F<9<87AD6;86=87I<F;4;4@7 ;8>778H<684EFE>45E 5>A6=E4D8;A?A:8@<E87 2;1 ?.C; 4@7?0.9=21DA>>87B>4F8<E2;1?52.>21 4@70><==21 EA>GF<A@FD84F874@7CG8@6;87B>4F8<EEFD8F6;874@7
4:87 <@EB86F870A@@<36;.9?6F2L

L

;15:3-5>1=1C-9<81;2/;88-.;=-?5;:
N ;15:3/;881/?5:3:1B9-:@2-/?@=5:3>/=-<-?9@8?5<812-/585?51>
N -5>1=5:&<;7-:1*->4=1@>10 ?5: 2;=-5=/=-2?-88;D
>411?-:0<8-?1<=;0@/?> CCCCCC

==G8@95:@95:

";=?491=5/-: 534?)145/81>H><=A%#"%'#%'"!0A@C& "%><>A6(%7! ?B:5K
:=4/E  ><99/.08<D86F<H8A@ @7
A9 '<9808;<6>8E
D8 GE8D86K6><@: D8 GE8
D86AH8DK5K
:.;E.:2;1:2;@?

A082>-<>91C6123<>@529A:6;A:??<06.@6<;I?
9A:6;A:*>.;?=<>@.@6<;><A= D20A@6B2)A::.>E )2=I'8<=<9 6;.9(2=<>@)2=@  -E??)05A9@F *%)$645@%2@.9? 88;D><=;/1>>01>53:102;=45345:/=1->5:3
=1/;A1=D;2:1B>/=-<LLL";A185> -3@-= -:0%;A1=% %%/D/810
8@95:5@9%8-@:/410
5:
88;D:;B@>105:-3@-=+-:0+-8>;2@?@=181/?=5/)145/81
$=1>>>4;<>/=-<>13=13-?10      LL";A185> 0A-:E'! >
%-88;D
105/-?10=;@:0?=5<=-58B-D
.1?B11:1=9-:D ($-/ -+,.

''#044!")&1" 4('" "')4(%5!5%")%5&5&'(,4$=;0@/1=@>?;91=/;88-.;=-?5;:88;D1>53:L;=0  5:?=;0@/10

N DCG"&' #!&%#'"'" ")& ! /&#=4?#% %,
N "!&"'5=A<&' #!#%"('"!!'">"%!'&!>%5=&(##%&N '"&#-'%%&!&"'")%&!%'(%!"'&%#N !=<##'"!&%&0
L B 4B >4B ?6B+++&'%!'7"%&'%('(%/L B 4B=4B>6B++++'% !.!'&&'!'7"%&!&/
L A 4A6A+++ "% ',!'%('(%7/L B=4B>6B+++&'%('(%7"%&#&'%('(%##'"!&N !@&%#&'% &02 "*(3.2 (3.2 "* 3.2  3% * #-+,/(,/+$ & $ )   #L";A185> 0A-:E'! &> 2;/@>>10;:.1:05:3 2;=95:3
%''!&' !'(( #'!@8?59-?1=5-8/-=01>53:F !-0588-/'LL

8;:3B5?4 05221=1:?9-?1=5-8>";A185>ICCC-:0CCC>1=51>
-8@95:@9-88;D>B1=1/4;>1:2;=?41;@?1=<-:18>/8;>@=1>-:0
2=;:?-:0=1-=>?=@/?@=1
;/@>10;:6;5:5:3?1/4:;8;351>5:=1<8-/5:3>?118>
''#044!")&1" 4('" "')45'B5&5&'(,4.'><=D&$ !,0

';D;?--9=DF 8@95:5@9 ;;05:(&9;018>

L'41-9=D01A18;<91:??1-9-59102;=->?D85:301>53:/;:/1<?
?4-?-/451A1>>?=;:34-=9;:D.1?B11:=125:191:?-:0->1:>@-8
-?481?5/59-31/=1-?5:3-:1B-<<=;-/4?;?419-=71?H';D;?->-50G'41=1>@8?5>-:1B>53:-?@=101>53:8-:3@-31?4-??-71>?41/-=5:?;-.1-@?52@8-:02@?@=5>?5/:1B05=1/?5;:HL @:I                                                !           "                           0 (!=C.",&"# (&!&&&'*%'%&

Recycling of 6xxx Series Aluminium
Alloys (based on Al-Mg-Si) and theeffects of varying alloying elements(fundamental to alloy design)CCC&1=51>88;D>&<1/525/-?5;:>' &'&!
<1>+<1>

>
B<B= #=<@%&'%",&@<(!$(&#&?B(!$( &#&B?(!$( 5)1CCC&1=51>88;D>&<1/525/-?5;:>' &'&

AA",&*' ! ( &#'"!"%(<1C*'G(<1=*'G(CCC&1=51>88;D>8!3&55:<=59-=D1C?=@010<=;0@/?>Exploring the effects of specific alloying elements............
")1><=C")1><=D……..Mn, Cr, Ti, Sc to follow

CCC&1=51>88;D'D<1>-:0(>1>
=;0 B5=1 0=-B:1C?=@>5;:> 2;=35:3>>411? >?-9<5:3>

 

'%'%'"! B><=%!&#"%'
6'7

%&. (&&.
B<B?
'%(&.,'& B<<A
B<B=B===

%!&#"%'
6"'%7

%!. '% &.'%(&.%%'B<B=!!%!

'%('(%&.
%"''!#%'&

B<B=B<D>6%7

(!% &.%''(%B<B<B<B?
6&"'7

&' '' %!&0( !( #%"('&21-?/4)-=5-?5;:13-@?;9;?5A1-88;D><8-:?0-?-2?6;42@ .9*%);;A.9A@<:<@6B299<E?  == 
A><;,.992E)@229<>=<>.@6<; %60564.;%.53<A1 1B %.@2> (2?   
== ;-82;==1/D/812=51:08D-88;D>

,&%#%',"%*' !"% "'"!.(&!2%'),%"3&#&"! ! !'&!% + (  '&"! !"% !'&.!
"%%'"&(''%$(% !'&"2 !,3##'"!&
+ #"%*%"('B+++&%&",&6*'G70 

%""$ #$$ "$ &  &
&
&" ! #"'"' 

&


&


&

 


&


&

&$"%#  '"'

  

     .? ! %.@)06<>A:   ==  $645@%2@.9? .?2@ .9 "'%&<BI  == .? >22;#.A3:.; D@>A?6<;*205;<9<4E*I .? >22; #.A3:.; :.16%.53<A1 "'%2/I == 



'1/4:;8;3D2;==1/D/812=51:08D-88;D>

!%& '(%##%"&'"0L "'"!
N &('"!&6&$(!.!'% '& "% .&%'"!7
N "!'%"!#%'"!"%!%! !'/
N "''%!&(&#'',L" "!&'"!
N &('"!&/ ""%&#%&"&N (&"!.!(!'5(#!""5"*!
L %"#%',4#%"&& "&N (!&!&')',/N %#''"!4!/N "% !/%,&'&'"!/.?@<;2@ .9 
%2@%.@*>.;?
N "%%"&"!

L %"(#%"&& "!"%!&'%('(%)"('"!!B+++%&( !( +'%(&"!&# &&$"  #$-+,-=?525/5-8"1@=-8"1?B;=7>
<=;<1=?51>;28&5/->?5:3-88;D>

:.172@ .9 *%)$645@%2@.9? ==2(%! !3 "8%"('"!9
+D<?4DK?<>>FB4,86K6>87?<>>FB4

+D<?4DK?<>>FB4,86K6>87?<>>FB4
9AD864EF
+D<?4DK?<>>FB4,86K6>87?<>>FB4

5<.@2>22; *%)$645@%2@.9?

 ==   9</.99A:6;6A:(20E096;4<>;2>?@<;2<3)A?@.6;./922B29<=:2;@;:>@95:3?41@=.-:95:1?41G913->4=1001=H