ABSTRACT

In the present work an attempt has been made to study and analyze the hardness and other
physical properties change in heat treated aluminum alloys which involves various type of
processes and methods. The Al 6063 sample of 8mm thick slab were cut into pieces measuring
60 x 40 mm heated in furnace at ambient air condition up to 500°C. Once the temperature
reaches its recrystallization temperature the samples were kept in furnace for approximately 5 to
6 hours and followed by rapid water quenching and are exposed to atmosphere for cooling.
Specimen are again reheated up to temperature of 150 °C for 6,7,8,9,10 and 11 hours. After
reheating, the specimen is taken out from furnace at every hour one by one starting from 6 hours
of reheating and are kept in ambient air condition for cooling. The specimen is then subjected for
better surface finish and are tested under various hardness testing machine and the analysis is
done. The temperature of furnace used for heat treatment is approximately 500°C and keep it for
5 to 6 hours more before quenching.

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 INTRODUCTION
Heat treatment is the process of heating the metal, holding it at that temperature, and then
cooling it back. During the process, the metal part will undergo changes in its mechanical
properties. This is because the high temperature alters the microstructure of the metal. Heat
treatment is also used in the manufacture of many other materials such as glass. Heat treatment
involves the use of heating or chilling, normally to extreme temperatures, to achieve the desired
result such as hardening of softening of a material. Heat treatment techniques include annealing,
case hardening, carburizing, normalizing and quenching.

The alteration of morphological and physical properties of aluminum alloys can be achieved by
solution heat treatment in which the aluminum alloys such as 2618 is heated up to 530 °C for
thick sections and are followed by water quenching for 24 hours. Maximum hardness of 2618
aluminum alloy is achieved by aging the specimen at 200 °C after the solution heat treatment at
530 °C for 24 hours. For 6061 aluminum alloy specimens with annealing method the specimen is
heat treated at 400 °C for 5 hours and then kept in the furnace for cooling slowly, with the age
hardening method the specimen is first heat treated at 530 °C for 6 hours and quench in water for
72 hours and then it is reheated at 150 °C for 2 hours and are finally normalized in room
temperature. For observing the microstructure or morphological variation in the specimens
Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM) and X-Ray
Diffraction (XRD) are used. For evaluating the mechanical properties Tensile test, Brinell
hardness test, Charpy & Izod impact test etc. are used. Age hardening is the heat treatment
method implemented on heat treatable aluminum alloys to improve some of the mechanical
properties of the specimen.

Microstructure plays an important role in the mechanical properties of a material. The final
outcome depends on many different factors. These include time of heating, time of keeping the
metal part at a certain temperature, rate of cooling, surroundings condition etc. The parameters
depend on the heat treatment method, type of metal and part and size. Over the course of this
process, the metal’s properties will change. Among those properties are electrical resistance,
hardness, toughness, and corrosion resistance. Although the term heat treatment applies only to
processes where the heating and cooling are done for the specific purpose of altering properties
intentionally, heating and cooling often occur incidentally during other manufacturing processes
such as hot forming or welding. Literatures have also suggested that after heat treatment of
aluminum alloys with the annealing method the ultimate tensile strength, yield strength and
hardness decrease by 50 % and with the age hardening method at 150 °C can increase some
amount of the tensile strength of the specimen but with age hardening method at 200 °C can
increase more amount of tensile strength of the specimen [1] . While heat treatment originated as
an ancient art in man’s attempt to improve the performance of materials in their practical
applications; modern day evolution of digitalization in the heat treatment industry, as well as the
role of Industry 4.0 and 5.0 and the Internet of Things (IOT) in driving innovation in this field

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has also been studied extensively keeping it a relavant branch of research in current day and age
[2].
At present, 7XXX series aluminum alloys (Al 7XXX alloys) are widely used in bearing
components, such as aircraft frame, spars and stringers, for their high specific strength, high
specific stiffness, high toughness, excellent processing, and welding performance. Therefore, Al
7XXX alloys are important structural materials in aviation [3]. Furthermore, investigations
reveal that among the grades of aluminum alloys from 1xxx to 7xxx series the 2xxx,6xxx and
7xxx series of aluminum alloys are heat treatable in which 2xxx series (2024, 2224, 2324, 2524,
etc.) where copper is the primary alloying element, 6xxx series (6061,6063,6082, etc.) where
magnesium and silicon are the primary alloying element, and 7xxx series (7075, 7475, 7050,
etc.) where zinc is the primary alloying element.
This research attempts to evaluate the effects of age-hardening on the mechanical
behavior of aluminum (6063) alloy reinforced with alumina (Al2O3) particles. Aluminum
(6063)/Al2O3 composites containing 0, 5, 7, 9 and 10 wt% Al2O3 particles respectively were
fabricated using double stir casting technique and representative samples from each composition
were subjected to age-hardening treatment at 180 °C for 60 min, 120 min and 180 min
respectively [4]. The present study reports on the influence of state of ageing on mechanical
properties of 6063 Al-Mg-Si alloy. Ageing response has been invested at 175 oC for duration
ranging from 10 min to 14 days via measurements of hardness and tensile properties,
examinations of tensile fracture surfaces and detailed analyses of strain hardening behavior. The
time to peak aged condition has been identified as 8 h. Irrespective of state of ageing, a linear
correlation between hardness and yield strength has been established through a statistical
analysis [5].

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 MOTIVATION

The growth of several industries, such as electronics, construction, and aerospace, is largely
attributed to the enhancement in the field of materials science and engineering. The Al6063
alloy which is mostly used in aerospace and other architectural industries replacing even
some of ferrous alloys in the modern age because of its good strength to weight ratio and
excellent resistance to corrosive environments. Thus, by adopting methods like artificial
aging the mechanical properties can also significantly improved to cater to the needs of the
industry. This serves as our motivation to identify best aging parameters of the aluminum
alloy considered in our study, which is Al6063 alloy. Understanding how thermal processes
impact material performance by examining the impact of distinct heat treatment process
parameters and artificial aging on the microstructure and mechanical characteristics of
aluminum alloys will increase the knowledge of enhancement of mechanical properties of
material by heat treatment as well as age hardening.

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 LITERATURE REVIEW
[6]. Suhair et al. investigated the effect of heat treatment on mechanical properties such as yield
strength, hardness, and modulus of elasticity and dynamic characteristics such as natural
frequency and dynamic response etc. under impulse loading for 6061 and 2024 aluminum alloys
in 0, T4, and T6 treatment conditions to study the effects of heat treatments, the results showed
an improvement of the mechanical and dynamic properties for aluminum alloys, and that heat
treatment gives acceptable results, due to the improvement of these properties that reach up to
20%.
[7]. Chen et al. examined and study the effects of heat treatment on the microstructure and
mechanical properties of extruded 2196 Al-Cu-Li alloy and the precipitation behavior and
strengthening mechanism were investigated. It was found that the solution treatment and
artificial aging had a significant strengthening effect on the mechanical properties of the extruded
alloy, which was related to the type, size, number density, and distribution of the precipitates.
The pre-stretching deformation can introduce a large number of vacancies and dislocations,
which provide conditions for atomic diffusion and precipitation of the phases, and further
improve the mechanical properties of the alloy.
[8]. Jon et al. investigated the effect of dislocation retention after ageing on 6xxx-series alloys, a
non-heat-treatable 5005 alloy was selected to measure the change in mechanical properties due
to dislocation annihilation during dynamic recovery. As a result, increased in yield strength of
120% and tensile strength of 50% compared with the as-received material were achieved.
[9]. Muhammad et al. examined the room temperature quasi-static tensile tests which are
conducted at the strain rate of 0.001 s − 1 on machined surface specimens, and uniaxial fully-
reversed strain-controlled fatigue tests and are performed on both as-built and machined surface
specimens. Some differences in microstructure and tensile properties of the LB-PBF AlSi10Mg
fabricated with LPW and EOS powders are noticeable. Among the Al alloys, the LB-PBF
Scalmalloy possesses the highest strength and high ductility as well as the highest fatigue
resistance credited to its ultrafine/nano-size grains and precipitates.
[10]. Hamid et al. investigated the impact of the annealing procedure on the mechanical and
metallurgical properties of the 2024 alloy, bending test was conducted, while the mechanical and
metallurgical properties were analyses through tensile, hardness, microstructure, and corrosion
tests. The test specimens were annealed by heating them to 300°C and 400°C in an electrical
furnace for two hours, followed by cooling to room temperature. The results showed a decrease
of about 40% in the tensile strength and hardness but the bending strength increased by roughly
25%, and the specimens were able to bend at a high angle without cracking or breaking, unlike
the base metal.
[11]. Ibrahim investigated the effects of re-solution treatment of AA2618 aluminum alloy. In this
study solution heat treatments of 520 °C – 640 °C for 14 – 24 h were applied followed by

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artificial aging. Studies were out by optical microscopy, scanning electron microscopy and
energy dispersive X-ray spectroscopy techniques which showed that recrystallisation was not
observed by solution treatment at 530 °C whereas it did occur as the solution treatment and the
duration time were increased above 530 °C. Increasing the solution treatment temperature further
coarsened both the grains and the precipitates, resulting in significant reduction in hardness.
[12]. Bin K et al. investigated the hot deformation behavior and microstructural evolution of
homogeneous annealed AA7020 aluminum alloy were investigated by isothermal compression
tests over the temperatures range of 673−793 K and strain rates range of 0.001−1 s-1. According
to the experimental results, the flow stress of AA7020 aluminum alloy exhibits a typical dynamic
recovery characteristic, and a six-order polynomial strain compensation of Arrhenius-type
constitutive equation is developed to describe the hot deformation behavior of the alloy.
[13]. Yichao et al. investigated the mechanical properties and stress corrosion cracking (SCC)
resistance of 7xxx series aluminum alloys are significantly affected by the composition and
distribution of precipitates formed during heat treatment. Only a small change in average
composition of Q-GBPs was found with cooling rate; but a large scatter was observed. This is
caused by significant Zn/Cu/Al composition gradients developing along their principal growth
directions in both AA7050 and AA7085 alloys. This concentration gradient did not reduce
significantly after a T76 treatment. Chemical gradients were predicted to develop in the Q-GBPs
due to the changing local equilibrium at the growth front during the cooling.

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 INFERENCES DRAWN FROM LITERATURE SURVEY
The solution heat treatment temperature and the reheating temperature conditions are identified
from the different research paper which help in selecting optimum temperature for heat treatment
of Al6063 alloys. The effects of aging/reheating at elevated temperature are studied which help
in better understanding that how reheating temperature impacts the hardness of aluminum alloys.
From different literatures it is found that which grades of aluminum alloys are heat treatable and
what are the primary alloying element as well as the composites of alloys which help in selecting
the material that are heat treatable and also age hardened.

RESEARCH GAP
The Al6063 is the aluminum alloy which comes under 6xxx series of aluminum alloys and has a
magnesium and silicon as the primary alloying element can be hardened using different process
parameters which enhances the properties of the material which can be used in aerospace, and
many other industries where the good strength to weight ratio of material is required. For study
of effect different process parameters on hardness of aluminum alloys following are the research
gaps:
 Reheating at different temperature also increases the mechanical properties of material but it
is only possible if there is multiple number of furnace because the furnace gives required
elevated temperature same for every specimen so to provide different elevated temperature
for artificial aging requires multiple furnaces.
 Limited manuscripts related to heat treatment of Al6063 alloys which is age hardened at
different temperatures and time leads to lack of knowledge in the study which include
recrystallisation temperature, and many other process parameters.
 It has been found from different literatures and research that the different elevated
temperature has better enhancement of hardness, yield strength, and corrosive resistance
compare to same elevated temperature for artificial aging but it requires multiple number of
furnaces according to each specimen so non availability of multiple furnaces leads to a big
research gap.

OBJECTIVES
To study the effect of heat treatment process parameters on hardness of Al6063 alloys for
enhancement of mechanical properties (hardness etc.) which includes -
 To study the effect of aging time on hardness of Al6063 alloy.

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 To identify best aging conditions for enhanced hardness for Al6063 alloy.

METHODOLOGY
The study on effect of heat treatment process parameters on hardness of Al6063 alloy includes
several processes such as sample preparation where the specimen is cut into multiple pieces and
are subjected for heat treatment up to its recrystallisation temperature and then it is rapidly
submerged in distilled water for rapid cooling and after quenching it is again reheated at elevated
temperature for several hours respectively. After reheating the specimen are taken out at different
time intervals and the hardness test is done after cooling the specimen in atmospheric air
condition. Hardness test is done using Rockwell hardness test machine.
1. Sample Preparation: The 8mm slab of Al6063 alloy is cut into six number of pieces
having 60X40 mm cross section and the surface is smoothened using flat file if there is rust
on specimen otherwise no surface finish required.

Figure 1: Aging Sample

2. Heat Treatment & Quenching: Specimen are placed in furnace for heat treatment up to
recrystallisation temperature that is 500°C and are kept at that temperature for 10 minutes
before quenching. The specimen is taken out one by from furnace and are followed by
rapid quenching in distilled water and are exposed to ambient air condition.

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 Figure 2: Recrystalization of Al6063
alloy

3. Reheating/Age hardening: Now after quenching the specimen are again placed at furnace
for reheating or artificial aging at the temperature of 150°C for 6 hours and the specimen
are taken out one by one in every one-hour interval starting from first specimen which is
taken out at 6 hours after one-hour other specimen is taken out which is reheated till 7
hours respectively and the process is continued till 11 hours which is the last specimen.

Figure 3: Aging treatment of

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4. Hardness Testing: After age hardening the specimen are subjected to various types of
mechanical properties test such as Rockwell Hardness Test etc. Basically, for aluminum
alloy 1/8-inch ball indenter is used for hardness test at the load of 250 Kgf.

Figure 4: Sample after aging for

5. Report & Documentation: After testing the analysis is done by comparing and plotting
the graph for Rockwell hardness number and aging time.

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 RESULT AND DISCUSSION
In the present study the Al 6063 sample of 8mm thick slab were cut into pieces measuring 60 x
40 mm heated in furnace at ambient air condition up to 500°C. Once the temperature reaches the
recrystallization temperature of Al 6063 i.e., 500°C, the samples were quenched in cold distilled
water following which they were heated for prolonged duration inside the furnace for artificial
aging treatment. Six specimens were heated up to temperature of 150 °C for 6-11 hours and each
specimen was labeled based on their aging duration. Rockwell indentation test was performed for
hardness testing wherein minor and major loads are applied and the hardness are recorded from
the dial indicator in the instrument. Two and half rotation moves the minor load scale by 1mm
and it should not cross the value 3 while applying minor load. Convention dictates that 1/8-inch
ball indenter is used for aluminum alloys at load of 250kgf which is also suggested by some of
the literatures in the subject. The major load lever should be in unload position before testing,
once the minor load is set then raise the major load lever in load position and wait for 30 seconds
and then unload the lever slowly and take the reading from the dial indicator. The same
procedure is repeated for every sample for at least three observation and the mean value of
hardness number is recorded and shown graphically in figure 5.

Figure 5: Aging time v/s Hardness plot

As per the analysis and testing after age hardening, we get the minimum hardness increased in
the specimen which is taken out after reheating at 150°C till 6 hours and the maximum hardness
is observed in specimen which is reheated at 150°C up to 11 hours. All the Rockwell hardness
number of the samples are 44, 49, 55.33, 56.63, 60.33 and 67.33 for the aging time 6, 7, 8, 9, 10
and 11 hours respectively. The enhancement of properties of a material is due to the
microstructural changes in morphology of Al6063 alloy which includes magnesium and silicon

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as primary alloying element which fully converted to aluminum matrix which can only be
analyze using Scanning Electron Microscopy (SEM) and X-Ray Diffraction (XRD) in future.
Similarly the enhancement of properties is achieved by different reheating/age hardening
temperature for different samples which was studied in literature can be adopted for study of
effect of heat treatment process parameter on hardness of aluminum alloys like Al6063 using
multiple furnaces at same time in future.

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