Problems Aluminium

For these applications, aluminium is anodized in an acid electrolyte, usually 10% sulphuric acid although chromic acid and oxalic acid are also employed. The latter at low current density gives excellent results and is used for aluminium which is to be coloured. Chromic acid is preferred for the anodizing of complex shapes where thorough rinsing of the surface after oxidation is a problem aluminium will corrode in sulphuric acid but not in chromic acid. 

Static electricity may disrupt the packing of powdered samples. When static electricity is a problem, aluminium foil is spread on the work surface and an electric wire connected from the foil to electric ground. Tweezers are available made from PTFE and other non-metallic materials, which also reduces static electricity. Powdered samples should be packed into the sample vessel on the metal foil, ideally in a low-humidity environment. 

This paper compares experimental data for aluminium and steel specimens with two methods of solving the forward problem in the thin-skin regime. The first approach is a 3D Finite Element / Boundary Integral Element method (TRIFOU) developed by EDF/RD Division (France). The second approach is specialised for the treatment of surface cracks in the thin-skin regime developed by the University of Surrey (England). In the thin-skin regime, the electromagnetic skin-depth is small compared with the depth of the crack. Such conditions are common in tests on steels and sometimes on aluminium. 

It is normal practice to provide a flexible copper joint at the generator or the transformer end as the terminals are also of copper and usually have a smaller spacing between them, where termination of aluminium (lexibles may present a problem (although the use of aluminium flexible is not forbidden). 

Another problem in the construction of tlrese devices, is that materials which do not play a direct part in the operation of the microchip must be introduced to ensure electrical contact between the elecuonic components, and to reduce the possibility of chemical interactions between the device components. The introduction of such materials usually requires an annealing phase in the construction of die device at a temperature as high as 600 K. As a result it is also most probable, especially in the case of the aluminium-silicon interface, that thin films of oxide exist between the various deposited films. Such a layer will act as a banier to inter-diffusion between the layers, and the transport of atoms from one layer to the next will be less than would be indicated by the chemical potential driving force. At pinholes in the AI2O3 layer, aluminium metal can reduce SiOa at isolated spots, and form the pits into the silicon which were observed in early devices. The introduction of a tlrin layer of platinum silicide between the silicon and aluminium layers reduces the pit formation. However, aluminium has a strong affinity for platinum, and so a layer of clrromium is placed between the silicide and aluminium to reduce the invasive interaction of aluminium. 

The hydrides of the later main-group elements present few problems of classification and are best discussed during the detailed treatment of the individual elements. Many of these hydrides are covalent, molecular species, though association via H bonding sometimes occurs, as already noted (p. 53). Catenation flourishes in Group 14 and the complexities of the boron hydrides merit special attention (p. 151). The hydrides of aluminium, gallium, zinc (and beryllium) tend to be more extensively associated via M-H-M bonds, but their characterization and detailed structural elucidation has proved extremely difficult. 

Chloroaluminate laboratory preparations proved to be easily extrapolated to large scale. These chloroaluminate salts are corrosive liquids in the presence of protons. When exposed to moisture, they produce hydrochloric acid, similarly to aluminium chloride. However, this can be avoided by the addition of some proton scavenger such as alkylaluminium derivatives. In Difasol technology, for example, carbon-steel reactors can be used with no corrosion problem. 

Copper alloys in wrought or cast form are used for other purposes in ships and other marine installations, such as for propellers bearings, valves and pumps. One widespread application of aluminium-brass is its use for heating coils in tankers carrying crude oil or petroleum products. Some corrosion problems encountered in this and other applications on board ship have been described by Gilbert and Jenner . 

Vast amounts of continuously galvanised steel sheets are produced, and unless they are painted or otherwise coated, their life depends on the thickness of the galvanising and the service environment in which they are used. Similarly in the case of steel sheets coated with aluminium or aluminium-zinc alloys, their performance is dictated by their coating thickness (see Section 13.4). A problem often associated with such material is corrosion at the cut edges. From work carried out by BISRA and others it has been shown that providing the bare steel edge is less than 3 mm in width, the amount of corrosion is minimal and the life of the sheet is not adversely... 

Table 10.9 lists some common zinc anode alloys. In three cases aluminium is added to improve the uniformity of dissolution and thereby reduce the risk of mechanical detachment of undissolved anode material . Cadmium is added to encourage the formation of a soft corrosion product that readily crumbles and falls away so that it cannot accumulate to hinder dissolution. The Military Specification material was developed to avoid the alloy passivating as a result of the presence of iron . It later became apparent that this material suffered intergranular decohesion at elevated temperatures (>50°C) with the result that the material failed by fragmentation". The material specified by Det Norske Veritas was developed to overcome the problem the aluminium level was reduced under the mistaken impression that it produced the problem. It has since been shown that decohesion is due to a hydrogen embrittlement mechanism and that it can be overcome by the addition of small concentrations of titanium". It is not clear whether... 

Aluminium anodes are less constant in their electrochemical characteristics than zinc. This presents no major problem provided the designer is aware of their properties. They suffer from reduced capacity and increased operating potential (and hence risk of passivation) with increasing temperatures above approximately 50°C (Fig. 10.14), decreasing salinity (Figs. 10.15 and 10.16) and decreasing operating current density (Fig. 10.17). 

Cleaners containing silicate can cause problems. They should not be used prior to an alkaline process on aluminium, owing to the formation on the surface of alkali-insoluble aluminium silicate. Silicated cleaners can also cause problems before some surface-sensitive zinc phosphating solutions, especially the more modern low-zinc type. 

A separate problem is the establishment of a good process for electroplating aluminium which must necessarily be based upon a non-aqueous electrolyte. This field is a history of many discoveries, but few developed processes have been claimed, although recent work suggests that at least... 

The purity of the zinc used in the galvanising bath is not critical. Grades which contain just over 1% lead are usually used indeed, lead is essential to avoid operational problems. Lead is soluble in molten zinc up to about 1%, but slab zinc containing a higher percentage of lead is helpful as the excess lead separates and prevents dross from sticking to the bottom of the bath and thus aids its removal. Aluminium is often deliberately added in very small quantities (about 0.005%) to brighten the appearance of the work... 

Where the end use of the product is known, there is usually preference to use either zinc or aluminium, both technically and because of the works problems associated with use of an alloy (identification, separation of overspray). However, in some countries (such as the United States) where there has been a recent-surge in anti-corrosion uses of metal spraying, a zinc-15%-aluminium alloy wire has been widely used. The original commercial experience was with 65-35% alloys used in powder form. Both have many of the advantages of the parent metals. At one time, the zinc-5%-aluminium alloy was also of interest. These alloy coatings may prove particularly satisfactory for sprayed coatings on articles where service conditions are not known in advance. 

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