Optimization of the manufacturing sequence in Al-Li alloy systems used in the aerospace industry

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The Canadian Road Map on Transformation Technology of Aluminum 2006 revealed that in order for aluminum to maintain its strategic position as a material of choice in all industries like the transportation industry, significant progress must be made in the development of high-strength, high-stiffness aluminium alloys and the development of cheaper processes for the transformation of Al. For the aerospace industry, this statement is critical since Al is facing competition from carbon-based composites. Alcoa, which is the major manufacturer of aerospace Al alloy grades, is well engaged in taking up this challenge and has recently developed a third generation of Al-Li alloys. However, the state of the art in alloy development requires optimization of the processing conditions, which is far from being achieved for these new alloys. This research proposal is to study three manufacturing processes: extrusion, friction-stir welding and freeforming, as well as studying processing variables for property improvement of two Al-Li alloys, namely 2099 and 2199. The know-how for these three processes was identified by Alcoa as critical prior to the alloy's utilization in aircraft components. This project is a joint effort by researchers from McGill and Laval University, two of the institutional members of REGAL and Alcoa.