The smelting of alumina (aluminum oxide)  to aluminum in the smelter uses an electrolysis process (Hall-Héroult process) that uses electricity for heating and reduction and thus the carbon electrode is not consumed.

Alumina (Aluminum oxide) is a fine black power.

Nearly pure molten aluminum is taken from the smelter to the casthouse for alloying (if required) and then cast into sow, ingots, billets, or slab depending on customer requirements.

Bauxite is converted to Alumina (Aluminum oxide)  through several mechanical and chemical processing stages.

The process of forming a thick and hard layer of oxide on aluminum parts.

A heat treatment process applied to welded joints to remove the residual stresses that leave the region hard and brittle.

A geometry optimization process that helps to redesign the part to reduce the maximum stresses.

Cold saw.

Machining (Metal cutting using Milling and Lathe operations)

Abrasive cutting/grinding using angle grinder or cut off saw.

Water jet cutting

Electro-discharge Machining (EDM)

Various forms of welding

Plasma cutting

Drilling

A very economical and environmentally friendly source of steel.

Steel pieces are reheated in a furnace and then rolled into the desired diameter (wire rods).

The chemical composition cannot be changed or controlled.

If the wall thickness is too thin, issues such as plate buckling or local buckling could limit the load capabilities of the structure.

Concentrating all the material close to the center, like in the case of a solid circular rod will increase the critical buckling load of the member.

A thin wall circular hollow section (CHS) is expected to have a high critical buckling load.

A square hollow section (SHS) is inferior in performace in terms of critical buckling load compared to a circular hollow section (CHS) of the same thickness and cross-section area.

Tempering is recommended after the aging process to reduce brittleness.

Can only achieve enhanced mechanical properties if done on Aluminum Alloy and not pure Aluminum.

First, it involved heating till alloy elements fully dissolves in the aluminum and then quenching.

Can achieve enhance mechanical properties if done to pure aluminum.

Surface needs to be shot peened to produce a layer with residual compressive stresses.

Part will also require quenching to achieve a hardened surface.

Part are soaked in a carbon rich environment at elevated temperatures for a significant amount of time to allow the carbon to seep into the surface resulting in the surface regions with a higher carbon concentration.

Case hardening will only be effective if the entire part is made of medium or high carbon steel.

Mild steel/Low carbon steel is the preferred cost effective option for case hardened parts.