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Aluminium alloy
From Wikipedia, the free encyclopedia
Aluminium alloys are alloys in which aluminium (Al) is the predominant metal. The
typical alloying elements are copper, magnesium, manganese, silicon and zinc. There
are two principal classifications, namely casting alloys and wrought alloys, both of
which are further subdivided into the categories heat-treatable and non-heat-treatable.
About 85% of aluminium is used for wrought products, for example rolled plate, foils
and extrusions. Cast aluminium alloys yield cost-effective products due to the low
melting point, although they generally have lower tensile strengths than wrought alloys.
The most important cast aluminium alloy system is AlSi, where the high levels of
silicon (4.013%) contribute to give good casting characteristics. Aluminium alloys
are widely used in engineering structures and components where light weight or
corrosion resistance is required.[1]
Alloys composed mostly of aluminium have been very important in aerospace manufacturing since the introduction of metal
skinned aircraft. Aluminium-magnesium alloys are both lighter than other aluminium alloys and much less flammable than alloys
that contain a very high percentage of magnesium.[2]
Aluminium alloy surfaces will keep their apparent shine in a dry environment due to the formation of a clear, protective layer of
aluminium oxide. In a wet environment, galvanic corrosion can occur when an aluminium alloy is placed in electrical contact with
other metals with more negative corrosion potentials than aluminium.
Aluminium alloy compositions are registered with The Aluminum Association. Many organizations publish more specific
standards for the manufacture of aluminium alloy, including the Society of Automotive Engineers standards organization,
specifically its aerospace standards subgroups,[3] and ASTM International.
Contents
1 Engineering use and aluminium alloys properties
1.1 Overview
1.2 Aluminium alloys versus types of steel
1.3 Heat sensitivity considerations
1.4 Household wiring
2 Alloy designations
2.1 Temper designation
2.2 Wrought alloys
2.3 Cast alloys
2.4 Named alloys
3 Applications
3.1 Aerospace alloys
3.1.1 Scandiumaluminium
3.1.2 List of aerospace aluminium alloys
3.2 Marine alloys
3.3 Cycling alloys
3.4 Automotive alloys
4 References
4.1 Bibliography
5 External links
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Aluminium also is subject to internal stresses and strains when it is overheated; the tendency of the metal to creep under these
stresses tends to result in delayed distortions. For example, the warping or cracking of overheated aluminium automobile
cylinder heads is commonly observed, sometimes years later, as is the tendency of welded aluminium bicycle frames to gradually
twist out of alignment from the stresses of the welding process. Thus, the aerospace industry avoids heat altogether by joining
parts with adhesives or mechanical fasteners. Adhesive bonding was used in some bicycle frames in the 1970s, with unfortunate
results when the aluminium tubing corroded slightly, loosening the adhesive and collapsing the frame.
Stresses in overheated aluminium can be relieved by heat-treating the parts in an oven and gradually cooling itin effect
annealing the stresses. Yet these parts may still become distorted, so that heat-treating of welded bicycle frames, for instance,
can result in a significant fraction becoming misaligned. If the misalignment is not too severe, the cooled parts may be bent into
alignment. Of course, if the frame is properly designed for rigidity (see above), that bending will require enormous force.
Aluminium's intolerance to high temperatures has not precluded its use in rocketry; even for use in constructing combustion
chambers where gases can reach 3500 K. The Agena upper stage engine used a regeneratively cooled aluminium design for
some parts of the nozzle, including the thermally critical throat region; in fact the extremely high thermal conductivity of aluminium
prevented the throat from reaching the melting point even under massive heat flux, resulting in a reliable lightweight component.
Household wiring
Main article: Aluminium wire
Because of its high conductivity and relatively low price compared with copper in the 1960s, aluminium was introduced at that
time for household electrical wiring in North America, even though many fixtures had not been designed to accept aluminium
wire. But the new use brought some problems:
The greater coefficient of thermal expansion of aluminium causes the wire to expand and contract relative to the dissimilar
metal screw connection, eventually loosening the connection.
Pure aluminium has a tendency to "creep" under steady sustained pressure (to a greater degree as the temperature rises),
again loosening the connection.
Galvanic corrosion from the dissimilar metals increases the electrical resistance of the connection.
All of this resulted in overheated and loose connections, and this in turn resulted in some fires. Builders then became wary of
using the wire, and many jurisdictions outlawed its use in very small sizes, in new construction. Yet newer fixtures eventually
were introduced with connections designed to avoid loosening and overheating. At first they were marked "Al/Cu", but they
now bear a "CO/ALR" coding.
Another way to forestall the heating problem is to crimp the aluminium wire to a short "pigtail" of copper wire. A properly done
high-pressure crimp by the proper tool is tight enough to reduce any thermal expansion of the aluminium. Today, new alloys,
designs, and methods are used for aluminium wiring in combination with aluminium terminations.
Alloy designations
Wrought and cast aluminium alloys use different identification systems. Wrought aluminium is identified with a four digit number
which identifies the alloying elements.
Cast aluminium alloys use a four to five digit number with a decimal point. The digit in the hundreds place indicates the alloying
elements, while the digit after the decimal point indicates the form (cast shape or ingot).
Temper designation
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The temper designation follows the cast or wrought designation number with a dash, a letter, and potentially a one to three digit
number, e.g. 6061-T6. The definitions for the tempers are:[5][6]
-F
As fabricated
-H
Strain hardened (cold worked) with or without thermal treatment
-H1
Strain hardened without thermal treatment
-H2
Strain hardened and partially annealed
-H3
Strain hardened and stabilized by low temperature heating
Second digit
A second digit denotes the degree of hardness
-HX2 = 1/4 hard
-HX4 = 1/2 hard
-HX6 = 3/4 hard
-HX8 = full hard
-HX9 = extra hard
-O
Full soft (annealed)
-T
Heat treated to produce stable tempers
-T1
Cooled from hot working and naturally aged (at room temperature)
-T2
Cooled from hot working, cold-worked, and naturally aged
-T3
Solution heat treated and cold worked
-T4
Solution heat treated and naturally aged
-T5
Cooled from hot working and artificially aged (at elevated temperature)
-T51
Stress relieved by stretching
-T510
No further straightening after stretching
-T511
Minor straightening after stretching
-T52
Stress relieved by thermal treatment
-T6
Solution heat treated and artificially aged
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-T7
Solution heat treated and stabilized
-T8
Solution heat treated, cold worked, and artificially aged
-T9
Solution heat treated, artificially aged, and cold worked
-T10
Cooled from hot working, cold-worked, and artificially aged
-W
Solution heat treated only.
Note: -W is a relatively soft intermediary designation that applies after heat treat and before aging is completed. The -W
condition can be extended at extremely low temperatures but not indefinitely and depending on the material will typically last no
longer than 15 minutes at ambient temperatures.
Wrought alloys
The International Alloy Designation System is the most widely accepted naming scheme for wrought alloys. Each alloy is given a
four-digit number, where the first digit indicates the major alloying elements.
1000 series are essentially pure aluminium with a minimum 99% aluminium content by weight and can be work
hardened.
2000 series are alloyed with copper, can be precipitation hardened to strengths comparable to steel. Formerly referred
to as duralumin, they were once the most common aerospace alloys, but were susceptible to stress corrosion cracking
and are increasingly replaced by 7000 series in new designs.
3000 series are alloyed with manganese, and can be work hardened.
4000 series are alloyed with silicon. They are also known as silumin.
5000 series are alloyed with magnesium.
6000 series are alloyed with magnesium and silicon, are easy to machine, and can be precipitation hardened, but not to
the high strengths that 2000 and 7000 can reach.
7000 series are alloyed with zinc, and can be precipitation hardened to the highest strengths of any aluminium alloy.
8000 series is a category mainly used for lithium alloys.[citation needed]
Wrought aluminium alloy composition limits (% weight)
Alloy
Si
Fe
Cu
Mn
Mg
Cr
Zn
Ti
Bi
Ga
Pb
Zr
Each Total
Al
0.03
99.5 min
1060
0.25 0.35 0.05 0.03 0.03 0.03 0.05 0.05 0.03 0.03 0.03 0.03 0.03 0.03
99.6 min
1100
0.95 Si+Fe
0.05
0.05
0.20
0.05
Limits
0.10
0.005
0.002
99.99
min
2014
0.50
0.7
1.2
0.15
2024
0.50 0.50
0.15
2219
0.2
0.30
5.8 0.20
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0.02
0.10
0.05 0.02
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6.8
0.7
0.40
0.15 0.10
0.05 1.0
0.20 1.5
3003
0.6
3004
0.30 0.7
0.25
3102
0.40 0.7
0.10
4041
4.5
0.80 0.30 0.05 0.05
6.0
0.25
0.10
1.0 0.8
1.5 1.3
0.25
0.05
0.40
0.30
0.10
0.10
0.20
5005
remainder
2.2 0.15
0.10
2.8 0.35
5052
5083
0.15
5086
0.15
5154
3.10 0.15
0.25 0.40 0.10 0.10 3.90 0.35 0.20
0.20
5356
0.06
0.20
5454
0.20
5456
0.20
5754
2.6
0.30 0.20
3.6
0.15
6005
0.6
0.40
0.35 0.10 0.10
0.10 0.10
0.9
0.6
0.10
6005A
0.50
0.40
0.35 0.30 0.50
0.30 0.20
0.9
0.7
0.10
6060
0.30 0.10
0.35
0.10 0.10
0.05 0.15
0.6 0.30
0.6
0.10
6061
0.40
0.7
0.8
0.15
0.8 0.04
0.15
0.25
0.40
1.2 0.35
0.15
6063
0.20
0.45
0.35 0.10 0.10
0.10 0.10
0.6
0.9
0.10
6066
0.9
0.7 0.6 0.8
0.50
0.40 0.25
1.8
1.2 1.1 1.4
0.20
6070
1.0
0.15 0.40 0.50
0.50
0.10 0.25
1.7
0.40 1.0 1.2
0.15
6082
0.7
0.40 0.60
0.50 0.10
0.25 0.20
1.3
1.0 1.2
0.10
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4.50 0.05
0.10
5.50 0.20
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6105
0.10
6162
0.40
0.7
0.50 0.20 0.10
0.10 0.25
0.8
1.1
0.10
6262
0.40
0.7
0.8
0.15
6351
0.7
0.40 0.40
0.50 0.10
1.3
0.8 0.8
0.20
6463
0.20
0.45
0.15 0.20 0.05
0.6
0.9
0.05
7005
7022
0.50 0.50
0.20
7068
001.60 0
2.20 0
7.30
0.12 0.15 2.40 0.10 3.00 0.05 8.30
00.01
7072
0.7 Si+Fe
7075
1.2
2.1 0.18 5.1
0.40 0.50 2.0 0.30 2.9 0.28 6.1
0.20
7079
0.3
0.10
7116
0.15 0.30
0.50
0.8
0.05
1.1
1.4
4.2
0.05 0.05
5.2
0.03
7129
0.15 0.30
0.50
1.3
4.2
0.10
0.10
0.05 0.05
0.9
2.0
5.2
0.03
7178
0.40 0.50
1.6
2.4 0.18 6.3
0.30
2.4
3.1 0.28 7.3
0.40
0.15
0.8 0.04
0.15
0.25
0.40
1.2 0.14
0.40
0.7
0.40
0.7
0.20
0.01
0.06
0.08
0.05 0.15 remainder
0.20
0.05 0.15 remainder
0.05
0.15
0.8
1.3
remainder
0.05 0.15 remainder
0.20
8000
remainder
7178
remainder
all elements, whether a table column exists for them or not, for which no other limits
are specified.
Cast alloys
The Aluminum Association (AA) has adopted a nomenclature similar to that of wrought alloys. British Standard and DIN have
different designations. In the AA system, the second two digits reveal the minimum percentage of aluminium, e.g. 150.x
correspond to a minimum of 99.50% aluminium. The digit after the decimal point takes a value of 0 or 1, denoting casting and
ingot respectively.[1] The main alloying elements in the AA system are as follows:[citation needed]
1xx.x series are minimum 99% aluminium
2xx.x series copper
3xx.x series silicon, copper and/or magnesium
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UNS
Temper
Elongation in 2 in
[%]
201.0
A02010 T7
60.0 (414)
50.0 (345)
3.0
204.0
A02040 T4
45.0 (310)
28.0 (193)
6.0
242.0
A02420
23.0 (159)
N/A
N/A
T61
32.0 (221)
20.0 (138)
N/A
29.0 (200)
N/A
1.0
T4
29.0 (200)
13.0 (90)
6.0
T6
32.0 (221)
20.0 (138)
3.0
T62
36.0 (248)
28.0 (193)
N/A
T7
29.0 (200)
16.0 (110)
3.0
23.0 (159)
13.0 (90)
1.5
A03190 T5
25.0 (172)
N/A
N/A
T6
31.0 (214)
20.0 (138)
1.5
25.0 (172)
14.0 (97)
1.0
T6
34.0 (234)
21.0 (145)
1.0
T6
32.0 (221)
20.0 (138)
2.0
A03550 T51
25.0 (172)
18.0 (124)
N/A
T71
30.0 (207)
22.0 (152)
N/A
36.0 (248)
25.0 (172)
2.5
19.0 (131)
9.5 (66)
2.0
T6
30.0 (207)
20.0 (138)
3.0
A03560 T7
31.0 (214)
N/A
N/A
T51
23.0 (159)
16.0 (110)
N/A
T71
25.0 (172)
18.0 (124)
3.0
T6
34.0 (234)
24.0 (165)
3.5
T61
35.0 (241)
26.0 (179)
1.0
A04430 F
17.0 (117)
7.0 (48)
3.0
B443.0 A24430 F
17.0 (117)
6.0 (41)
3.0
512.0
A05120 F
17.0 (117)
10.0 (69)
N/A
514.0
A05140 F
22.0 (152)
9.0 (62)
6.0
520.0
A05200 T4
42.0 (290)
22.0 (152)
12.0
295.0
319.0
328.0
355.0
A02950
A03280
C355.0 A33550 T6
356.0
A356.0 A13560
443.0
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535.0
A05350 F
35.0 (241)
18.0 (124)
9.0
705.0
A07050 T5
30.0 (207)
17.0 (117)
5.0
707.0
A07070 T7
37.0 (255)
30.0 (207)
1.0
710.0
A07100 T5
32.0 (221)
20.0 (138)
2.0
712.0
A07120 T5
34.0 (234)
25.0 (172)
4.0
713.0
A07130 T5
32.0 (221)
22.0 (152)
3.0
T5
42.0 (290)
38.0 (262)
1.5
T51
32.0 (221)
27.0 (186)
3.0
A07710 T52
36.0 (248)
30.0 (207)
1.5
T6
42.0 (290)
35.0 (241)
5.0
T71
48.0 (331)
45.0 (310)
5.0
771.0
850.0
A08500 T5
16.0 (110)
N/A
5.0
851.0
A08510 T5
17.0 (117)
N/A
3.0
852.0
A08520 T5
24.0 (165)
18.0 (124)
N/A
by the customer
Named alloys
Alclad aluminium sheet formed from high-purity aluminium surface layers bonded to high strength aluminium alloy core
material
Birmabright (aluminium, magnesium) a product of The Birmetals Company, basically equivalent to 5251
Duralumin (copper, aluminium)
Pandalloy Pratt&Whitney proprietary alloy, supposedly having high strength and superior high temperature performance.
Magnalium
Magnox (magnesium, aluminium)
Silumin (aluminium, silicon)
Titanal (aluminium, zinc, magnesium, copper, zirconium) a product of Austria Metall AG. Commonly used in high
performance sports products, particularly snowboards and skis.
Y alloy, Hiduminium, R.R. alloys: pre-war nickel-aluminium alloys, used in aerospace and engine pistons, for their ability
to retain strength at elevated temperature.
Applications
Aerospace alloys
Scandiumaluminium
The addition of scandium to aluminium creates nanoscale Al3Sc precipitates which limit the excessive grain growth that occurs in
the heat-affected zone of welded aluminium components. This has two beneficial effects: the precipitated Al3Sc forms smaller
crystals than are formed in other aluminium alloys[9] and the width of precipitate-free zones that normally exist at the grain
boundaries of age-hardenenable aluminium alloys is reduced.[9] Scandium is also a potent grain refiner in cast aluminium alloys,
and atom for atom, the most potent strengthener in aluminium, both as a result of grain refinement and precipitation
strengthening. However, titanium alloys, which are stronger but heavier, are cheaper and much more widely used.[10]
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The main application of metallic scandium by weight is in aluminium-scandium alloys for minor aerospace industry components.
These alloys contain between 0.1% and 0.5% (by weight) of scandium. They were used in the Russian military aircraft Mig 21
and Mig 29.[9]
Some items of sports equipment, which rely on high performance materials, have been made with scandium-aluminium alloys,
including baseball bats ,[11] lacrosse sticks, as well as bicycle[12] frames and components, and tent poles. U.S. gunmaker Smith
& Wesson produces revolvers with frames composed of scandium alloy and cylinders of titanium. [13]
List of aerospace aluminium alloys
The following aluminium alloys are commonly used in aircraft and other aerospace
structures:[14]
7068 aluminium
7075 aluminium
6061 aluminium
6063 aluminium
2024 aluminium
5052 aluminium
Note that the term aircraft aluminium or aerospace aluminium usually refers to 7075.[15][16]
The following list of aluminium alloys are currently produced,[citation needed] but less widely[citation needed] used:
2090 aluminium
2124 aluminium
2195 aluminium Al-Li alloy, used in Space Shuttle Super Lightweight external tank
2219 aluminium Al-Cu alloy, used in the original Space Shuttle Standard Weight external tank
2324 aluminium
5059 aluminium Used in experimental rocket cryogenic tanks
6013 aluminium
7050 aluminium
7055 aluminium
7150 aluminium
7475 aluminium
Marine alloys
These alloys are used for boat building and shipbuilding, and other marine and salt-water sensitive shore applications.[17]
5052 aluminium alloy
5059 aluminium alloy
5083 aluminium alloy
5086 aluminium alloy
6061 aluminium alloy
6063 aluminium alloy
4043, 5183, 6005A, 6082 also used in marine constructions and off shore applications.
Cycling alloys
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These alloys are used for cycling frames and components[citation needed]
2014 aluminium
6061 aluminium
6063 aluminium
7005 aluminium
7075 aluminium
Scandium aluminium
Automotive alloys
6111 aluminium and 2008 aluminum alloy are extensively used for external automotive body panels, with 5083 and 5754 used
for inner body panels. Hoods have been manufactured from 2036, 6016, and 6111 alloys. Truck and trailer body panels have
used 5456 aluminum.
Automobile frames often use 5182 aluminum or 5754 aluminum formed sheets, 6061 or 6063 extrusions.
Wheels have been cast from A365.0 aluminum or formed 5xxx sheet. [18]
References
1. ^ a b I. J. Polmear, Light Alloys, Arnold, 1995
2. ^ http://www.materials.manchester.ac.uk/pdf/research/latest/magnesium/elke_hombergsmeier_AEROMAG%20Paper_07.pdf
3. ^ SAE aluminium specifications list (http://www.sae.org/servlets/product?
PROD_TYP=STD&PARENT_BPA_CD=AERO&TECH_CD=ALUMI), accessed 8 October 2006. Also SAE Aerospace Council
(http://www.sae.org/about/board/committees/arsp.htm), accessed 8 October 2006.
4. ^ R.E. Sanders, Technology Innovation in aluminium Products, The Journal of The Minerals, 53(2):2125, 2001. Online ed.
(http://www.tms.org/pubs/journals/JOM/0102/Sanders-0102.html)
5. ^ "Sheet metal material" (http://www.precisionsheetmetal.com/home/materials.htm). Archived
(http://web.archive.org/web/20090615063211/http://www.precisionsheetmetal.com/home/materials.htm) from the original on 15
June 2009. Retrieved 2009-07-26.
6. ^ Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003). Materials and Processes in Manufacturing (9th ed.). Wiley. p. 133.
ISBN 0-471-65653-4.
7. ^ a b ASM Metals Handbook Vol. 2, Properties and Selection of Nonferrous Alloys and Special Purpose Materials, ASM
International (p. 222)
8. ^ ASTM B 26 / B 26M 05
9. ^ a b c d Ahmad, Zaki (2003). "The properties and application of scandium-reinforced aluminum". JOM 55 (2): 35.
Bibcode:2003JOM....55b..35A (http://adsabs.harvard.edu/abs/2003JOM....55b..35A). doi:10.1007/s11837-003-0224-6
(http://dx.doi.org/10.1007%2Fs11837-003-0224-6).
10. ^ Schwarz, James A.; Contescu, Cristian I.; Putyera, Karol (2004). Dekker encyclopedia of nanoscience and nanotechnology
(http://books.google.com/?id=aveTxwZm40UC&pg=PA2274) 3. CRC Press. p. 2274. ISBN 0-8247-5049-7.
11. ^ Bjerklie, Steve (2006). "A batty business: Anodized metal bats have revolutionized baseball. But are finishers losing the sweet
spot?". Metal Finishing 104 (4): 61. doi:10.1016/S0026-0576(06)80099-1 (http://dx.doi.org/10.1016%2FS00260576%2806%2980099-1).
12. ^ "Easton Technology Report : Materials / Scandium"
(http://www.eastonbike.com/downloadable_files_unprotected/r&d_files/R&D-03%20Scandium.pdf). EastonBike.com. Retrieved
2009-04-03.
13. ^ "Small Frame (J) Model 340PD Revolver" (http://www.smith-wesson.com/webapp/wcs/stores/servlet/ProductDisplay?
storeId=10001&catalogId=11101&langId=-1&productId=14765&tabselected=tech&isFirearm=Y&parent_category_rn=15704).
Smith & Wesson. Retrieved 2008-10-20.
14. ^ Fundamentals of Flight, Shevell, Richard S., 1989, Englewood Cliffs, Prentice Hall, ISBN 0-13-339060-8, Ch 18, pp 373
386.
15. ^ "Aluminum in Aircraft"
(http://www.aluminum.org/Content/NavigationMenu/TheIndustry/TransportationMarket/Aircraft/default.htm). Archived
(http://web.archive.org/web/20090421062405/http://www.aluminum.org/Content/NavigationMenu/TheIndustry/Transportation
en.wikipedia.org/wiki/Aluminium_alloy
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8/21/13
Bibliography
External links
Aluminium alloys for die casting according to the Japanese Standards, China National Standards, U.S. Standards and
German Standards (http://www.gwp-ag.com/media/www.gwpag.com/org/med_645/804_aluminum_alloys_for_die_casting.pdf)
Aluminium alloys for chill casting and low pressure casting according to the Japanese, Chinese, American and German
industrial standard (http://www.gwp-ag.com/media/www.gwpag.com/org/med_645/803_aluminum_alloys_for_chill_casting_and_low_pressure_casting.pdf)
Aluminium alloys for extrusion according to the German Standards (http://www.gwp-ag.com/media/www.gwpag.com/org/med_645/805_aluminum_alloys_for_extrusion.pdf)
The Aluminium Association's chemical composition standards for wrought aluminium
(http://www.aluminum.org/Content/NavigationMenu/TheIndustry/IndustryStandards/Teal_Sheets.pdf)
"The EAA Alumatter" computer-based reference database containing technical information on the most widely used
aluminium alloys, their mechanical, physical and chemical properties (http://www.aluminium.matter.org.uk/aluselect/)
"Applications for Aluminium Alloys and Tempers. (http://www.pa-international.com.au/images/stories/Applications-forAluminum-Alloys-and-Tempers.pdf)
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