Smithells Light Metals Handbook

Smithells Light Metals Handbook Smithells Light Metals Handbook Edited by E. A. Brandes CEng, BSc(Lond), ARCS, FIM an...

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Smithells Light Metals Handbook

Smithells Light Metals Handbook Edited by

E. A. Brandes CEng, BSc(Lond), ARCS, FIM and

G. B. Brook DMet(Sheff), FEng, FIM

Butterworth-Heinemann Linacre House, Jordan Hill, Oxford OX2 8DP 225 Wildwood Avenue, Woburn, MA 01801-2041 A division of Reed Educational and Professional Publishing Ltd

OXFORD BOSTON JOHANNESBURG MELBOURNE NEW DELHI SINGAPORE

First published 1998  Reed Educational and Professional Publishing Ltd 1998 All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England W1P 9HE. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to the publishers

British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library ISBN 0 7506 3625 4 Library of Congress Cataloguing in Publication Data A catalogue record for this book is available from the Library of Congress

Typeset by Laser Words, Madras, India Printed and bound in Great Britain by Hartnolls Ltd, Bodmin, Cornwall

Contents

Preface

vii

1 Related specifications Related specifications for wrought aluminium alloys Related specifications for magnesium alloys Titanium and titanium alloys corresponding grades or specifications

2 General physical properties of light metal alloys and pure light metals 2.1 2.2 2.3 2.4

General physical properties of pure light metals and their alloys The physical properties of aluminium and aluminium alloys The physical properties of magnesium and magnesium alloys The physical properties of titanium and titanium alloys

3 Mechanical properties of light metals and alloys 3.1 Mechanical properties of aluminium and aluminium alloys Alloy designation system for wrought aluminium Temper designation system for aluminium alloys 3.2 Mechanical properties of magnesium and magnesium alloys 3.3 Mechanical properties of titanium and titanium alloys

4 Aluminium and magnesium casting alloys 4.1 Aluminium casting alloys 4.2 Magnesium alloys

1 2 3 3

5

5 6 10 13

14 14 14 15 40 55

67 68 80

vi

Contents

5 Equilibrium diagrams

93

5.1 Index of binary diagrams

93

6 Metallography of light alloys 6.1 Metallographic methods for aluminium alloys 6.2 Metallographic methods for magnesium alloys 6.3 Metallographic methods for titanium alloys

7 Heat treatment of light alloys 7.1 Aluminium alloys Annealing Stabilizing Hardening 7.2 Magnesium alloys Safety requirements Environment Conditions for heat treatment of magnesium alloys castings

8 Metal finishing

163 163 168 171

173 173 173 173 173 176 176 176 176

179

8.1 Cleaning and pickling processes Vapour degreasing Emulsion cleaning 8.2 Anodizing and plating processes 8.3 Plating processes for magnesium alloys Dow process (H. K. Delong) Conditions Electroless plating on magnesium ‘Gas plating’ of magnesium (vapour plating)

179 179 179 182 185 185 185 185 185

9 Superplasticity of light metal alloys

186

10 Light metal-matrix composites

188

Index

193

Preface

The light metals covered by this handbook are only those of industrial importance aluminium, magnesium and titanium. The values given have been updated to the time of publication. They are intended for all those working with light metals; for research or design purposes Reference to source material may be found in Smithells Metals Reference Book (revised 7th edition). For design purpose values of mechanical properties must be obtained from the relevant specifications. Equilibrium diagrams are taken to be the most suitable for general work. For specialist work on any system, original sources should be consulted. E.A.B. Chalfont St Peter, Bucks

1

Related specifications

2

RELATED SPECIFICATIONS FOR WROUGHT ALUMINIUM ALLOYS

BS international

Nominal composition old ISO No. Al

1050A 1080A 1200 1350 2011 2014A 2017A 2024

99.5 99.8 99 99.5 Cu6BiPb Cu4SiMg Cu4MgSi Cu4Mg1

2031 2117 2618A

Cu2NiMgFeSi Cu2Mg Cu2Mg1.5 Fe1Ni1 Mn1 MnMg Si5 Si12 Mg1 Mg5 Mg4.5Mn Mg3.5 Mg2 Mg3.6 Mg3Mn Mg1SiCu Mg0.5Si Si1MgMn Zn4.5Mg Zn6MgCu

3103 3105 4043 4047 5005 5056A 5083 5154A 5251 5454 5554 6061 6063 6082 7020 7075

UK former BS designation 1B 1A 1C 1E FC1 H15 2L97, 2L98, L109, L110, DTD5100A H12 3L86 H16 N3 N31 N21 N2 N41 N6 N8 N5 N4 N51 N52 H20 H9 H30 H17 2L95, L160, L161, L162

France former NF

W. Germany Wk. No.

A5 A8 A4 A5/6 A U5 PbBi A U4SG A U4G A U4G1

3.0255 3.0285 3.0205 3.0257 3.1655 3.1255 3.1325 3.1355

A U2N A U2G A U2GN

3.1305

Italy Canada

Sweden

990

4 007 4 004 4 010

CB60 CS41N

4 355 4 338

S5 S12 G0.6 G5M G4.5MC

A G2M A G2.5MC

3.3525 3.3537

A GSUC

3.3211

A SGM0.7 A Z5G A Z5GU

3.2315 3.4335 3.4365

New UNI

Japan

4 507 4 509 3 567

A1050 A1080 A1200

AK 8

6 362 3 581

CG42

D 16

3 583

9002/4

A2024

CG30

D 18 AK 4-1

3 577 3 578

9002/1 9002/6

A2217

3 568

9003/3 9003/5

4054

4106 3.3555 3.3547

Old UNI

9001/2 9001/4 9001/1 9001/5 9002/5 9002/3

3.0515 3.0505 A A A A A

USSR

GM41 GR40 GM31N GM31P GS11N GS10 ZG62

4140

A2011 A2014

A3105 A4043

5 764

9005/1

A5005

7 790

9005/5

A5083

3 574 7 789

9005/3

6 170

9006/2

A5454 A5554 A6061 A6063

3 571 7 791 3 735

9006/4 9007/1 9007/2

AMG3

4104 4 212 4 425 SM6958

AD3 AD31 V95

A7075

Smithells Light Metals Handbook

Table 1.1

Related specifications

3

Table 1.2 RELATED SPECIFICATIONS FOR MAGNESIUM ALLOYS Cast alloys Nominal composition

UK designation

UK BS2970 MAG

RE3Zn2.5 Zr0.6

ZRE1

6-TE

EZ33A-T5

4442B G-TR3Z2 MG-C-91 3.6204

3.5103

Zn4.2RE1.3 Zr0.7

RZ5

5-TE

ZE41A-T5

4439A G-Z4TR

MG-C-43 3.6104

3.5101

Th3Zn2.2 Zr0.7

ZT1

8-TE

HZ32A-T5 4447B G-Th3Z2

MG-C-81 3.6254

3.5105

Zn5.5Th1.8 Zr0.7

TZ6

9-TE

ZH62A-T5 4438B

MG-C-41 3.5114

3.5102

Al8Zn0.5 Mn0.3

A8

1-M

AZ81A-F

G-A9

MG-C-61

3.5812

Al9.5Zn0.5 Mn0.3

AZ91

3-7B

AZ91C-T4

G-A9Z1

Al7.5/9.5 Zn0.3/1.5 Mn0.15min

C

7-M

USA ASTM

USA AMS

France AFNOR

Standard AECMA

W. Germany W. Germany aircraft DIN 1729

3.5194 3.5912

1.4.2 Wrought alloys Zn3Zr0.6

ZW3

Al6Zn1Mn0.3 AZM Al8.5Zn0.5 Mn0.12min

E-151M

AZ80

Al3Zn1Mn0.3 AZ31

MG-P-43

E-121M AZ61A-F

S-1110

4350H G-A6Z1

MG-P-63

W.3510

3.5612

AZ80A

4360D

MG-P-61

W.3515

3.5812

AZ31B-0

4375F

MG-P-62

W.3504

3.5312

G-A2Z1

Table 1.3 TITANIUM AND TITANIUM ALLOYS. CORRESPONDING GRADES OR SPECIFICATIONS

IMI designation

UK British Standards (Aerospace series) and Min. of Def. DTD seriesŁ

France AIR-9182, 9183, 9184

Germany BWB series†

AECMA recommendations

IMI 115

BS TA 1, DTD 5013

T-35

3.7024

Ti-POI

IMI 125

BS TA 2,3,4,5

T-40

3.7034

Ti-PO2

IMI 130

DTD 5023, 5273, 5283, 5293

T-50

IMI 155

BS TA 6

IMI 160 IMI 230

BS TA 7,8,9 BS TA 21, 22, 23, 24, BS TA 52 55, 58 DTD 5043 BS TA 14, 15, 16, 17 BS TA 10, 11, 12, 13, 28, 56

IMI 315 IMI 317 IMI 318 IMI 318 ELI (extra low interstitial)

USA AMS series‡

ASTM grade 1

(

T-60

3.7064

Ti-PO4

T-U2.

3.7124

Ti-P11

T-A5E T-A6V

T-A6VELI

Ti-P65 3.7164

Ti-P63

USA ASTM series

AMS 4902, 4941, 4942, 4951

ASTM grade 2

AMS 4900

ASTM grade 3

AMS 4901 AMS 4921

AMS 4909, 4910, 4926, 4924, 4953, 4966 AMS 4911, 4928, 4934, 4935, 4954, 4965, 4967

AMS 4907, 4930, 4931

ASTM grade 4

ASTM grade 5

ASTM grade 3, F. 136. continued overleaf

4

Smithells Light Metals Handbook

Table 1.3 (continued )

IMI designation

UK British Standards (Aerospace series) and Min. of Def. DTD seriesŁ

IMI 325 IMI 550 IMI 551 IMI 624

BS TA 45 51, 57 BS TA 39 42

France AIR-9182, 9183, 9184

Germany BWB series†

T-A3V2.5

3.7194

T-A4DE

3.7184

T-A6Zr4 DE

3.7144

IMI 646 IMI 662

IMI 679 IMI 680 IMI 685 IMI 811 IMI 834

AECMA recommendations

T-E11DA T-A6ZD T-A8DV

3.7154

USA ASTM series

AMS 4943 4944

ASTM grade 9

Ti-P68 AMS 4919, 4975, 4976 AMS 4981 AMS 4918, 4971, 4978, 4979 AMS 4974

3.7174

BS TA 18 20, 25-27 DTD 5213 BS TA 43, 44

USA AMS series‡

Ti-P67 AMS 4915, 4916

T-A6E Zr4Nb

Ł UK BS 3531 Part 1 (Metal Implants in Bone Surgery), and Draft British Standard for Lining of Vessels and Equipment for Chemical Processes, Part 9, also refer. † Germany DIN 17850, 17860, 17862, 17863, 17864 (3.7025/35/55/65), and TUV 230-1-68 Group I, II, III and IV also refer. ‡ USA MIL-T-9011, 9046, 9047, 14577, 46038, 46077, 05-10737 and ASTM B265-69, B338-65, B348-59T, B367-61T. B381-61T, B382-61T also refer.

2

General physical properties of light metal alloys and pure light metals

2.1

General physical properties of pure light metals and their alloys

Table 2.1

PHYSICAL PROPERTIES OF ALUMINIUM, MAGNESIUM AND TITANIUM

Property Atomic weight C D 12 Atomic number Density (g cm 1 ) liquid at 660 ° C Al, 651 ° C Mg, 1685 ° C Ti Melting point ° C Boiling point ° C Thermal conductivity Wm 1 K 1 at ° C 0 100 200 400 600 800 1 1 Specific heat Jkg K at ° C 20 0 100 200 300 400 600 800 6 1 Coefficient of expansion 10 K at ° C 0 100 100 200 300 400 600 800 Electrical resistivity at ° C 20 100 200 300 400 600 800 Temp. coefficient of resistivity 0 100 ° C 10 3 K 1

Aluminium

Magnesium

Titanium

26.98154 13 2.70 2.385 660.323 (fixed pt ITS-90) 2520

24.305 12 1.74 1.590 649

47.88 22 4.5 4.11 1667

238 238 238

900 917 984 1030 1076

23.5 23.9 24.3 25.3 26.49

2.67 3.55 4.78 5.99 7.30

4.5

1090 155.5 167 130

3285 16 15 14 13 (13)

1022 1038 1110

519 528 569

1197

619 636 682

26.0 26.1 27.0

8.9 8.8 9.1

28.9

9.4 9.7 9.9

4.2 5.6 7.2

54 70 88

12.1

119 152 165

4.25

Note: For surface tension and viscosity of liquid metals see Metal Reference Book 7th ed. pp. 14 7 to 14 8

3.8

6

Smithells Light Metals Handbook

2.2

The physical properties of aluminium and aluminium alloys

Table 2.2 THE PHYSICAL PROPERTIES OF ALUMINIUM AND ALUMINIUM ALLOYS AT NORMAL TEMPERATURES sand cast

Material Al Al Cu Al Mg Al Si Al Si Cu

Al Si Cu MgŁ Al Cu Mg Ni (Yalloy) Al Cu Fe Mg Al Si Cu Mg Ni (Lo Ex)

Ł Die cast.

Nominal composition % Al Al Cu Cu Cu Mg Mg Mg Si Si Si Cu Si Cu Si Cu Mg Cu Mg Ni Cu Fe Mg Si Cu Mg Ni Si Cu Mg Ni

99.5 99.0 4.5 8 12 3.75 5 10 5 11.5 10 1.5 4.5 3 17 4.5 0.5 4 1.5 2 10 1.25 0.25 12 1 1 2 23 1 1 1

Density g cm 3

Coefficient of expansion 20 100 ° C 10 6 K 1

Thermal conductivity 100 ° C Wm 1 K 1

Resistivity µ m

2.70 2.70 2.75 2.83 2.93 2.66 2.65 2.57 2.67 2.65 2.74

24.0 24.0 22.5 22.5 22.5 22.0 23.0 25.0 21.0 20.0 20.0

218 209 180 138 130 134 130 88 159 142 100

3.0 3.1 3.6 4.7 4.9 5.1 5.6 8.6 4.1 4.6 6.6

69

2.76

21.0

134

4.9

71

2.73

18.0

134

8.6

88

2.78

22.5

126

5.2

71

2.88

22.0

138

4.7

71

2.71

19.0

121

5.3

71

2.65

16.5

107

Modulus of elasticity MPa ð103

71

71 71 71

88

Table 2.3 THE PHYSICAL PROPERTIES OF ALUMINIUM AND ALUMINIUM ALLOYS AT NORMAL TEMPERATURES wrought

Specification 1199

1050A 1200

Al Al Al Al

99.992

Density g cm 3

Coefficient of expansion 20 100 ° C 10 6 K 1

H111 H18

2.70

23.5

H111 H18

2.70

23.5

H111 H18

2.71

23.5

H111 H18

2.71

23.5

T4 T6

2.8 2.8

22 22

239 234 239 234 230 230 230 230 226 226 226 226 142 159

T3 T6

2.77 2.77

23 23

151

5.7 5.7

73 73

T8

2.59

23.6

88.2

9.59

76

T8

2.58

23.9

84

9.59

75

H111 H12 H14 H16 H18

2.74

23.0

180

3.9

0.0030

151

4.8

0.0024

ConditionŁ Sheet

99.8

Extruded Sheet

99.5

Extruded Sheet

99

Extruded Sheet Extruded

2014A

2024 2090 2091

3103

Cu Mg Si Mn Cu Mg Mn Cu Li Zr Cu Li Mg Zr Mn

4.4 0.7 0.8 0.75 4.5 1.5 0.6 2.7 2.3 0.12 2.1 2.0 1.50 0.1 1.25

Sheet

Extruded

Thermal conductivity 100 ° C Wm 1 K 1

Resistivity µ cm 2.68 2.70 2.68 2.74 2.76 2.79 2.80 2.82 2.85 2.87 2.89 2.86 5.3 4.5

Temp. coeff. of resistance 20 100 ° C 0.0042 0.0042 0.0042 0.0042 0.0042 0.0041 0.0041 0.0041 0.0041 0.0040 0.0040 0.0040

Modulus of elasticity MPa ð103 69 69 69 69 69 69 69 69 69 69 69 69 74

69

General physical properties of light metal alloys and pure light metals

1080A

Nominal composition %

continued overleaf

7

8

Table 2.3 (continued) wrought

5083 5251

5154A

Mg Mn Cr Mg Mn

4.5 0.7 0.15 2.0 0.3

Mg

3.5

5454

Mg Mn Cr

2.7 0.75 0.12

Al Li Al Mg Li

Li Mg Li Li Mg Mg Si Cu Cr Mg Si Mg Si

2.0 3.0 2.0 3.0 2.0 1.0 0.6 0.2 0.25 0.5 0.5 0.5 0.5

Mg Si Mn Mg Si

1.0 1.0 0.7 1.0 1.0

Al Li Mg 6061

6063 6063A 6082 6082

Density g cm 3

Coefficient of expansion 20 100 ° C 10 6 K 1

Thermal conductivity 100 ° C Wm 1 K 1

2.67

24.5

2.69

Resistivity µ cm

Temp. coeff. of resistance 20 100 ° C

Modulus of elasticity MPa ð103

109

6.1

0.0019

71

24

155

4.7

0.0025

70

2.67

23.5

2.68

24

4.9 5.3 5.4 5.7 5.1

0.0023 0.0021 0.0021 0.0019

H111 H22 H24

147 142 138 134 147

Sheet Sheet

T6 T6

2.56 2.52

77 79

Sheet

T6

2.46

84

Bar

H111 T4 T6

2.7 2.7 2.7

23.6 23.6 23.6

180 154 167

2.70

23.0

2.7 2.7

24 24 24 23 23

3.5 3.3 3.5 3.2 3.3 4.1 3.7

0.0033 0.0035

2.7

193 201 197 209 201 172 184

2.69

23.0

188 193

3.6 3.4

0.0033 0.0035

ConditionŁ Sheet Sheet Extruded Sheet Extruded Sheet

H111 H12 H14 H111 H13 H16 H111 H14

Extruded

T4 T6 Bar T4 T5 T6 Bar/Extruded T4 T6 Sheet

T4 T6

70 70

68.9 68.9 68.9

0.0031 0.0031

71 69 69 69 69 69 69

Smithells Light Metals Handbook

Specification

Nominal composition %

6463 Al Cu Mg Si (Duralumin)

Al Si Cu Mg (Lo Ex) Al Zn Mg

7075

8090

H111 D Annealed. H12,22 D Quarter hard. H14,24 D Half hard. H16,26 D Three-quarters hard. H18,28 D Hard.

0.65 0.4 4.0 0.6 0.4 0.6 4.5 0.5 0.75 0.75 4.0 1.5 2.0 12.0 1.0 1.0 1.0 10.0 1.0 0.7 0.4 5.7 2.6 1.6 0.25 2.5 1.3 0.95 0.1

Bar

T5 T6 T6

2.71 2.71 2.80

23.4 23.4 22.5

209 201 147

3.1 3.3 5.0

0.0023

Sheet

T4 T6

2.81

22.5

147 159

5.2 4.5

0.0022 0.0026

73

Forgings

T6

2.78

22.5

151

4.9

0.0023

72

Forgings

T6

2.66

19.5

151

4.9

0.0023

79

Forgings

2.91

23.5

151

4.9

0.0023

Extrusion T6

2.80

23.5

130

5.7

0.0020

Plate

2.55

21.4

93.5

9.59

Sheet

T4 D Solution treated and naturally aged. T6 D Solution treated and artificially aged.

69 69 73

72

77

General physical properties of light metal alloys and pure light metals

Al Cu Mg Ni (Yalloy)

Mg Si Cu Mg Si Mn Cu Mg Si Mn Cu Mg Ni Si Cu Mg Ni Zn Cu Mn Mg Zn Mg Cu Cr Li Cu Mg Zr

9

The physical properties of magnesium and magnesium alloys THE PHYSICAL PROPERTIES OF SOME MAGNESIUM AND MAGNESIUM ALLOYS AT NORMAL TEMPERATURE

Material Pure Mag Mg Mn

Nominal composition† % Mg 99.97 (MN70)Mn (AM503)Mn

Mg Al Mg Al Zn

Mg Zn Mn Mg Zn Zr

AL80Al Be (AZ31)Al Zn

Condition

Density at 20 ° C g cm 3

T1

1.74

0.75 approx.

T1

1.75

Melting point °C Sol. Liq. 650 650

651

Coeff. of thermal expansion 20 200 ° C 10 6 K 1

Thermal conductivity Wm 1 K 1

Electrical resistivity µ cm

Specific heat 20 200 ° C J kg 1 K 1

Weldability by argon arc process‡

27.0

167

3.9

1 050

A

26.9

146

5

1 050

A

1.5

T1

1.76

650

651

26.9

142

5.0

1 050

A

0.75 approx. 0.005

T1

1.75

630

640

26.5

117

6

1 050

A

3 1

T1

1.78

575

630

26.0

(84)

10.0

1 050

A

Relative damping capacity§

C

(A8)Al Zn

8 0.5

AC AC T4

1.81 1.81

475Ł

600

27.2 27.2

84 84

13.4

1 000 1 000

A

C

(AZ91)Al Zn

9.5 0.5

AC AC T4 AC T6

1.83 1.83 1.83

470Ł

595

27.0 27.0 27.0

84 84 84

14.1

1 000 1 000 1 000

A

C

(AZM)Al Zn

6 1

T1

1.80

510

610

27.3

79

14.3

14 000

A

(AZ855)Al Zn (ZM21)Zn Mn

8 0.5 2 1

T1

1.80

475Ł

600

27.2

79

14.3

1 000

A

T1

1.78

(ZW1)Zn Zr

1.3 0.6

T1

1.80

625

645

27.0

134

5.3

1 000

A

(ZW3)Zn Zr (Z5Z)Zn Zr

3 0.6 4.5 0.7

T1

1.80

600

635

27.0

125

5.5

960

C

AC T6

1.81

560

640

27.3

113

6.6

960

C

(ZW6)Zn Zr

5.5 0.6

T5

1.83

530

630

26.0

117

6.0

1050

C

27.0

A A

Smithells Light Metals Handbook

Table 2.4

10

2.3

Mg Y RE Zr

Mg RE Zn Zr

Mg Ag RE Zr

4.0 3.4 0.6

AC T6

1.84

550

640

26.7

51

14.8

966

A

(WE54)Y RE() Zr

5.1 3.0 0.6

AC T6

1.85

550

640

24.6

52

17.3

960

A

(ZRE1)RE ZN Zr

2.7 2.2 0.7

AC T5

1.80

545

640

26.8

100

7.3

1 050

A

(RZ5)Zn RE Zr (ZE63)Zn RE Zr

4.0 1.2 0.7 6 2.5 0.7

AC T5

1.84

510

640

27.1

113

6.8

960

B

AC T6

1.87

515

630

27.0

109

5.6

960

A

(ZTY)Th Zn Zr (ZT1)Th Zn Zr

0.8 0.5 0.6 3.0 2.2 0.7

T1

1.76

600

645

26.4

121

6.3

960

A

AC T5

1.83

550

647

26.7

105

7.2

960

A

(TZ6)Zn Th Zr

5.5 1.8 0.7

AC T5

1.87

500

630

27.6

113

6.6

960

B

(QE22)Ag 2.5 RE(D) 2.0 Zr 0.6

AC T6

1.82

550

640

26.7

113

6.85

1000

A

AC T6

1.81

540

640

26.6

113

6.85

1000

A

(EQ21)RE(D) Ag Cu Zr

2.2 1.5 0.07 0.7

B

(B)

continued overleaf

General physical properties of light metal alloys and pure light metals

Mg Th Zn ZrŁŁ

(WE43)Y RE() Zr

11

(continued)

Mg Zn Cu Mn

MG Ag RE ŁŁ Th Zr

(ZC63)Zn Cu Mn (ZC71)Zn Cu Mn

6.0 2.7 0.5 6.5 1.3 0.8

(QH21)Ag RE(D) Th Zr (ZA)Zr

2.5 1.0 1.0 0.7 0.6

AC Sand cast. T4 Solution heat treated. T5 Precipitation heat treated. T6 Fully heat treated. † Mg Al type alloys normally contain 0.2 0.4% Mn to improve corrosion resistance. ŁŁ Thorium containing alloys are being replaced by alternative Mg alloys.

Melting point °C Sol. Liq.

Coeff. of thermal expansion 20 200 ° C 10 6 K 1

Thermal conductivity Wm 1 K 1

Electrical resistivity µ cm

Condition

Density at 20 ° C g cm 3

AC T6

1.87

465

600

26.0

122

5.4

962

B

T6

1.87

465

600

26.0

122

5.4

62

B

AC T6

1.82

540

640

26.7

113

6.85

1005

A

AC

1.75

650

651

27.0

(146)

(4.5)

1050

A

T1 Extruded, rolled or forged. RE Cerium mischmetal containing approx. 50% Ce. Ł Non-equilibrium solidus 420 ° C. () Estimated value. RE(D) Mischmetal enriched in neodynium. RE() Neodynium + Heavy Rare Earths.

Specific heat 20 200 ° C J kg 1 K 1

Weldability by argon arc process‡

‡ Weldability rating: A Fully weldable.

§ Damping capacity rating: A Outstanding.

B Weldable. C Not recommended where fusion welding is involved.

B Equivalent to cast iron.

Relative damping capacity§

A

C Inferior to cast iron but better than Al-base cast alloys.

Smithells Light Metals Handbook

Nominal composition† %

Material

Mg Zr

12

Table 2.4

General physical properties of light metal alloys and pure light metals

2.4

13

The physical properties of titanium and titanium alloys

Table 2.5 PHYSICAL PROPERTIES OF TITANIUM AND TITANIUM ALLOYS AT NORMAL TEMPERATURES

Material IMI designation

Temp. Coefficient Thermal coefficient Magnetic of conof Specific suscept. Nominal expansion ductivity Resistivity resistivity heat 10 6 composition Density 20 100 ° C 20 100 ° C 20 ° C 20 100 ° C 50 ° C cgs units g 1 % g cm 3 10 6 K 1 W m 1 K 1 µ cm µ cm K 1 J kg 1 K 1

CP Titanium Commercially pure IMI 230 Cu 2.5 IMI 260/261 Pd 0.2 IMI 315 Al 2.0 Mn 2.0 IMI 317 Al 5.0 Sn 2.5 IMI 318 Al 6.0 V 4.0 IMI 550 Al 4.0 Mo 4.0 Sn 2.0 Si 0.5 IMI 551 Al 4.0 Mo 4.0 Sn 4.0 Si 0.5 IMI 679 Sn 11.0 Zr 5.0 Al 2.25 Mo 1.0 Si 0.2 IMI 680 Sn 11.0 Mo 4.0 Al 2.25 Si 0.2 IMI 685 Al 6.0 Zr 5.0 Mo 0.5 Si 0.25 IMI 829 Al 5.5 Sn 3.5 Zr 3.0 Nb 1.0 Mo 0.3 Si 0.3 IMI 834 Al 5.8 Sn 4.0 Zr 3.5 Nb 0.7 Mo 0.5 Si 0.35 C 0.06

4.51

7.6

16

48.2

0.0022

528

C3.4

4.56 4.52 4.51

9.0 7.6 6.7

13 16 8.4

70 48.2 101.5

0.0026 0.0022 0.0003

528 460

C4.1

4.46

7.9

6.3

163

0.0006

470

C3.2

4.42

8.0

5.8

168

0.0004

610

C3.3

4.60

8.8

7.9

159

0.0004

4.62

8.4

5.7

170

0.0003

400

C3.1

4.84

8.0

7.1

163

0.0004

4.86

8.9

7.5

165

0.0003

4.45

9.8

4.8

167

0.0004

4.53

9.45

7.8

4.55

10.6

530

3

Mechanical properties of light metals and alloys

The following tables summarize the mechanical properties of the more important industrial light metals and alloys. In the tables of tensile properties at normal temperature the nominal composition of the alloys is given, followed by the appropriate British and other specification numbers. Most specifications permit considerable latitude in both composition and properties, but the data given in these tables represent typical average values which would be expected from materials of the nominal composition quoted, unless otherwise stated. For design purposes it is essential to consult the appropriate specifications to obtain minimum and maximum values and special conditions where these apply. The data in the tables referring to properties at elevated and at sub-normal temperatures, and for creep, fatigue and impact strength have been obtained from a more limited number of tests and sometimes from a single example. In these cases the data refer to the particular specimens tested and cannot be relied upon as so generally applicable to other samples of material of the same nominal composition.

3.1

Mechanical properties of aluminium and aluminium alloys

The compositional specifications for wrought aluminium alloys are now internationally agreed throughout Europe, Australia, Japan and the USA. The system involves a four-digit description of the alloy and is now specified in the UK as BS EN 573, 1995. Registration of wrought alloys is administered by the Aluminum Association in Washington, DC. International agreement on temper designations has been achieved, and the standards agreed for the European Union, the Euro-Norms, are replacing the former British Standards. Thus BS EN 515. 1995 specifies in more detail the temper designations to be used for wrought alloys in the UK. At present, there is no Euro-Norm for cast alloys and the old temper designations are still used for cast alloys. In the following tables the four-digit system is used, wherever possible, for wrought materials. 3.1.1

Alloy designation system for wrought aluminium

The first of the four digits in the designation indicates the alloy group according to the major alloying elements, as follow: 1XXX 2XXX 3XXX 4XXX 5XXX 6XXX 7XXX 8XXX 9XXX

aluminium of 99.0% minimum purity and higher copper manganese silicon magnesium magnesium and silicon zinc other element, incl. lithium unused

Mechanical properties of light metals and alloys

15

1XXX Group:

In this group the last two digits indicate the minimum aluminium percentage. Thus 1099 indicates aluminium with a minimum purity of 99.99%. The second digit indicates modifications in impurity or alloying element limits. 0 signifies unalloyed aluminium and integers 1 to 9 are allocated to specific additions. 2XXX-8XXX Groups: In these groups the last two digits are simply used to identify the different alloys in the groups and have no special significance. The second digit indicates alloy modifications, zero being allotted to the original alloy.

National variations of existing compositions are indicated by a letter after the numerical designation, allotted in alphabetical sequence, starting with A for the first national variation registered. The specifications and properties for Cast Aluminium Alloys are tabulated in Chapter 4. 3.1.2

Temper designation system for aluminium alloys

The following tables use the internationally agreed temper designations for wrought alloys, (BS EN 515. 1995) and the more frequently used ones are listed below. The old ones still used for existing BS specifications e.g. BS 1490. 1989 for castings are compared with the new ones at the end of this section.

U.K.

Meaning

F H111

As manufactured or fabricated Fully soft annealed condition

Strain-hardened alloys H H1x H2x H3x H12,H22,H32 H14,H24,H34 H16,H26,H36 H18,H28,H38 Heat-treatable alloys T1 T2 T3 T4 T5 T6 T7 T8 T9 T10

Strain hardened non-heat-treatable material Strain hardened only Strain hardened only and partially annealed to achieve required temper Strain hardened only and stabilized by low temperature heat treatment to achieve required temper Quarter hard, equivalent to about 20 25% cold reduction Half hard, equivalent to about 35% cold reduction Three-quarter hard, equivalent to 50 55% cold reduction Fully hard, equivalent to about 75% cold reduction Cooled from an Elevated Temperature Shaping Process and aged naturally to a substantially stable condition Cooled from an Elevated Temperature Shaping Process, cold worked and aged naturally to a substantially stable condition Solution heat-treated, cold worked and aged naturally to a substantially stable condition Solution heat-treated and aged naturally to a substantially stable condition Cooled from an Elevated Temperature Shaping Process and then artificially aged Solution heat-treated and then artificially aged Solution heat-treated and then stabilized (over-aged) Solution heat-treated, cold worked and then artificially aged Solution heat-treated, artificially aged and then cold worked Cooled from an Elevated Temperature Shaping Process, artificially aged and then cold worked

A large number of variants in these tempers has been introduced by adding additional digits to the above designations. For example, the addition of the digit 5 after T1-9 signifies that a stress relieving treatment by stretching has been applied after solution heat-treatment.

16

Smithells Light Metals Handbook

A full list is given in BS EN 515. 1995 but some of the more common ones used in the following tables are given below. T351 T3510 T3511 T352 T651 T6510 T6511 T73 T7651

T76510 T76511

Solution heat-treated, stress-relieved by stretching a controlled amount (usually 1 3% permanent set) and then naturally aged. There is no further straightening after stretching. This applies to sheet, plate, rolled rod and bar and ring forging. The same as T351 but applied to extruded rod, bar, shapes and tubes. As T3510, except that minor straightening is allowed to meet tolerances. Solution heat-treated, stress-relieved by compressing (1 5% permanent set) and then naturally aged. Solution heat-treated, stress-relieved by stretching a controlled amount (usually 1 3% permanent set) and then artificially aged. There is no further straightening after stretching. This applies to sheet, plate, rolled rod and bar and ring forging. The same as T651 but applied to extruded rod, bar, shapes and tubes. As T6510, except that minor straightening is allowed to meet tolerances. Solution heat-treated and then artificially overaged to improve corrosion resistance. Solution heat-treated, stress-relieved by stretching a controlled amount (Again about 1 3% permanent set) and then artificially over-aged in order to obtain a good resistance to exfoliation corrosion. There is no further straightening after stretching. This applies to sheet, plate, rolled rod and bar and to ring forging. As T7651 but applied to extruded rod, bar, shapes and tubes. As T7510, except that minor straightening is allowed to meet tolerances.

In some specifications, the old system is still being applied. The equivalents between old and new are as follows. BS EN 515 BS1470/90 Pre-1969 BS F M H111 0 0 T3 TD WD T4 TB W T5 TE P T6 TF WP T8 TH WDP TH7 is as TH and then stabilised. F/M is as manufactured or fabricated.

Table 3.2

ALUMINIUM AND ALUMINIUM ALLOYS-MECHANICAL PROPERTIES AT ROOM TEMPERATURE

Wrought Alloys

Nominal composition Specification %

Form

Condition

0.2% Proof stress MPa

Tensile strength MPa

Fatigue Elong. % strength on 50 mm Shear Brinell (unnotched) Impacy Fracture (½2.6 mm) strength hardness 500 MHz engery toughness p MPa (P D 5D2 ) MPa J (MPa m1/2 ) or 5.65 S0

Remarks

Al 99.99

Sheet

H111 H14 H18

20 60 85

55 85 110

55 20 12

50 60 70

15 23 28

Highest quality reflectors

1080A

Al 99.8

Sheet

H111 H14 H18

25 95 125

70 100 135

50 17 11

60 70 70

19 29 29

Domestic trim, chemical plant

Wire

H111 H14 H18

60 70

19 30 35 41

65 75 85 65

21 30 40 22

65 75 70 65 75

21

1050A

1350

Al 99.5

Al 99.5

Sheet

H111 H14 H18 Bars and sections as extruded Rivet stock H15 Tubes H111 H18 < 75 mm H18 > 75 mm Wire H111 H14 H18

Wire

H111 H14 H18

70 90 105 110 140 130 160 35 105 130 50 125

80 110 145 75 140 75 120 125 110 115 42 75 100 115 115 170 140 195 28 97 165

83 110 186

47 15 10 38

55 69 103

General purpose formable alloy

21 30 38 48 Electrical conductors 48 continued overleaf

Mechanical properties of light metals and alloys

1199

17

18

Table 3.2 (continued ) Wrought Alloys

1200

Al 99,0

2011

2014

2014A

Cu 5.5 Bi 0.5 Pb 0.5 Cu 4.4 Mg 0.7 Si 0.8 Mn 0.75 Cu 4.4 Mg 0.7 Si 0.8 Mn 0.75

Form Sheet

H111 H13 H14 H16 H18 Bars and sections as extruded Tubes H111 H > 75 mm H < 75 mm Extruded bar T3 25 mm T6 50 75 mm Wire T3 10 mm Plate T451 T651 Bar/tube T6510 Sheet Clad sheet Bars and sections Tubes Wire

2024

Cu 4.5 Mg 1.5 Mn 0.6

Condition

River stock Bolt and screw stock Plate

35 95 115 125 145 40

Tensile strength MPa

Fatigue strength (unnotched) 500 MHz MPa

Elong. % on 50 mm (½2.6 mm) p or 5.65 S0

Shear strength MPa

Brinell hardness (P D 5D2 )

43 20 12 11 9 38 40 6 6 14 16

70 75 80 90 95 70 70 100 95 240 240

22 31 35 38 42 23 21 34 32 95 100

35 40 50 60 60 45Ł

22 10 8

260 290

108 139

140 125

115 135

130Ł 130Ł 95Ł 95Ł 140 124

128 120 295 260 350 290 415 440

90 105 120 135 160 85 90 131 124 340 370 365 425 485 490

T4 T6 T4 T6 T4 T6 T4 T6 T4 T6 T4 T6

270 430 250 385 315 465 310 415 340 425 340 425

450 480 425 440 465 500 425 480 445 465 450 460

20 10 22 10 17 10 12 9 15

260 295 250 260

T3 T351

345 325

485 470

18 19

285 285

115 135 115 135 115 135

120 120

Impacy engery J

Fracture toughness (MPa m1/2 )

Remarks

27 31

General purpose, slightly higher strength than 105A

26 27

Free machining alloy

140 140

Heavy duty applications in transport and aerospace, e.g. large parts, wings Aircraft applications (cladding when used 1070A) 22 8

Structural applications, especially transport and aerospace

Smithells Light Metals Handbook

Specification

Nominal composition %

0.2% Proof stress MPa

2024

Cu 4.5 Mg 1.5 Mn 0.6

Plate/sheet extrusions

H111 T4 T6

75 325 395

185 470 475

20 20 10

125 285

47 120

90 140

2117

Cu 2.5 Si 0.6 Mg 0.4

Sheet

T4

165

295

24

195

70

95

2090

Cu 2.7 Li 2.7 Zr 0.12

Plate Plate (12.5 mm)

T81 T81

517 535

550 565

8 11

2091

Cu 2.1 Li 2.0 Mg 1.50 Zr 0.1

Plate (12 mm) Plate (40 mm) Extrusion (10 mm) Extrusion (30 mm) Plate (12 mm) Plate (38 mm) Sheet

T8 ð 51 T8 ð 51 T851

310 310 505

420 430 580

14 6 7

T851

465

520

11

35

T851 T851 T8

460 430 390

525 495 495

10 8 10

43 38 38

Cu 6 Mn 0.3 V 0.1

Plate/sheet/ forgings

H111 T4 T6

75 185 290

170 360 415

18 20 10

105

2004

Cu 6 Zr 0.4

Sheet

H111 T6

150 300

230 420

15 12

100Ł 150Ł

2031

Cu 2.3 Ni 1.0

Forgings

T4 T6

235 340

355 420

22 15

201 201

95 95

Cu 2.0 Mg 1.5 Si 0.9 Fe 0.9 Ni 1.0

Forgings

H111 T6

70 330

170 430

20 8

295

45 130

Mg 0.9 Si 0.9 Fe 0.9 2618A

Vehicle body sheet 71 34

High strength, low density aero-alloy Medium strength, low density aero-alloy in damage-tolerant temper Medium strength, low density aero-alloy Medium strength, low density aero-alloy Weldable, creep resistant, hightemperature aerospace applications Superplastically deformable sheet Aero-engines, missile fins

85Ł 170Ł

Aircraft engines

continued overleaf

Mechanical properties of light metals and alloys

2219

Aircraft structures

19

20

Table 3.2

(continued )

Wrought Alloys

3103

Mn 1.25

Form Sheet

Wire

Condition H111 H12 H14 H16 H18 H111 H14 H18

Tensile strength Mpa

65 110 125 130 140 155 160 180 185 200 60 115 135 155 170 200 205 245

Elong.% on 50 mm (½2.6 mm) p or 5.65 S0

Fatigue strength Shear Brinell (unnotched) Impacy Fracture strength hardness 500 MHz energy toughness MPa (P D 5D2 ) MPa J (MPa m1/2 )

40 17 11 8 7

80 90 95 105 110

3105

Mn 0.35 Mg 0.6

Sheet

H111 H14 H18

55 150 195

115 170 215

24 5 3

85 105 115

3004

Mn 1.2 Mg 1.0

Sheet

H111 H14 H18

70 200 250

180 240 285

20 9 5

110 125 145

3008

Mn 1.6 Fe 0.7 Zr 0.3

Sheet

H111 H18

50 270

120 280

23 4

3003 Mn 1.2 clad with 4343 Si 7.5

Sheet

H111 H12 H14 H16

40 125 145 170

110 130 150 175

30 10 8 5

3003 Mn 1.2 clad with 4004 Si 1.0 Mg 1.5

Sheet

Physical properties

as for 3003 clad with 4343

30 40 44 47 51 30 45 55 65

50 55 60 70 70

34 29

Remarks General purpose, holloware, building sheet

20

Building cladding sheet

45 63 77

95 105 110

Sheet metal work, storage tanks Thermally reistant alloy. Vitreous enamelling

75 85 95 105

Flux brazing sheet

Vacuum brazing sheet

Smithells Light Metals Handbook

Specification

Nominal composition %

0.2% Proof stress MPa

4032

4043A

Si 12.0 Cu 1.0 Mg 1.0 Ni 1.0 Si 5.0

Forgings

T6

240

325

5

Rolled wire

4047A

Si 12.0

5657

75

130

20

Wire

F

189

225

8

Mg 0.8

Sheet

H111 H14 H18

40 140 165

110 160 195

25 12 7

75 95 105

28 40 50

High base purity, bright trim alloy

5005

Mg 0.8

Sheet

H111 H14 H18

40 150 195

125 160 200

25 6 4

75 95 110

28

Architectural trim, commercial vehicle trim

5251

Mg 2.25 Mn 0.25

Sheet

22 7 2 16 20 8 5 4

110 125 140

Bar Sheet

185 245 285 170 180 220 250 270

45 70 80

Mg 2.0 Mn 0.3

95 230 275 60 60 130 175 215

125 145 175

5251

H111 H14 H18 F H111 H22 H24 H28

125 132 139

47 65 74

92 124

95 100 230 255

185 200 250 270

20 20 6 5

125

45

95Ł

95 260 290

200 280 310

Wire

H111 H18

110

Pistons

Welding filler wire Brazing rod

50 29

Sheet metal work Marine and transport applications; good workability combined with good corrosion resistance and high fatigue resistance

49

48 75 85 continued overleaf

Mechanical properties of light metals and alloys

Bars and sections as extruded (F) Tubes H111 H14 H18

115

21

22

Table 3.2 (continued ) Wrought Alloys

Mg 3.5 Mn 0.5

H111 H22 H24 Bars and sections as extruded (F) Tubes H111 H14

125 245 275 125 125 220

240 295 310 230 225 280

Wire

H111 H14 H18

125 265 310

240 295 355

Rivet stock

H111 H12 H111 H22 H24

125 105 200 225

250 290 250 277 297

22 7 5

159 165 179

65 77 85

170 210 180

72 110 77

Form

Condition

Sheet

24 10 9 25 20 7

Mg 2.7 Mn 0.75 Cr 0.12

Sheet

5083

Mg 4.5 Mn 0.7 Cr 0.15

Sheet

H111 H24 Bars and sections as extruded (F)

170 290 180

310 370 315

21 9 19

5083

Mg 4.5 Mn 0.7 Cr 0.15

Tube

180 300

320 375

20 7

250

330

12

5556A

Mg 5

Wire

H14

5056A

Mg 5.0 Mn 0.5

Wire

H111 H14 H18

Rivet stock

H111 H12 Bolt and screw H14 stock

140 300 300 340 340 400 400 450 140 300

300 350 340

55 80 95 55 55

115 125 130 140Ł

Welded structures, storage tanks, salt water service 48

55 90 100

5454

H111 H14

155 175 175 145

Remarks

115 125 130

Higher strength alloy for marine and transport, pressure vessels and welded structures Marine applications, cryogenics, welded pressure vessels.

77

Weld filler wire 65 95 110 120 65

Rivets, bolts, screws

Smithells Light Metals Handbook

Tensile strength MPa

Nominal composition Specification % 5154A

Fatigue Elong.% strength on 50 mm Shear Brinell (unnotched) Impacy Fracture (½2.6 mm) strength hardness 500 MHz energy toughness p MPa (P D 5D2 ) MPa J (MPa m1/2 ) or 5.65 S0

0.2% Proof stress MPa

6060

Mg 0.5 Si 0.4

Bar

T4 T5 T6

90 130 190

150 175 220

20 13 13

6063

Mg 0.5 Si 0.5

Bars, sections and forgings

F T4 T6

85 115 210

155 180 245

30 30 20

Wire

H111 T4 T6

115 195

115 180 230

280 160 210

310 200 240

Mg 1.0 Si 0.5

Bar

T6510 T5 T6

6061

Mg 1.0 Si 0.6 Cr 0.25 Cu 0.2

Bars and sections Wire

T4 T6 T8 6 mm T8 (6 10 mm)

Bar Bolt and screw stock

T6510 T8

280 290

Mg 1.0 Si 1.0 Mn 0.7

Bar/extrusion

Mg 1.0

Bars, sections and forgings

T5 T6510 T451 T651 T6 T4 T6 T4 T6

6082

Si 1.0 Mn 0.5

Plate

Tubes

100 130 160

35 52 75

43 31

Architectural extrusions (fast extruding)

50 70 22 12 12

129 117 152

50 65 78

20 13

160 200

60 90

310 340

13

205

100

260 285 150 289 285 160

300 315 240 315 315 240

15 11 19 12 12 25

185

85

205 180

68 104 100 65

285 160 285

310 245 325

13 20 10

215

145 230 280 310 310 400 385 430 295 385 380 415

60 70

100 65 95

79 69 85

Transport, windows, furniture, doors and architectural uses, pipes (irrigation) 34 27

Intermediate strength extrusion alloy

95

41 34

continued overleaf

Mechanical properties of light metals and alloys

6063A

Medium strength extrusion alloy for doors, windows, pipes, architectural use; weldable and corrosion-resistant

23

24

Table 3.2

(continued )

Wrought Alloys

6463

Tensile strength Mpa

T4 T6

130 215

180 240

16 12

150 205 150

Form

Condition

55 79

70 70

60

97 115

Remarks

Mg 0.55 Si 0.4

Bar

6009

Si 0.8 Mg 0.6 Mn 0.5 Cu 0.4

Sheet

T4 T6

130 325

235 345

24 12

7020

Zn 4.5 Mg 1.2 Zr 0.15

Bars and sections T4 T6

225 310

340 370

18 15

7075

Zn 5.6 Mg 2.5 Cu 1.6 Cr 0.25

Sheet/plate/ forgings/ extrusion

H111 T4 T73

105 505 435

230 570 505

17 11 13

7050

Zn 6.2 Mg 2.2 Cu 2.3 Zr 0.12

Thick section plate/ forgings

T736

455

515

11

7475

Zn 5.7 Mg 2.2 Cu 1.5 Cr 0.2

Sheet/plate/ forgings

T61 T7351

525

460

12

7016

Zn 4.5 Mg 1.1 Cu 0.75

Extrusions

T6

315

360

12

Bright anodized vehicle bumpers

7021

Zn 5.5 Mg 1.5 Cu 0.25 Zr 0.12

Extrusion

H111 T6

115 395

235 435

16 13

Bumper backing bars

Vehicle body sheet

100 126 150 330

60 150

Transportable bridging

160

220

270

220

7

Aircraft structures

Low quench sensitivity, high stress corrosion resistance. Aircraft structures High base purity. High fracture toughness. Aircraft structures

Smithells Light Metals Handbook

Nominal composition Specification %

Fatigue Elong.% strength on 50 mm Shear Brinell (unnotched) Impacy Fracture (½2.6 mm) strength hardness 500 MHz energy toughness p MPa (P D 5D2 ) MPa J (MPa m1/2 ) or 5.65 S0

0.2% Proof stress MPa

8079

Fe 0.7

Foil

8090

Li 2.5 Cu 1.3 Mg 0.95 Zr 0.1

Plate Plate (38/65 mm)

Sheet

Extrusion

8090

8091

35 160

95 175

26 2

483

518

4.3

42

T8151

387

476

6.5

42.5

T8771

483

518

4.3

42

T81

360

420

T6 T8

373 436

472 503

5.7 5

75

T81551

440

510

4

45

T82551 T851

460 515

515 580

4.2 5

39 30 40

11

Domestic foil

42

Extrusion (10 mm) Extrusion (30 mm) Plate (12 mm)

T851

460

520

9

T851

455

500

7

33

Li 2.4 Cu 1.2 Mg 0.50 Zr 0.14

Forging

T651

468

517

7

28.1

T651

400

453

7

36.7

Li 2.5 Cu 1.2 Mg 0.66 Zr 0.12 Li 2.4 Cu 1.9 Mg 0.85 Zr 0.1

Forging

420

499

7.8

16.98

As 2090 but lower density Under-aged, damagetolerant condition Peak-aged, medium strength condition Under-aged, damagetolerant condition with a recrystallized grain structure Peak-aged, medium strength condition Damage-tolerant condition Peak-aged, medium strength condition

Peak-aged (32 h at 170 ° C. (Shrimpton) Under-aged (20 h at 150 ° C). (Shrimpton) Soln. trt, 530 ° C, WQ, aged 30 h at 170 ° C

continued overleaf

Mechanical properties of light metals and alloys

8090

H111 H18

25

26

Table 3.2 (continued ) Wrought Alloys

Specification 8091

Li 2.4 Cu 2.0 Mg 0.70 Zr 0.08

8091

Form Plate (40 mm)

Li 2.3 Cu 1.7 Mg 0.64 Zr 0.13

Forging

460

164

408

159

408

158

436

503

8.2

20.72

Remarks Peak-aged (6% stretch, 32 h at 170 ° C Peak aged (no stretch, 100 h at 170 ° C) Duplex-aged (ditto, 24 h at RT, 48 h at 170 ° C) soln. trt. 530 ° C, WQ, aged 20 h at 170 ° C

Cast alloys 25 25

30Ł 30Ł

19 19

High conductivity, high ductility

60 65

45 95

8 12

Very high corrosion resistance

230 230

85 95

55

15

Strength + corrosion resistance

5 6

90 120

40 50

55 85

170

8

110

55

75

215

10

130

195 210

240 290

3 6

Al

(LMO)

Al 99.0

Sand cast Chill cast

F F

30 30

80 80

30 40

Al Mg

(LM5)

Mg 5.0 Mn 0.5

Sand cast Chill cast

F F

100 100

160 215

6 10

(LM10) Mg 10.0

Sand cast Chill cast

T4 T4

180 190

295 340

12 18

(LM18) Si 5.0

Sand cast Chill cast

F F

60 70

125 155

(LM6) Si 11.5 (LM20) (LM6)

Sand cast

F

65

Chill cast

F

Si 7 Mg 0.4

Sand cast Chill cast

T6 T6

Al Si

Al Si Mg (2L99)

55 55

1.5 2.5

Intricate castings

45Ł

4

60

60Ł

9.5

Very similar alloys, excellent casting characteristics and corrosion resistance. LM6 has slightly supperior corrosion resistance

90

56 90

Good strength in fairly difficult castings. Cast vehicle wheels

Smithells Light Metals Handbook

Nominal composition %

Fatigue 0.2% Elong.% strength Proof Tensile on 50 mm Shear Brinell (unnotched) Impacy Fracture stress strength (½2.6 mm) strength hardness 500 MHz energy toughness p MPa (P D 5D2 ) MPa J (MPa m1/2 ) Condition MPa MPa or 5.65 S0

Al Cu Si

(L154)

Cu 4.2 Si 1.2

(L155) Al Cu Si

(LM24) (LM4)

(LM22)

(LM2) Al Cu Mg

(LM12)

Cu 3.5 Si 8.0 Cu 3.0 Si 5.0

Al Cu

(L119)

Al Zn Mg

(DTT) 5008B

Al Cu Si Zn

(LM27)

Al Si Cu Mg

(LM30)

Si 17.0 Cu 4.5 Mg 0.6

(LM16)

Si 5.0 Cu 1.0 Mg 0.5

Zn 5.3 Mg 0.6 Cr 0.5 Cu 2.0 Si 7.0

T4 T4 T6 T6 F F F F T6 T6 T4

170 175 215 215 110 150 90 100 230 260 115

225 280 295 320 200 320 155 170 260 330 260

8 15 5 10 3 2 3 3 1 3 9

Aircraft castings

Sand Chill Chill Chill Sand

cast cast cast cast cast

F F F T6 T6

85 95 155 285 200

140 185 185 310 225

1 2 1

Sand cast

T4

220

5

Sand cast

F

85

155

2

Chill cast Chill cast Die cast Die cast

F F F O

100 160 240 265

180 180 275 295

3 0.5 1 1

Sand cast Chill cast

T4 T4

130 130

210 245

3 6

200 210

80 85

70 85

1.5 2.5

Sand cast Chill cast

T6 T6

245 275

255 310

1 2

215 225

100 110

60 70

1 1.5

85 90 85 85 70 80 105 110 75

70 80 85 130 90

2

70Ł 75Ł

0.7 0.7

4.5

55 60 0.9 60

75

Excellent die casting alloy General engineering, particularly sand and permanent mould castings Good combination of impact resistance and strength General purpose die casting alloy Castings to withstand high hydraulic pressure Sand castings for elevated temperature service Colour anodizing alloy

Versatile general purpose alloy

80 110 120

Die castings with high wear resistance, especially automobile cylinder blocks Water-cooled cylinder heads and applications requiring leak-proof castings

Mechanical properties of light metals and alloys

Cu 3.0 Si 5.0 Mn 0.5 Cu 1.5 Si 10.0 Cu 10.0 Mg 0.25 Cu 5.0 Ni 1.5

Sand cast Chill cast Sand cast Chill cast Chill cast Die cast Sand cast Chill cast Sand cast Chill cast Chill cast

continued overleaf

27

28

Table 3.2 (continued ) Cast Alloys

Specification

Form

Sand cast T5 Chill cast T5

120 160

185 255

2 2.5

120 160

70 80

55Ł 70Ł

1.5 2.5

Sand cast T6 Chill cast T6

235 275

255 310

1 1

200 230

100 110

70Ł 85Ł

0.7 1.5

Al Cu Mg Ni (L35) (Y Alloy)

Sand Chill Sand Chill Sand Chill Sand Chill Sand Chill

90 90 135 165 95 100 225 240 220 240

140 180 165 220 170 230 255 310 235 290

2.5 4 1.5 2.5 3 8 1 3 1 2

Al Si Cu Mg Zn

Sand cast F Chill cast F

130 130

180 200

1 2

Sand cast T5 Chill cast T5

120 170

130 210

0.3 0.3

120 120

Sand cast T6 Chill cast T6

120 170

130 210

0.3 0.3

120 120

Al Si Mg Mn (LM9)

Si 12.0 Mg 0.4 Mn 0.5

(LM25) Si 7.0 Mg 0.3

Al Si Cu Mg Ni

Cu 4.0 Mg 1.5 Ni 2.0 (LM21) Si 6.0 Cu 4.0 Mg 0.2 Zn 1.0 Si 23.0 Cu 1.0

(LM29) Mg 1.0 Ni 1.0

cast cast cast cast cast cast cast cast cast cast

F F T5 T5 T7 T7 T6 T6 T6 T6

60 60 75 85 65 70 105 105 115 115 85 90

Fluidity, corrosion resistance and high strength. Extensive use for low-pressure castings

The most widely used general purpose, highstrength casting alloy

55 75 60 95 80Ł 110Ł

Remarks

1.5 4.5

Highly stressed components operating at elevated temperatures General engineering applications, particular crankcases Pistons for high performance internal combustion engines High performance piston alloy

Smithells Light Metals Handbook

Nominal composition %

Fatigue 0.2% Elong.% strength Proof Tensile on 50 mm Shear Brinell (unnotched) Impacy Fracture stress strength (½2.6 mm) strength hardness 500 MHz energy toughness p MPa (P D 5D2 ) MPa J (MPa m1/2 ) Condition MPa MPa or 5.65 S0

(LM28)

(LM13)

Si 19.0 Cu 1.5 Mg 1.0 Ni 1.0 Si 11.0 Cu 1.0 Mg 1.0 Ni 1.0

Chill cast

T5

170

190

0.5

120

Sand cast Chill cast Chill cast

T6 T6 T5

120 170

130 200 220

0.5 0.5 1

120 120 105

Sand Chill Sand Chill

Lo Ex

cast cast cast cast

T6 T6 T7 T7

190 280 140 200

200 290 150 210

0.5 1 1 1

190

115 125 75 75

Si 9.0 Cu 3.0 Mg 1.0 Ni 0.7

Chill cast

T5

180

230

1

105

Al Cu Si Mg Fe Ni

(3L52)

Cu 2.0 Si 1.5 Mg 1.0 Fe 1.0 Ni 1.25

Sand cast Chill cast

T6 T6

260 305

285 335

1 1

120 125

Al Cu Si Fe Ni Mg

(3L51)

Cu 1.5 Si 2.0 Fe 1.0 Ni 1.4 Mg 0.15

Sand cast Chill cast

T5 T5

135 150

170 210

2.5 3.5

Ł Fatigue Limit for 50 ð 106 cycles. M D as manufactured. H111 D annealed.  H2    H4 intermediate tempers.  H5   H6 H8 D fully hard temper.

(1) (2) (3) (4)

Special Special Special Special

temper for maximum stress corrosion resistance (US designation T73). heat treatment for combination of properties (US designation T736). heat treatment for combination of properties (US designation T61). heat treatment for combination of properties (US designation T7351).

70 75

Low expansion piston alloy 1.4

1.4

80

Piston alloy

Aircraft engine castings for elevated temperature service

Aircraft engine castings

Mechanical properties of light metals and alloys

(LM26)

85Ł 100Ł

29

30

Smithells Light Metals Handbook

Table 3.3 ALUMINIUM AND ALUMINIUM ALLOYS

Nominal composition %

Condition

Al (1095)

Al 99.95

Rolled rod

(1200)

Al 99

Material (specification)

MECHANICAL PROPERTIES AT ELEVATED TEMPERATURES

Temp. °C

Time at temp. h

0.2% Proof stress MPa

Tensile strength MPa

35 35 30 25 14 11 6 115 105 85 50 17 11 6 150 125 95 30 14 11 6 40 37 34 30 25 17 14 145 130 110 60 30 17 14 185 110 60 30 17 14 55 55 55 50 40 30 20

55 45 25 12 5 90 75 60 40 30 17 14 125 110 90 65 30 17 14 165 150 125 40 30 17 14 110 90 75 60 40 30 20 150 145 125 95 50 30 20 200 155 95 50 30 20 145 145 130 95 60 40 30

Elong. % on 50 mm or p 5.65 S0

Wrought Alloys H111

H111

H14

H18

Al Mn (3103)

Mn 1.25

H111

H14

H18

Al Mg (5050)

Mg 1.4

H111

24 93 203 316 427 24 100 148 203 260 316 371 24 100 148 203 260 316 371 24 100 148 203 260 316 371 24 100 148 203 260 316 371 24 100 148 203 260 316 371 24 148 203 260 316 371 24 100 148 203 260 316 371

10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000

61 63 80 105 131 45 45 55 65 75 80 85 20 20 22 25 75 80 85 15 15 20 65 75 80 85 40 43 47 60 65 70 70 16 16 16 20 60 70 70 10 11 18 60 70 70

Mechanical properties of light metals and alloys

31

Table 3.3 (continued )

Material (specification)

Nominal composition %

Al Mg (cont.)

Al Mg Cr (5052)

(5154)

Mg 2.25 Cr 0.25

Mg 3.5 Cr 0.25

Temp. °C

Time at temp. h

0.2% Proof stress MPa

Tensile strength MPa

H14

24 100 148 203 260 316 371

10 000 10 000 10 000 10 000 10 000 10 000 10 000

165 165 150 50 40 35 20

195 195 165 95 60 40 30

H18

24 100 148 203 260 316 371

10 000 10 000 10 000 10 000 10 000 10 000 10 000

200 200 175 60 40 35 20

220 215 180 95 60 40 30

H111

24 100 148 203 260 316 371

10 000 10 000 10 000 10 000 10 000 10 000 10 000

90 90 90 75 50 35 20

195 190 165 125 80 50 35

30 35 50 65 80 100 130

H14

24 100 148 203 260 316 317

10 000 10 000 10 000 10 000 10 000 10 000 10 000

215 205 185 105 50 35 20

260 260 215 155 80 50 35

14 16 25 40 80 100 130

H18

24 100 148 203 260 316 371

10 000 10 000 10 000 10 000 10 000 10 000 10 000

255 255 200 105 50 35 20

290 285 235 155 80 50 35

8 9 20 40 80 100 130

H111

24 100 148 203 260 316 371

10 000 10 000 10 000 10 000 10 000 10 000 10 000

125 125 125 95 60 40 30

240 240 195 145 110 70 40

25 30 40 55 70 100 130

H14

24 100 148 203 260 316 371

10 000 10 000 10 000 10 000 10 000 10 000 10 000

225 220 195 110 60 40 30

290 285 235 175 110 70 40

12 16 25 35 70 100 130

H18

24 100 148 203 260 316 371

10 000 10 000 10 000 10 000 10 000 10 000 10 000

270 255 220 105 60 40 30

330 310 270 155 110 70 40

8 13 20 35 70 100 130

Condition

Elong. % on 50 mm or p 5.65 S0

continued overleaf

32

Smithells Light Metals Handbook

Table 3.3 (continued )

Material (specification)

Nominal composition %

Al Mg Mn (5056A)

Mg 5.0 Mn 0.3

Al Mg Si (6063)

Mg 0.7 Si 0.4

T6

(6082)

Mg 0.6 Si 1.0 Cr 0.25

T6

(6061)

Mg 1.0 Si 0.6 Cu 0.25 Cr 0.25

T6

Al Cu Mn (2219)

Cu 6.0 Mn 0.25

Condition As extruded

Forgings

F

T6

Al Cu Pb Bi (2011)

Cu 5.5 Pb 0.5 Bi 0.5

T4

Al Cu Mg Mn (2017)

Cu 4.0 Mg 0.5 Mn 0.5

T4

(2024)

Cu 4.5 Mg 1.5 Mn 0.6

T4

Temp. °C

Time at temp. h

20 50 100 150 200 250 300 350 24 100 148 203 260 316 371 24 100 148 203 206 316 371 24 100 148 203 260 316 371 20 100 150 200 250 300 350 400 24 100 148 203 260 316 371 24 100 148 203 260 316 371 24 100 148 203 260 316 371

1 000 1 000 1 000 1 000 1 000 1 000 1 000 1 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 100 100 100 100 100 100 100 100 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000

0.2% Proof stress MPa

Tensile strength MPa

145 145 145 135 111 75 50 20 215 195 135 45 25 17 14 230 270 175 65 35 30 25 275 260 213 105 35 17 14 230

300 300 300 245 215 130 95 60 240 215 145 60 30 20 17 330 290 185 80 45 35 30 310 290 235 130 50 30 20 385 365 325 280 205 145 70 30 375 320 195 110 45 25 17 430 385 274 150 80 45 30 470 422 295 180 95 50 35

220 185 135 110 45 20 295 235 130 75 30 14 11 275 255 205 115 65 35 25 340 305 245 145 65 35 25

Elong. % on 50 mm or p 5.65 S0 25 27 32 45 56 77 100 140 18 15 20 40 75 80 105 17 19 22 40 50 50 50 17 18 20 28 60 85 95 8

15 16 25 35 45 90 125 22 18 16 28 45 95 100 19 17 17 22 45 75 100

Mechanical properties of light metals and alloys

33

Table 3.3 (continued )

Material (specification) Wrought alloys Al Cu Mg Si Mn (2014)

Nominal composition %

Cu 4.4 Mg 0.4 Si 0.8 Mn 0.8

Al Cu Mg Ni (2618)

Cu 2.2 Mg 1.5 Ni 1.2 Fe 1.0

(2031)

Cu 2.2 Mg 1.5 Ni 1.2 Fe 1.0 Si 0.8

Al Si Cu Mg Ni (4032)

Si 12.2 Cu 0.9 Mg 1.1 Ni 0.9

(4032) Al Zn Mg Cu (7075)

Zn 5.6 Cu 1.6 Mg 2.5 Cr 0.3

Al Mg (LM 5)

Mg 5.0 Mn 0.5

(LM 10)

Mg 10.0

Al Si (LM 18)

Si 5.0

Temp. °C

Condition

T6

24 100 148 203 260 316 371 Forgings T6 20 100 150 200 250 300 350 Forgings T6 20 150 200 250 300 350 400 Forgings T6 20 100 200 250 300 350 Forgings T6 24 100 148 203 260 316 371 T6 24 100 148 203 260 316 371 Cast alloys Sand cast F 20 100 200 300 400 Sand cast T4 20 100 150 200 300 400 Pressure die F 24 cast 100 148 203 260

Time at temp. h

0.2% Proof stress MPa

Tensile strength MPa

Elong. % on 50 mm or p 5.65 S0

10 000 10 000 10 000 10 000 10 000 10 000 10 000 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000 10 000

415 385 275 80 60 35 25 415Ł 410 400 260 85 45 35 325Ł 340 260 170 70 30 20 325Ł 310 255 110 45 30 320 305 225 60 35 20 14 505 430 145 80 60 45 30

485 455 325 125 75 45 30 480 465 430 295 110 70 50 430 440 300 210 115 50 30 430 400 310 155 75 40 380 345 255 90 55 35 25 570 455 175 95 75 60 45

13 14 15 35 45 64 20 10

1 000 1 000 1 000 1 000 1 000 1 000 1 000 1 000 1 000 1 000 1 000 10 000 10 000 10 000 10 000 10 000

95 100 95 55 15 180 205 154 105 40 11 110 110 103 80 40

160 160 130 95 30 340 350 270 185 90 45 205 175 135 110 55

4 3 3 4 4 16 10 0 42 85 100 9 9 10 17 23

8

13

9 9 9 30 50 70 90 11 15 30 60 65 80 65

continued overleaf

34

Smithells Light Metals Handbook

Table 3.3

(continued )

Temp. °C

Time at temp. h

0.2% Proof stress MPa

Tensile strength MPa

Elong. % on 50 mm or p 5.65 S0

24 100 148 206 260 20 100 200 300 400 20 100 200 300 400

10 000 10 000 10 000 10 000 10 000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

145 145 125 105 40 95Ł 140 110 40 20 270Ł 255 60 25 12

270 225 185 150 75 155 180 135 60 30 325 290 90 40 25

2 2 21 3 7 13 2 2 2 12 27 2 2 25 65 65

20

1000

200Ł

275

1 2 1 2 1 2

Material (specification)

Nominal composition %

(LM 6)

Si 12.0

Pressure die cast

F

Al Si Cu (LM 4)

Si 5.0 Cu 3.0 Mn 0.5

Sand cast

F

Al Si Mg (LM 25)

Si 5.0 Mg 0.5

Chill cast

T6

Al Cu Mg Ni

Cu 4.0

Sand cast

T6

(4L 35)

Mg 1.5

100

1000

255

325

Ni 2.0

200 300 400

1000 1000 1000

150 30 15

135 55 40

Condition

Al Si Ni Cu Mg

Si 12.0

20

1000

275Ł

285

(LM 13)

Ni 2.5

100

1000

280

320

Cu 1.0 Mg 1.0

200 300 400 20 100 200 300 400

1000 1000 1000 1000 1000 1000 1000 1000

110 30 15 200Ł 195 110 35 15

165 60 35 275 250 170 60 35

Chill cast

T6

Chill cast Special

T6

32 60 1 2 1 2 1 2

15 25 1 1 3 15 50

Ł 0.1% Proof stress.

Table 3.4 ALUMINIUM AND ALUMINIUM ALLOYS Material (specification)

Nominal composi tion %

Al (1200)

Al 9.0

Condition Rolled and drawn rod

H111

H18

Al Mn (3103)

Mn 1.25

Rolled and drawn rod

H111

MECHANICAL PROPERTIES AT LOW TEMPERATURES

Temp. °C

0.2% Proof stress MPa

Tensile strength MPa

Elong.% on 50 mm or 50 mm

Reduction in area %

24 28 80 196 24 28 80 196 24 28 80 196

34 34 37 43 140 144 147 165 40 40 50 60

90 95 100 170 155 155 165 225 110 115 130 220

42.5 43.0 47.5 56 16 152 18.0 35.2 43.0 44.0 45.0 48.8

76.4 76.4 77.0 74.4 59.8 59.4 65.3 67.0 80.6 80.6 79.9 71.2

Fracture toughness MPa m1/2

Mechanical properties of light metals and alloys

35

Table 3.4 (continued ) Material (specification)

Al Mg (5052)

(5154)

Nominal composi tion %

Mg 2.5 Cr 0.25

Mg 3.5 Cr 0.25

Temp. °C

0.2% Proof stress MPa

Tensile strength MPa

Elong.% on 50 mm or 50 mm

Reduction in area %

24 28 80 196

180 185 195 220

195 205 215 290

15.0 15.0 16.5 32.0

63.5 64.4 66.5 62.3

24 28 80 196

97 99 97 115

199 201 210 330

33.2 35.8 40.8 50.0

72.0 74.2 76.4 69.0

H18

24 28 80 196

235 230 236 275

275 280 290 400

16.6 18.3 20.6 30.9

59.1 63.2 64.5 57.4

H111

26 28 80 196

115 115 115 135

240 240 250 350

28 32 35 42

66 72 73 60

H18

26 80 196 253

275 280 325 370

330 340 455 645

9 14 30 35

Condition Rolled and drawn rod

H18

Rolled and drawn rod

H111

Sheet

(5056A)

Mg 5.0 Mn 0.2

Plate

H111

20 75 196

130 130 145

290 290 420

30.5 38.2 50.0

32.0 48.2 36.2

Al Mg Si (6063)

Mg 0.7 Si 0.4

Extrusion

T4

26 28 80 196

90 105 115 115

175 190 200 260

32 33 36 42

78 75 75 73

Extrusion

T6

26 28 80 196

215 220 225 250

240 250 260 330

16 16 17 21

36 36 38 40

24 28 80 196

300 310 305 330

320 352 330 385

15.2 12.0 14.9 18.3

38.8 34.0 38.7 34.7

24 28 80 196

270 280 290 315

315 330 345 425

21.8 21.5 22.5 26.5

56.4 52.5 53.7 46.5

24 28 80 196

300 305 320 400

480 500 510 615

23.3 24.4 25.3 26.7

31.8 33.1 30.8 26.3

24 28 80 196

400 405 415 460

500 502 514 605

14.5 12.7 13.3 14.0

25.8 21.5 22.0 19.7

26 28 80 196 26 28 80 196

290 290 302 380 415 415 420 470

430 440 440 545 485 485 495 565

20 22 22 20 13 13 14 14

28 28 26 20 31 29 28 26

Al Mg Si-Cr (6151)

Mg 0.7 Si 1.0 Cr 0.25

Forging

T6

Al Mg Si Cu Cr (6061)

Mg 1.0 Si 0.6 Cu 0.25 Cr 0.25

Rolled and drawn rod

T6

Al Cu Mg Mn (2024)

Cu 4.5 Mg 1.5 Mn 0.6

Rolled and drawn rod

T4

Rolled and drawn rod

T8

Rod

T4

Al Cu Si Mg Mn (2014)

Cu 4.5 Si 0.8 Mg 0.5 Mn 0.8

Rod

T6

Fracture toughness MPa m1/2

continued overleaf

36

Smithells Light Metals Handbook

Table 3.4 (continued ) Material (specification)

Nominal composition %

Condition

Temp. °C

0.2% Proof stress MPa

Tensile strength MPa

Elong.% on 50 mm or 50 mm

26 80 196 253 27 196 269 27 73 196 269 24 28 80 196

410 460 530 590 535 600 615 440 460 495 550 485 490 505 570

465 510 610 715 565 715 820 480 495 565 630 560 570 590 670

12 14 11 7 11 13.5 17.5 6 7 10 7 15.0 15.3 15.3 16.0

Forging T6

(2090)

(2091)

Al Zn Mg Cu (7075)

Cu 2.7 Li 2.3 Zr 0.12 Cu 2.1 Li 2.0 Mg 1.50 Zr 0.1 Zn 5.6 Mg 2.5 Cu 1.6

Plate (12.5 mm)

T81

Plate (38 mm)

T8

Rolled and drawn rod

T6

Reduction in area %

Fracture toughness MPa m1/2

24 24 22 22 34 57 72 24 32 32 32 29.1 26.2 23.6 20.1

H111 D Annealed. H18 D Fully hard temper. T4 D Solution treated and naturally aged. T6 D Solution treated and precipitation treated.

Table 3.5 ALUMINIUM ALLOYS

CREEP DATA

Temp. °C

Stress MPa

Minimum creep rate % per 1000 h

H111

20 20 80 80 250 250 250 250

24.1 27.6 7.0 8.3 1.4 2.1 2.8 4.1

0.005 0.045 0.005 0.01 0.005 0.01 0.015 0.055

0.39 1.28 0.045 0.065 0.047 0.047 0.052 0.152

H111

80

45

0.005

0.085

110 115 125 30 45 60 3.90 7.7 15

0.055 0.17 0.21 0.08 0.20 0.62 0.045 0.12 0.35

0.33 0.57 1.19 0.21 0.39 0.92 0.10 0.25 0.60

100 100 100 150 150 200 200

40 55 75 7.5 15 7.5 15

0.013 0.022 0.046 0.126 0.147 0.107 0.273

0.126 0.107 0.174 0.413 0.647 0.341 0.658

205 205 205

17 34 51

0.04 0.09 0.14

Nominal composition %

Condition

Al (1080)

99.8

Sheet

Al Mg (5052) (LM 5)

Mg

Sheet

Mg 5.6

Cast

100 100 100 200 200 200 300 300 300

(LM 10)

Mg 10

Cast

Al Cu

Cu 4

Cast

Material (specification)

Total extension % in 1000 h

Mechanical properties of light metals and alloys

37

Table 3.5 (continued )

Material (specification)

Nominal composition %

Condition

Cu 10

Cast

Al Si (LM 13)

Si 13 Ni 1.7 Mg 1.3

Sandcast (modified)

Al Mn (3103)

Mn 1.25

Extruded rod

Al Cu Si (2025)

Cu 4 Si 0.8

Extruded T4

Al Cu Mg Mn (2024)

Cu 4.5 Mg 1.5 Mn 0.6

Clad sheet T4

Clad sheet T6

Al Cu Mg Ni (2218)

Cu 4 Mg 1.5 Ni 2.2

Forged T4

Temp. °C

Stress MPa

Minimum creep rate % per 1000 h

205 315 315 205 205 315 315 315 100 100 200 200 200 300 300 300 200 200 200 200 200 200 200 300 300 150 150 150 200 200 200 250 250 250 35 100 100 150 150 190 190 35 35 100 100 150 150 190 190 100 100 100 200 200 300 300 400

70 8.90 13.1 34 68 8.90 13.1 17 45 60 15 23 30 3.8 7.7 15 15 31 34.8 38.6 42.5 46 54 7.5 15 90 125 155 30 45 60 15 23 30 415 344 385 276 327 140 200 424 430 347 363 242 289 117 193 193 232 270 77 108 7 15 1.5

0.69 0.13 0.29 0.01 0.11 0.12 0.43 0.99 0.016 0.06 0.016 0.054 0.14 0.013 0.047 0.223 0.001 0.022 0.040 0.060 0.13 0.15 0.73 0.007 0.39 0.03 0.045 0.325 0.035 0.1 0.040 0.02 0.07 2.36 10.0 1.0 10.0 1.0 10.0 1.0 10.0 1.0 10.0 1.0 10.0 1.0 10.0 1.0 10.0 0.01 0.02 0.04 0.028 0.16 0.037 0.5 0.05

Total extension % in 1000 h

0.190 0.675 0.096 0.179 0.432 0.026 0.098 0.428

0.340 0.395 0.722 0.107 0.204 0.700 0.156 0.176

0.394 0.440 0.835 0.173 0.345 0.078 0.640 0.110

continued overleaf

38

Smithells Light Metals Handbook

Table 3.5 (continued )

Material (specification)

Nominal composition %

Temp. °C

Stress MPa

Minimum creep rate % per 1000 h

Cast T4

200 200 300 300 400

77 116 7 15 1.50

0.01 0.08 0.018 0.08 0.06

Condition

Al Cu Mg Zn (7075)

Zn 5.6 Cu 1.6 Mg 2.5

Clad sheet T6

35 35 35 100 100 100 150 150 150 190 190 190

430 480 495 295 355 370 70 170 245 45 75 125

Al Mg Si Mn (6351)

Mg 0.7 Si 1.0 Mn 0.6

Extruded rod

100 100 100 100 150 150 150 200 200 200 200

193 201 232 255 93 108 154 31 46 62 77

Total extension % in 1000 h 0.153 0.287 0.072 0.151 0.132

0.1 1.0 10.0 0.1 1.0 10.0 0.1 1.0 10.0 0.1 1.0 10.0 0.007 0.010 0.11 1.6 0.0087 0.023 0.22 0.011 0.040 0.13 0.28

H111 D Annealed. T4 D Solution treated and naturally aged, will respond to precipitation treatment. T6 D Solution treated and artificially aged.

Table 3.6 ALUMINIUM ALLOYS

Material (specification) Al Mg (5056)

Nominal composition %

FATIGUE STRENGTH AT VARIOUS TEMPERATURES

Condition

Temp. °C

Endurance (unnotched) MPa

MHz

Remarks

Mg 5.0

Extruded

65 35 C20

184 164 133

20

Rotating beam

Mg 7.0

Extruded rod

65 35 C20

182 178 173

20

Rotating beam

(LM 10)

Mg 10.0

Sand cast (oil quenched)

20 150 200

93 77 40

30

Rotating beam

Al Si (LM 6)

Si 12.0

Sand cast (modified)

20 100 200 300

51 43 35 25

50

Rotating beam, 24 h at temp.

Al Cu (2219)

Cu 6.0

Forged T6

20 150 200 250 300 350

117 65 62 46 39 23

120

Reverse bending stresses

Mechanical properties of light metals and alloys Table 3.6

39

(continued )

Material (specification)

Nominal composition %

Al Si Cu (LM 22)

Si 4.6 Cu 2.8

Al Cu Si Mn (2014)

Endurance (unnotched) °C

MPa

MHz

Remarks

Sand cast

20 100 200 300

62 54 60 42

50

Rotating beam

Cu 4.5 Si 0.8 Mn 0.8

Forgings T6

148 203 260

65 45 25

100

Rotating beam

Al Cu Mn Mg (2014)

Cu 4.0 Mn 0.5 Mg 0.5

Extruded T4 rod

25 148 203 260

103 93 65 31

500

Rotating beam, 100 days at temp.

Al Cu Mg Si Mn (2014)

Cu 4.4 Mg 0.7 Si 0.8 Mn 0.8

Forgings T4

20 150 200 250 300

119 90 62 54 39

120

Reversed bending

Forgings T6

20 150 200 250 300

130 79 57 39 39

120

Reversed bending

Forged

20 148 203 260

117 103 65 45

500 100 100 100

Rotating beam after prolonged heating

Chill cast T6

20 100 200 300

100 105 108 80

50

Rotating beam, 24 h at temp.

20 150 200 250 300 350 20 100 200 300

113 82 70 59 39 39 97 107 97 54

120

24 149 204 260

151 83 59 48

500

Al Cu Mg Ni (2218)

Cu 4.0 Mg 1.5 Ni 2.0

Temp. Condition

Al Ni Cu

Ni 2.5 Cu 2.2

Forged T6

Al Si Cu Mg Ni (LM 13)

Si 12.0 Cu 1.0 Mg 1.0

Chill cast (Lo-Ex)

Al Zn Mg Cu (7075)

Zn 5.6 Mg 2.5 Cu 1.6 Cr 0.2

Plate T6

T4 D Solution treated and naturally aged, will respond to precipitation treatment. T6 D Solution treated and artificially aged.

50

Reversed bending

Rotating beam, 24 h at temp.

Reversed bending

40

Mechanical properties of magnesium and magnesium alloys

Table 3.7 MAGNESIUM AND MAGNESIUM ALLOYS (WROUGHT)

TYPICAL MECHANICAL PROPERTIES AT ROOM TEMPERATURE

Specifications

Material

NominalŁ composition %

Mg

Mg 99.9

Sheet, annealed Bar, extruded

Mg Mn

Mn 1.5

Sheet Extruded bar (1 in diam.) Extruded tube

Mg Al Zn

Form

DTD or BS (Air)

118C 142B 737A

BS (Gen. Eng.)

Tension

ASTM

Elektron

AM503

Compression

Proof stress 0.2% MPa

UTS MPa

Elong. %

Proof stress 0.2% MPa

Hardness VPN 30 kg

69 100

185 232

4 6

100 162 154

232 263 247

6 7 6

131 170 162

232 263 255

13 10 11

100 93

50 60 55 70 50 60

30 35 35 45

3370-MAG-S-101M 3373-MAG-E-101M 3373-MAG-E-101M

M1A-F, B107 M1A, B107

3370-MAG-S-1110 3370-MAG-S-111M 3373-MAG-E-111M

AZ31, B90 AZ31, B90 AZ31, B107

AZ31

3372-MAG-F-121M 3373-MAG-E-121N 3373-MAG-E-121M

AZ61, B91 AZ61, B107 AZ61, B107

AZM

183 183 170

293 293 278

8 8 8

147 147 147

60 70 55 70 60 70

AZ80A, B91

AZ855

208

293

8

185

65 75

124

35 45 45 55 45 55

Al 3.0 Zn 1.0 Mn 0.3

Sheet, annealed half hard Extruded bar and sections

Al 6.0 Zn 1.0 Mn 0.3

Forgings Extruded bar and sections Extruded tube

2L513 2L512 2L503

Al 8.0 Zn 0.5 Mn 0.3

Forgings

88C

Mg Zn Mn

Zn 2.0 Mn 1.0

Sheet, annealed half breed Extruded bar sections

5091 5101

3370-MAG-S-1310 3370-MAG-S-131M 3373-MAG-E-131M

ZM21

131 170 162

232 263 255

13 10 11

Mg Zn Zr

Zn 1.0 Zr 0.6

Sheet Extruded bar and sections Extruded tube

2L514 2L508 2L509

3370-MAG-S-141M 3373-MAG-E-141M 3373-MAG-E-141M

ZW1

178 208 193

263 293 278

10 13 7

154 177

55 70 60 75 60 75

Zn 3.0

Sheet

2L504

3370-MAG-S-151M

ZW3

185

270

8

154

60 70

Smithells Light Metals Handbook

3.2

Zr 0.6 Zn 5.5 Zr 0.6 Mg Zn Cu Mn

Forgings 2L514 Extruded bar and sections 2L505 (1 in diam.) Bars and sections Heat treated 5041A

Zn 6.5 Cu 1.3 Mn 0.8

Bars and sections Heat treated

Mg Th Zn ZrŁŁ

Th 0.8

(Creep resistant)

Zn 0.5 Zr 0.6

Extruded bar and sections 5111 Forgings 5111

Mg Th MnŁŁ (Creep resistant)

3372-NAG-F-151M 3373-MAG-E-151M

224 239

309 309

8 18

193 213

60 80 65 75

3373-MAG-E-161TE ZK60A-T5, B107-70 ZW6

270

340

10

255

60 80

ZC71

340

360

6

ZTy

147

263

18

50 70

147

232

13

50 70

ZC71-T6, B107

Th 2.0 Mn 0.75

Sheet

HM21-T8, B90

165

247

9

179

Th 3.0 Mn 1.2

Extruded bar and sections

HM31-T5

227

287

8

185

Mechanical properties of light metals and alloys

Nuclear alloys: Two wrought magnesium alloys (Magnox AL80; Mg0.75Al-0.005 Be and MN70; Mg0.75 Mn) of interest only for their nuclear and high-temperature properties have room-temperature tensile properties similar to those of AM503. Ł It is usual to add 0.2 0.4% Mn to alloys containing aluminium to improve corrosion resistance. M D As manufactured. O D Fully annealed. TE D Precipitation treated. ŁŁ Thorium-containing alloys are being replaced by alternative Mg alloys.

41

Material Mg Zr Mg Al Zn

composition % Zr 0.6 Al 6.0 Zn 3.0 Al 8.0 Zn 0.4 Al 9.5 Zn 0.4 Al 9.0 Zn 2.0

Mg Zn Zr Mg Zn RE Zr

Mg RE Zn Zr (Creep resistant) to 250 ° C) Mg Th Zn ZrŁŁ (Creep resistant to 350 ° C) Mg Zn Th ZrŁŁ

Zn 4.5 Zr 0.7 Zn 4.0 RE 1.2 Zr 0.7 Zn 6.0 RE 2.5 Zr 0.7 RE 2.7 Zn 2.2 Zr 0.7 Th 3.0 Zn 2.2 Zr 0.7 Zn 5.5 Th 1.8 Zr 0.7

Condition AC AC TB TF AC TB AC TB TF Die cast AC TB TF TE

DTD or BS (Air)

BS (Gen. Eng.)

Tension

ASTM KIA, B80 AZ63A-F, B80 AZ63A-T4, B80 AZ63A-T6, B80

Elektron

Proof stress 0.2% MPa

UTS MPa

Elong. %

Proof stress 0.2% MPa

Brinell hardnesst VPN 30 kg

185 199 275 275 158 247 154 232 239 216 165 275 275 263

2.0 5 10 5 4 11 2 6 2 3 2 8 2 6

54 97 97 131 86 82 93 90 124 108 97 97 145 162

40 50 50 55 73 50 60 50 60 55 65 55 65 75 85 60 70 65 63 84 65 75

3L124 3L125

2970 2970 2970 2970 2970

2L127

2970 MAG 4-TE

ZK51A-T5, B80

Z5Z

51 97 97 131 86 82 93 90 127 111 97 97 145 161

TE

2L128

2970 MAG 5-TE

ZE41A-T5, B80

RZ5

150

216

5

139

55 75

TF§

5045

ZE63

190

295

7

190

70 80

TE

2L126

2970 MAG 6-TE

EZ33A-T5, B80

ZRE1

95

162

4.5

93

50 60

TE

5005A

2970 MAG 8-TE

HZ32A-T5, B80

ZT1

93

216

7

93

50 60

TE

5015A

2970 MAG 9-TE

ZH62A-T5, B80

TZ6

167

270

8

162

65 75

3L122

MAG MAG MAG MAG MAG

1-M 1-TB 3-M 3-TB 3-TF

ZA

Compression

A8 AZ81A-T4, B80 AZ91C-F, B80 AZ1C-T4, B80 AZ91C-T6, B80 AZ91B-F, B94 AZ92A, B80

AZ91

Smithells Light Metals Handbook

Specifications NominalŁ

42

Table 3.8 MAGNESIUM AND MAGNESIUM ALLOYS (CAST) TYPICAL MECHANICAL PROPERTIES AT ROOM TEMPERATURE

Mg Th ZrŁŁ

Th 3.0 Zr 0.7

TF

Mg Ag RE‡ -Zr

Ag 2.5 RE 2.0‡ Zr 0.6 Ag 2.5 RE 2.0‡ Zr 0.6 RE(D)2.2 Ag 1.5 Zr 0.6 Cu 0.07

TF

Mg RE(D) Ag Zr-Cu

Mg Ag Th RE‡ ZrŁŁ

Mg Zn Cu Mn

93

208

5

93

50 60

MSR-A MSR-B

187 204

247 260

5 3

178 193

65 80 65 80

QE22A-T6, B80

QE22

200

260

4

195

65 80

EQ21A-T6, B80

EQ21

195

261

4

TF

QH21A-T6, B80

QH21A

210

270

4

TF

WE43-T6, B80

WE43

185

265

7

75 90

WE54-T6, B80

WE54

205

280

4

75 90

ZC63-T6, B80

ZC63

158

242

4.5

55 65

5025A 5035A

TF

5055

TF

5055

TF

TF

2970 MAG 12-TF

2970 MAG 13-TF

2970 MAG 14-TF

MTZ

75 90

200

65 80

Ł It is usual to add 0.2 0.4% Mn to alloys containing aluminium to improve corrosion resistance. RE D Cerium mischmetal containing approx. 50% cerium. RE./ D Neodymium plus Heavy Rare Earth metals. † Brinell tests with 500 kg on 10 mm ball for 30 s. RE(D) D Neodymium enriched mischmetal. ‡ Fractionated rare earth metals: MSR-A contains 1.7%; MSR-B contains 2.5%. § Solution heat treated in an atmosphere of hydrogen.

AC D Sand cast. TE D Precipitation heat treated. TB D Solution heat treated. TF D Fully heat treated. ŁŁ Thorium-containing alloys are being replaced by alternative Mg alloys.

Mechanical properties of light metals and alloys

Mg Y RE() Zr

Ag 2.5 RE 1.0‡ Th 1.0 Y 4.0 Zr 0.7 RE()3.4 Zr 0.6 Y 5.1 RE()3.0 Zr 0.6 Zn 6.0 Cu 2.7 Mn 0.5

HK31A-T6, B80

43

44

Smithells Light Metals Handbook

Table 3.9

MAGNESIUM AND MAGNESIUM ALLOYS (excluding high temperature alloys for which see table 3.10) TYPICAL TENSILE PROPERTIES AT ELEVATED TEMPERATURES

‘Short-time’ tension†

Material

Nominal compositionŁ %

Form and condition

Mg

Mg 99.95

Mg Al Zn

Al 8.0 Zn 0.4 (A8)

Mg Zn Zr

Mg Zn RE Zr

Test temp. °C

Young’s modulus GPa

Forged

20 100 150 200

45

Sand cast

20 100 150 200 250

45 34 32 25

Sand cast and solution treated

20 100 150 200 250

(AZ855)

Forged

Al 9.5 Zn 0.4 (AZ91)

0.2% proof stress MPa

UTS MPa

Elong. %

170 128 93 54

5 8 16 43

86 76 65 62

158 154 145 100 75

4 5 11 20 27

45 34 33 28

82 73 65 62

247 202 154 116 85

11 16 21 25 21

20 150 200

45

221 153 102

309 216 154

8 25 28

Sand cast

20 100 150 200 250

45

93

154 131 122 108 77

2 2 6 25 34

Sand cast and solution treated

20 100 150 200

45

90

232 222 196 139

6 12 16 20

Sand cast and fully heat treated

20 100 150 200 250

45 40 37 28 19

127 91 77 62 46

239 232 185 133 103

2 6 25 34 30

Zn 4.5 Zr 0.7 (Z5Z)

Sand cast and heat treated

20 100 150 200 250

45 34 28 22 19

161 124 102 79 57

263 185 145 113 85

6 14 20 23 20

Zn 3.0 Zr 0.6 (ZW3)

Extruded

20 100 200 250

45 40 22 12

255 162 46 11

309 182 127 100

18 33 56 71

Sheet

20 100 150 200 250

45 40 33

195 120 74

270 165 116 76 49

10 33 42 51 59

Sand cast Sand cast treated

20 20 150 200 250

45 41 40 38 33

150 134 120 99 74

216 195 167 131 99

4 6 19 29 35

Zn 4.0 Re 1.2 Zr 0.7 (RZ5)

Mechanical properties of light metals and alloys

45

Table 3.9 (continued ) ‘Short-time’ tension†

Material

Nominal compositionŁ %

Form and condition

Test temp. °C

Young’s modulus GPa

0.2% proof stress MPa

UTS MPa

Elong. %

Mg Zn Th ZrŁŁ

Zn 5.5 Th 1.8 Zr 0.7 (TZ 6)

Sand cast and heat treated

20 100 150 200 250

45 34 31 28 26

161 134 110 82 52

270 224 178 130 91

9 22 26 26 25

Mg Ag RE Zr (D)

Ag 2.5 RE(D)2.0 Zr 0.6 (QE22)

Sand cast and fully heat treated

20 100 150 200 250 300

45 41 40 38 34 31

201 185 171 154 102 68

259 232 210 185 142 88

4 12 16 20 27 59

Mg RE(D) Ag Zr Cu

Re(D)2.2 Ag 1.5 Zr 0.6 Cu 0.07 (EQ21)

Sand cast and fully heat treated

20 100 150 200 250 300

45 43 42 41 39 35

195 189 180 170 152 117

261 230 211 191 169 132

4 10 16 16 15 10

Mg Ag Re(D)ŁŁ Th Zr ‡

Ag 2.6 RE(D)1.0 Th 1.0 Zr 0.6 (OH21)

Sand cast and fully heat treated

20 100 150 200 250 300

45 41 40 38 37 33

210 199 190 183 167 120

270 242 224 205 185 131

4 17 20 18 19 20

Mg Y RE() Zr

Y 4.0 RE()3.4 Zr 0.6 (WE43)

Sand cast and fully heat treated

20 150 200 250 300

45 42 39 37 35

185 175 170 160 120

265 250 245 220 160

7 6 11 18 40

Y 5.1 RE()3.0 Zr 0.6 (WE54)

Sand cast and fully heat treated

20 100 150 200 250 300

45 43 42 41 39 36

205 197 195 183 175 117

280 260 255 241 230 184

4 4.5 5 6.5 9 14.5

Zn 6.0 Cu 2.7 Mn 0.5 (Zc63)

Sand cast and fully heat treated

20 100 150 200

45

158 141 134 118

242 215 179 142

4.5 9 14 11

Zn 6.5 Cu 1.3 Mn 0.8 (Zc71)

Extruded and fully heat treated

20 100 200

45 40 32

325 206 115

350 259 163

6 16 14

Mg Zn Cu Mn

Ł It is usual to add 0.2 0.4% Mn to alloys containing aluminium to improve corrosion resistance. † In accordance with BS1094: 1943; 1 h at temperature and strain rate 0.1 0.25 in in 1 min 1 . ‡ Tested according to BS4A4. RE D Cerium mischmetal containing approx. 50% Ce. RE(D) D Neodymium enriched mischmetal. RE./ D Neodymium plus Heavy Rare Earth metals. ŁŁ Thorium-containing alloys are being replaced by alternative Mg alloys.

46

Smithells Light Metals Handbook

Table 3.10 HIGH TEMPERATURE MAGNESIUM ALLOYS

TENSILE PROPERTIES AT ELEVATED TEMPERATURE

‘Short-time’ tension†

Material

Nominal compositionŁ %

Form and condition

Test temp. °C

Young’s modulus GPa

0.2% proof stress MPa

UTS MPa

Elong. %

Mg RE Zn

RE 2.7 Zn 2.2 Zr 0.7 (ZRE1)

Sand cast and heat treated

20 100 150 200 250 300 350

45 40 38 36 33 28 21

93 79 76 74 65 48 26

162 150 139 125 107 85 56

4.5 11 19 26 35 51 90

Mg Th ZrŁŁ

Th 3.0 Zr 0.7 (HK31) (MTZ)

Sand cast and fully heat treated

20 100 150 200 250 300 350

45 40 38 38 36 34 29

93 88 86 85 83 73 56

208 188 174 162 150 136 103

4 10 13 17 20 22 23

Mg Th Zn ZrŁŁ

Th 3.0 Zn 2.2 Zr 0.7 (ZT1)

Sand cast and heat treated

20 100 150 200 250 300 350

45 36 34 33 33 31 28

93 88 79 65 56 49 45

216 159 131 108 90 76 63

9 23 27 33 38 41 34

Th 0.8 Zn 0.5 Zr 0.6 (ZTY)

Sheet

20 100 150 200 250 300 350

45 41 41 40 40 34 29

181 179 176 165 124 73 17

266 224 201 171 134 96 56

10 10 11 15 20 27 38

Mg Ag RE(D) Zr

Ag 2.5 RE(D)2.0 Zr 0.6 (QE22)

Mg RE(D) Ag Zr Cu

RE(D)2.2 Ag 1.5 Zr 0.6 Cu 0.07 (EQ21)

Mg Ag RE(D) Th ZrŁŁ

Ag 2.5 RE(D)1.0 Th 1.0 Zr 0.6 (QH21)

Mg Y RE() Zr

Y 4.0 RE()3.4 (WE43) Y 5.1 RE()3.0 Zr 0.6 (WE54)

 Sand cast    and fully      heat    treated      Sand cast     and fully      heat    treated          Sand cast  and fully   heat     treated         Sand cast     and fully      treated     Sand cast     and fully      eat   treated

High strength cast alloys with good elevated temperature properties for which see Table 3.9

Ł It is usual to add 0.2 0.4% Mn to alloys containing aluminium to improve corrosion resistance. † In accordance with BS 1094: 1943; 1 h at temperature; strain rate 0.1 0.25 in in 1 min 1 . RE D Cerium mischmetal containing approx. 50% Ce. RE(D) D neodymium-enriched mischmetal. RE./ D Neodymium plus Heavy Rare Earths. ŁŁ Thorium containing alloys are being replaced by alternative Mg alloys.

Mechanical properties of light metals and alloys Table 3.11 HIGH-TEMPERATURE MAGNESIUM ALLOYS

47

LONG-TERM CREEP RESISTANCE

Stress to produce specified creep strains%

Material Mg RE Zn Zr

Nominal composition % RE 2.7 Zn 2.2 Zr 0.7 (ZRE1)

Form and Condition

Temp. °C

Time† h

0.05 MPa

0.1 MPa

Sand cast and heat treated

200

100 500 1 000

52 41 36

66 54 47

250

100 500 1 000 100 500 1 000 100 500 1 000

23 11

28 19 14 7.4 5.2 4.3 97

32 24 20 8 6.5 5.6 111 106 103

117 117 116

100 500 000 100 500 000 100 500 000 100 100

77

86 75 70 43 28 23 12 6.2 5.4 45Ł

97 88 83 52 37 31 19 8.6 6.9 63Ł 62Ł

101 96 91 67 52 43 32 15 12 97Ł 100Ł

28Ł

43Ł 29Ł 19Ł

65Ł 45Ł 27Ł

315

Zn 4.0 RE 1.2 Zr 0.7 (RZ5)

Sand cast and heat treated

100

150 1 200 1 250 1 Mg Th ZrŁŁ

Th 3.0 Zr 0.7 (HK31) (MTZ)

Sand cast and fully heat treated

200 1 260 315

Mg Th Zn ZrŁŁ

Mg Th Zn ZrŁ

Th 0.8 Zn 0.5 Zr 0.6 (ZTY) Th 3.0 Zn 2.2 Zr 0.7 (ZT1)

Sheet

Sand cast and heat treated

100 1 000 100

250

9.3Ł

14Ł

0.5 MPa

1.0 MPa

36 30 26

34 30

71 65 58

107 100 97 73 64 53 39 19 15 111Ł

32Ł

Stress of 46 MPa (3 tonf in 2 ) produced 0.03% creep strain Stress of 46 MPa (3 tonf in 2 ) produced 0.03% creep strain 50 56 63 66 43 51 58 63 39 48 56 61

250

100 500 1 000

42 35 31

300

100 500 000 100 500 000 100 500 000 100 500 000 100 500 000

23 19 17 14 12 10 10

28 21 19 19 13 12 12 9 8 8

35 25 21 24 16 13 18 10 8 11

46 36 32 29 21 15 21 12 9 12 8

51 36 26

66 56 51

82 69 63

96 85 80

52 41 36 36 25 20 23 14 10 13 9 8 102 94 90

100 500 1 000

26 15 11

32 22 17

45 26 20

56 40 31

62 49 40

1

1 350 1 375 1 Sand cast and heat treated

29 22 20 6.2 4.3 3.9 31Ł

100

325

Zn 5.5 Th 1.8 Zr 0.7 (TZ6)

5.6

0.2 MPa

150 1 200

48

Smithells Light Metals Handbook

Table 3.11 (continued ) Stress to produce specified creep strains%

Material Mg Ag RE(D) Zr

Nominal composition % Ag RE(D) Zr (QE22)

2.5 2.0 0.6

Form and Condition

Temp. °C

Time† h

0.05 MPa

Sand cast and fully heat treated

200

100 500 1 000

55

100 500 1 000

18

250

Mg RE(D) Ag Zr Cu

RE(D) Ag Zr Cu (EQ21)

2.2 1.5 0.6 0.07

Sand cast and fully heat treated

0.1 MPa

0.2 MPa

0.5 MPa

1.0 MPa

74 54 46

88 65 56

82 73

89 79

26 15 10

33 22 16

28 22

31 26

200

100 500 1 000

78 57 48

95 71 62

116 88 76

250

100 500 1 000

29 18 14

36 22 19

42 30 24

100 500 1 000

32 20

39 26 21

32 26

173 148 139

Mg Ag RE(D) Th ZrŁŁ

Ag RE(D) Th Zr (QH21)

2.5 1.0 1.0 0.6

Sand cast and fully heat treated

250

Mg Y RE() Zr

Y 4.0 RE() 3.4 Zr 0.6 (WE43)

Sand cast and fully heat treated

200

100 500 1 000

148

161 115 96

250

100 500 1 000

44

61 46 39

200

100 500 1 000

160 120 120

165 140 132

250

100 500 1 000

47 43 16

61 40 32

81 58 48

150

100 500 1 000

94 82 74

99 92 89

104 98 95

200

100 500 1 000

60 51 42

63 55 49

67 61 55

Y 5.1 RE() 3.0 Zr 0.6 (WE54)

Mg Zn Cu Mn

Zn Cu Mn (ZC63)

6.0 2.7 0.5

Sand cast and fully heat treated

Sand cast and fully heat treated

Ł Total strains. † 4 6 h heating to test temperature followed by 16 h soaking at test temperature. RE D Cerium mischmetal containing approx. 50% Ce. RE(D) D Neodymium-enriched mischmetal. RE./ D Neodymium plus Heavy Rare Earth metals. ŁŁ Thorium-containing alloys are being replaced by alternative Mg alloys.

22

36 30

Mechanical properties of light metals and alloys Table 3.12 HIGH-TEMPERATURE MAGNESIUM ALLOYS

49

SHORT-TERM CREEP RESISTANCE

Stress to produce specified creep strains%

Material Mg RE Zn Zr

Nominal composition % Re 2.7 Zn 2.2 Zr 0.7 (ZRE1)

Th 0.8 Zn 0.5 Zr 0.6 (ZTY)

Th 3.0 Zn 2.2 Zr 0.7 (ZT1)

130 128 125

136 134 129

84 83 82 59 58 49 107 105 99

92 91 89 73 69 56 116 114 103

111 110 108 80 76 62 127 124 114

123 120 114 85 83 68

130 129 125 90 88 73 136 134 125

86 83 71 62 59 48 96 95 94

90 88 76 69 66 53 103 103 102

94 91 81 76 73 59 119 118 117

99 96 86 79 76 64 138 137 137

30 60 600 30 60 600

80 78 74

88 86 82

103 102 96 110 95

117 116 107 159 157 145

163 160 149

128 127 120 165 162 151

30 60 600 30 60 600

20 18

32 28 15

48 40 20

80 67 31 100 96 85

93 82 42 118 114 103

102 98 66 125 123 114

30 60 600 30 60 600 30 60 600

58 57 56 55 53 50 96 93 63

65 64 63 60 59 59 113 109 90

71 69 68 64 63 61 120 117 102

84 81 74 73 72 71 128 124 110

102 99 86 76 76 74 137 133 114

111 107 98 82 80 77 144 137 119

30 60 600 30 60 600

70 65 56 54 52 44

77 74 60 59 57 49

85 80 66 64 62 53

96 90 74 70 66 56

99 94 77 74 70 58

107 99 82 76 73 59

250

30 60 600 30 60 600 30 60 600

76 74 73 52 51 42 100 99 86

30 60 600 30 60 600 30 60 600

Sand cast and heat treated

200

Sand cast and fully heat treated

250

Sheet

250

Sand cast and heat treated

200

250

315

Zn 5.5 Th 1.8 Zr 0.7 (TZ6)

118 117 116

30 60 600

350

Mg Th Zn ZrŁ

98 97 96

200

315

Mg Th Zn ZrŁ

Stress to fracture MPa

Sand cast and heat treated

315

Th 3.0 Zr 0.7 (HK31) (MTZ)

10.0 MPa

Time† s

250

Mg Th ZrŁ

5.0 MPa

Temp. °C

315

Zn 4.0 RE 1.2 Zr 0.7 (RZ5)

2.0 MPa

Form and condition

Sand cast and heat treated

200

250

315

0.05 MPa

† 1 h heating to test temperature followed by 1 h soaking at test temperature. RE D cerium mischmetal containing approx. 50% Ce. Ł Therium-containing alloys are being replaced by alternative Mg alloys.

1.0 MPa

83 79 67

116 113 93 86 82 69 145 145 144

50

Table 3.13 MAGNESIUM AND MAGNESIUM ALLOYS

FATIGUE AND IMPACT STRENGTHS

Material Mg Mn Mg Al Zn

NominalŁ composition % Mn 1.5 (AM503) Al 6.0 Zn 1.0 (AZM) Al 8 Zn 0.4 (A8)

Al 9.5 Zn 0.4 (AZ91)

Mg Zn Zr

Mg Zn RE Zr

Zn Zr (ZW3) Zn Zr (Z5Z) Zn RE Zr (RZ5) Zn RE

3.0 0.6

‡ Condition Extruded Extruded

Sand cast Sand cast and solution treated Sand cast Sand cast and solution treated Sand cast and fully heat treated Extruded

State

temp. °C

U N U N

20

U N U N U U U N U N

20

20

20 150 200 20 20

U N U N

20 20

Impact strength§ for single blow fracture

105

5 ð 105

106

5 ð 106

107

5 ð 107

MPa

MPa

Mpa

MPa

MPa

MPa

107 76 161 127

90 90 139 110

88 54 133 103

86 51 125 97

85 50 124 94

83 48 120 91

108 107 124 108 93 71 114 110 124 103

93 80 102 86 69 52 91 83 93 82

90 73 97 82 66 48 89 74 93 80

88 66 91 74 59 38 88 68 93 79

88 65 90 73 57 36 86 66 93 79

86 63 90 69 57 31 85 63

117 93 151 124

90 66 137 99

80 66 134 93

79 65 128 91

77 65 127 90

Test temp. °C

Unnotched

Notched

J

J

20

12 14

4 4.5

20

34 43

7 9.5

20

3 5

1.5 2

20

18 27

4.5 7

196 20

1.5 1.5 2.0

1 1.5

20

7 9.5

3 4

76 65 124 88

20

3 4

1 1.5

20

23 31

9.5 12

77

4.5 0.7

Sand cast and heat treated

U N

20

111 90

86 86

85 85

82 82

80 80

77 77

20 196

7 12 0.8

3 4

4.0 1.2 0.7

Sand cast and heat treated

20

99 93 85 74 82 59

97 91 80 69 80 54

97 88 73 62 79 52

96 86 69 59 77 52

94 83 65 54 74 51

4 5.5 0.7

1 2

Sand cast and heat treated

124 108 97 93 100 77

20 196

2.2 2.7

U N U U U N

20

6 7.5

1 2

150 200 20

Smithells Light Metals Handbook

Fatigue strength† at specified cycles

Zr (ZRE1)

0.7

U U U U

150 200 250 300

69 68 59 49

60 59 48 39

59 56 45 37

57 52 43 37

57 51 43 36

57 51 42 34

6 2.5 0.6

Sand cast and fully heat treatedŁŁ

U N

20

144 99

131 83

127 79

121 73

119 72

117 71

Ag RE(D) Zr (MSR B)

2.5 2.5 0.6

Sand cast and fully heat treated

U N N U

20

119 77

103 65

103 63

77

68

103 62 90 57

102 62 88 54

100 62 86 51

Ag Re(D) Th Zr (QH21)

2.5 1.0 1.0 0.6

Sand cast and fully heat treated

U N U

135 86 108

114 72 76

111 69 65

109 64 56

108 63 55

108 62 52

Mg Zn Th ZrŁŁ

Zn Th Zr (TZ6)

5.5 1.8 0.7

Sand cast and heat treated

U N

20

120 100

86 86

85 80

83 77

83 76

82 76

Mg Th ZrŁŁ

Th Zr (MTZ)

3.0 0.7

Sand cast and fully heat treated

U N U U

20 80

74 48 74 63

68 40 68 59

65 36 60 54

63 34 59 52

62 32 58 51

Mg Ag RE(D) Zr

Mg Ag RE(D)Th ZrŁŁ

200 250 20 250

200 250

0.5

20

12.9 17.6

2.3 2.7

20 196

8 11 0.5

1.5 3

continued overleaf

Mechanical properties of light metals and alloys

Zn RE Zr (ZE63)

196

51

52

Table 3.13 (continued )

NominalŁ composition %

Material Mg Th Zn ZrŁŁŁ

Th Zn Zr (ZTY) Th Zn Zr (ZT1)

‡ Condition

0.7 0.5 0.6

Extruded

3.0 2.2 0.7

Sand cast and heat treated

State U N U U U N U U U

temp. °C 20 200 250 20 200 250 325

Impact strength§ for single blow fracture

105

5 ð 105

106

5 ð 106

107

5 ð 107

MPa

MPa

Mpa

MPa

MPa

MPa

100 73 80 97 76 71 66

86 52 74 63 82 59 60 51

83 51 68 59 79 56 59 46 43

79 49 60 54 74 51 54 43 37

76 48 59 52 71 49 52 42 34

74 46 57 51 68 48 51 39 29

Mg RE(D) As Zr Cu

RE(D) Ag Zr Cu

2.2 1.5 0.6 0.07

Sand cast and fully heat treated

U

20

103

94

93

92

91

90

Mg Y RE() YZr

Y RE() Zr

4.0 3.4 0.6

Sand cast and fully heat treated

U U U

20 150 250

114 107 107

101 97 81

98 94 74

94 87 65

93 85 64

91 83 62

Y RE() Zr

5.9 3.0 0.6

Sand cast and fully heat treated

U U U

20 200 250

113 118 115

104 96 84

102 90 78

100 84 67

99 83 66

97 82 65

Zn Cu Mn

6.0 2.7 0.5

Sand cast and fully heat treated

U N

20

100 62

94 57

92 56

90 55

Mg Zn Cu Mn

Ł It is usual to add 0.2 0.4% Mn to alloys containing aluminium to improve corrosion resistance. ŁŁ Solution heat treated in an atmosphere of hydrogen.

† Wohler rotating beam tests at 2960 c.p.m. ‡ U D Unnotched. N D Notched. Semi-circular notch of 0.12 cm (0.047 in) radius. Stress concentration factor 1.8.

Test temp. °C

Unnotched

Notched

J

J

20

7 8

1.5 3

196

0.8

§ Hounsfield balanced impact test, notched bar values are equivalent to Izod values. RE(D) D Neodymium enriched mischmetal. ŁŁŁ Thorium-containing alloys are being replaced by alternative Mg alloys. RE./ D Neodymium plus Heavy Rare Earths.

Smithells Light Metals Handbook

Fatigue strength† at specified cycles

Mechanical properties of light metals and alloys Table 3.14 HEAT TREATMENT OF MAGNESIUM ALLOY CASTINGS Heat treatment conditions for magnesium sand castings can be varied depending on the particular components and specific properties required. The following are examples of the conditions used for each alloy which will give properties meeting current national and international specifications. NominalŁ composition %

Material Mg Al Zn

Condition

Time h

Temperature °C

(AZ80)

Al Zn

8.0 0.4

TB

12 24

400 420

(AZ91)

Al Zn

9.5 0.4

TB

16 24

400 420

TF

16 24

(AZ91)

8 16

400 420 Air cool 180 210

Mg Zn Zr

(Z5Z)

Zn Zr

4.5 0.7

TE

10 20

170 200

Mg Zn RE Zr

(RZ5)

Zn RE Zr

4.0 1.2 0.7

TE

2 4 10 20

320 340 Air cool 170 200

(ZRE1)

RE Zn Zr

2.7 2.2 0.7

TE

10 20

170 200

(HK31)

Th Zr

3.0 0.7

TF

2 4

(TZ6)

Zn Th Zr

5.5 1.8 0.7

TE

2 4 10 20

320 340 Air cool 170 200

(ZT1)

Th Zn Zr

3.0 2.2 0.7

TE

10 20

310 320

Mg Th Zr†

10 20 Mg Zn Th Zr†

560 570 Air cool 195 205

Mg Ag RE(D)Zr

(QE22)

Ag RE(D) Zr

2.5 2.0 0.6

TF

4 12 520 530 Water/Oil Quench 195 205 8 16

Mg RE(D) Ag Zr Cu

(EQ21)

RE(D) Ag Zr Cu

2.2 1.5 0.6 0.07

TF

4 12 515 525 Water/Oil Quench 195 205 12 16

Mg Ag RE(D) Th Zr

(QH21)†

Ag RE(D) Th Zr

2.5 1.0 1.0 0.6

TF

4 12 520 530 Water/Oil Quench 12 20 195 205

53

54

Smithells Light Metals Handbook

Table 3.14 (continued ) NominalŁ composition %

Material Mg Y RE() Zr

Mg Zn Cu Mn

Condition

Time h

Temperature °C

(WE43)

Y RE() Zr

4.0 3.4 0.6

TF

4 12 520 530 Water/Oil Quench 245 255 12 20

(WE54)

Y RE() Zr

5.1 3.0 0.6

TF

4.12 520 530 Water/Oil Quench/Air Cool 245 255 12 20

(ZC63)

Zn Cu Mn

6.0 2.7 0.5

TF

4 12 435 445 Water Quench 180 200 16 24

Note:- Above 350 ° C, furnace atmospheres must be inhibited to prevent oxidation of magnesium alloys. This can be achieved either by: (i) adding 1/2 1%SO1 gas to the furnace atmosphere; or (ii) carrying out the heat treatment in an atmosphere of 100% dry CO2 . Ł It is usual to add 0.2 0.4% Mn to alloys containing aluminium to improve corrosion resistance. RE D Cerium mischmetal containing approximately 50% cerium. TB D Solution heat treated. RE(D) D Neodymium-enriched mischmetal. TE D Precipitation heat treated. RE./ D Neodymium plus Heavy Rare Earth metals. TF D Fully heat treated. † Thorium-containing alloys are being replaced by alternative Mg alloys.

Mechanical properties at subnormal temperatures At temperatures down to 200 ° C tensile properties have approximately linear temperature coefficients: proof stress and UTS increase by 0.1 0.2% of the RT value per ° C fall in temperature, and

elongation falls at the same rate: modulus of elasticity rises approximately 19 MPa (2800 lbf in 2 ) per ° C over the range 0° to 100 ° C. No brittle-ductile transitions have been found. Tests at 70 ° C have suggested that the magnesium-zinc-zirconium alloys show the best retention of ductility and notched impact resistance at this temperature.

3.3

Mechanical properties of titanium and titanium alloys

Table 3.15 PURE TITANIUM, TYPICAL MECHANICAL PROPERTIES AT ROOM TEMPERATURE Elongation % DesignationŁ Iodide IMI 115

IMI 125

IMI 155 IMI 160

Ł IMI Nomenclature.

Pure, 60 HV Commercially pure

Commercially pure

Commercially pure

Commercially pure Commercially pure

† Up to 16.3 mm.

Condition

Annealed sheet Annealed rod Annealed wire † Annealed sheet Annealed rod Annealed tube Annealed sheet Annealed rod Annealed wire Hard-drawn wire Annealed sheet Annealed rod Annealed wire

Tensile strength MPa

103 255 220

241 370 370 390 460 460 480 540 540 550 700 640 670 690

340 305 325 420 360

540 500

on 50 mm

on 5D

55 33

Red. in area %

<1.83 mm

<3.25 mm

1t

2t

1 12 t

2t

2tC

2 21 t

Mod. of elasticity GPa

Mod. of rigidity GPa

105

38

80 40

70

28

57

24

48

23

46

38 30 35 25 24 11.5 24 24

Specification bend radius 180 ° bend

2 12 t

3t

Mechanical properties of light metals and alloys

IMI 130

Grade

0.2% proof stress MPa

55

IMI 230

Cu

6.0

Condition Annealed sheet Aged sheet Annealed rod Aged rod

0.2% proof stress MPa

Tensile strength MPa

520 670 500 580

620 770 630 740

IMI 260

Pd

0.2

Similiar to commercially Pure Titanium 115

IMI 261

Pd

0.2

Similiar to commercially Pure Titanium 125

IMI 315

Al 2.0 Mn 2.0

Annealed rod

590

720

IMI 317

Al Sn

5.0 2.5

Annealed sheet

820

860

930

1 000

IMI 318

Al V

6.0 4.0

Annealed sheet Annealed rod Aged rod (fastener stock) Hard-drawn wire

1 110 990 1 050

1 160 1050 1 140 1 410

IMI 550

Al Mo Sn Si

4.0 4.0 2.0 0.5

F.h.t. rod

1 070

IMI 551

Al Mo Sn Si

4.0 4.0 4.0 0.5

F.h.t.rod

1 140

Annealed rod

Elongation % on 50 mm

on 5D

Red. in area %

24 20

Specification bend radius 180 °

Mod. of elasticity GPa

2t(0.5 3 mm) 2t(typical)

125

27 22

45 41

125

21

50

120

16

Mod. of rigidity GPa

4t(<2 mm) 4 21 t. 3 mm/ 15

37

10

120 5t( 3.25 mm)

15 15

40 40

106

1 200

14

42

116

1 300

12

40

113

46

4

43

continued overleaf

Smithells Light Metals Handbook

DesignationŁ

Nominal composition %

56

Table 3.16 TITANIUM ALLOYS TYPICAL MECHANICAL PROPERTIES AT ROOM TEMPERATURE

Sn 11.0 Al 2.25 Mo 1.0 Si 0.2

Quenched and aged rod Air-cooled and aged rod

1 080 1 000

1230 1120

11 13

40 45

108

IMI 680

Sn 11.0 Mo 4.0 Al 2.25 Si 0.2

Quenched and aged rod Furnace-cooled and aged rod

1200

1350

12

37

115

1080

1160

14

47

IMI 685

Al Zr Mo Si

6.0 5.0 0.5 0.25

F.h.t. rod

920

1020

11

22

124

IMI 829

Al Sn Zr Nb Mo Si

5.5 3.5 3.0 1.0 0.3 0.3

F.h.t. rod

848

965

12

22

120

IMI 834

Al Sn Zr Nb Mo Si C

5.8 4.0 3.5 0.7 0.5 0.35 0.06

F.h.t. rod

931

1067

13

22

120

Ł IMI Nomenclature.

46

47

Mechanical properties of light metals and alloys

IMI 679

57

58

Smithells Light Metals Handbook

Table 3.17 COMMERCIALLY PURE TITANIUM SHEET, TYPICAL VARIATION OF PROPERTIES WITH TEMPERATURE

DesignationŁ

Temperature °C

0.2% proof stress MPa

Tensile strength MPa

Elongation on 50 mm %

IMI 115

196 100 20 100 200 300 400 450

442 306 207 168 99 53 42 36

641 444 337 296 218 167 131 120

34 34 40 43 38 47 52 49

IMI 125

20 100 200 300 400 450

334 250 184 142 127 119

479 397 300 232 190 175

31 32 40 45 38 35

IMI 130

196 100 20 100 200 300 400 450 500 20 100 200 300 400 450

730 590 394 315 205 139 102 93

855 737 547 462 331 247 199 182

28 28 28 29 37 40 34 28

460 372 219 151 110 96

625 537 386 281 221 202

25 26 32 36 33 26

IMI 155

Ł IMI nomenclature.

Mod. of elasticity GPa

Transformation temperature °C ˛/˛ C ˇ 865

108 99 91 83 65 46

˛ C ˇ/ˇ 915

Table 3.18 TITANIUM ALLOYS, TYPICAL VARIATION OF PROPERTIES WITH TEMPERATURE

Designation

Nominal composition %

IMI 230

Cu

2.5

Condition S.h.t (trans.)

Temperature °C

0.2% Proof stress MPa

Tensile strength MPa

Elongation % on 50 mm

on 5D

Red in area %

Mod. of elasticity GPa

20 100 200 300 400 500

500 410 310 270 250 220

605 540 450 410 380 380

24 29 33 31 30 33

Aged sheet (trans.)

20 100 200 300 400 500

622 553 471 457 429 357

761 704 635 607 573 468

24 23 26 23 19 21

Aged

20 100 200 300 400 500

638 601 507 496 415 361

795 761 687 658 592 491

22 21 23 20 21 27

40 39 45 50 53 57

107 100 92 85 78 71

Transformation temperature °C ˛/˛ C ˇ 790 ˛ C ˇ/ˇ 895 š 10

Pd

0.2

Similar to IMI 115

IMI 262

Pd

0.2

Similar to IMI 125

IMI 315

Al 2.0 Mn 2.0

Annealed rod

20 100 200 300 400 500

618 510 386 293 278 201

757 649 525 432 417 340

18 21 22 19 18 22

41 46 48 50 56 72

110 107 97 86 76 62

˛ C ˇ/ˇ 915 š 20

IMI 317

Al Sn

Annealed rod

20 100 200 300 400 500

822 692 494 415 374 346

919 798 638 576 522 485

18 19 18 19 18 21

39 40 44 42 41 57

112 109 105 89 84 81

˛/˛ C ˇ 950

5.0 2.5

˛ C ˇ/ˇ 1025 š 20

Mechanical properties of light metals and alloys

IMI 260

59

IMI 318

Nominal composition % Al V

6.0 4.0

Condition Annealed rod

Heat-treated rod (fastener stock)

IMI 550

Al Mo Sn Si

4.0 4.0 2.0 0.5

F.h.t. rod

IMI 551

Al Mo Sn Si

4.0 4.0 4.0 0.5

F.h.t rod

IMI 679

Sn Zr Al Mo Si

11.0 5.0 2.25 1.0 0.2

Quenched and aged rod

0.2% Proof stress MPa

Tensile strength MPa

196 100 20 100 200 300 400 500 600 700

1560 1165 970 825 710 645 580 450 125 40

20 100 200 300 400 500 20 100 200 300 400 500 600 20 100 200 300 400 500 600 20 100 200 300 400 450

Temperature °C

Elongation % on 5D

Red in area %

1675 1265 1040 920 815 750 700 605 265 135

6 12 15 17 18 18 18 26 58 127

29 33 38 43 49 56 63 72 85 94

106 102 96 90 85 79

1035 925 805 710 635 540 1081 965 805 700 655 585 310 1250 1125 925 815 745 670 460

1145 1035 925 850 805 695 1220 1130 960 900 835 780 585 1390 1300 1145 1045 970 920 755

14 15 16 16 18 25 15 15 16 16 17 19 26 10 11 14 15 14 18 27

49 49 60 55 60 68 83 27 29 38 38 41 55 65

116 112 106 101 95 90 85 113 108 103 98 93 88 81

1050 940 820 740 710 680

1230 1145 1020 990 940 910

10 11 12 11 11 11

37 43 45 46 46 46

on 50 mm

Mod. of elasticity GPa

Transformation temperature °C ˛ C ˇ/ˇ 1000 š 15

˛ C ˇ/ˇ 980 š 10

˛ C ˇ/ˇ 1050 š 15

˛ C ˇ/ˇ 950 š 10

Smithells Light Metals Handbook

Designation

60

Table 3.18 (continued )

IMI 680

IMI 685

Sn Mo Al si

11.0 4.0 2.25 0.2

Air-cooled and aged rod

20 100 200 300 400 500

1 020 895 770 695 665 600

1 095 995 900 865 850 795

14 16 16 14 14 15

41 47 49 49 48 48

108 103 99 94 90 85

Quenched and aged rod

20 100 200 300 400 450

1 180 1 020 905 835 805 725

1 330 1 190 1 105 1 075 1 020 975

12 14 15 15 14 13

43 49 53 56 57 54

106 100 96 94 90 88

Furnace-cooled and aged rod

196 100 20

1630 1 280 1 030

1730 1 380 1 130

8 21 10 15

36 43 49

196 100 20 100 200 300 400 500

1 480 1 1 40 890 800 720 650 595 535

1 560 1270 1 030 935 850 800 750 695

6 10 12 13 15 16 18 19

13 18 22 22 24 27 31 37

124 120 114 108 102 95

˛ C ˇ/ˇ 945 š 15

Al Zr Mn Si

6.0 5.0 0.5 0.25

F.h.t. rod

IMI 829

Al Sm Zr Nb Mo Si

5.5 3.5 3.0 1.0 0.3 0.3

F.h.t. rod

20 200 500 540 600

895 622 501 487 457

1 028 792 665 653 634

10 21 14 21 15 16 14

22 28 36 42 38

119 110 93 91 88

˛ C ˇˇ 1 015 š 15

IMI 834

Al Sn Zr Nb Mo Si C

5.8 4.0 3.5 0.7 0.5 0.35 0.06

F.h.t. rod

20 100 200 300 400 500 600

931 840 746 700 662 609 505

1 067 962 885 832 790 764 656

13 13 14 14 14 15 16

22 23 27 32 36 42 50

120 116 112 106 102 96 92

1045

˛ C ˇ/ˇ 1 020 š 10

Mechanical properties of light metals and alloys 61

62

Smithells Light Metals Handbook

Table 3.19 COMMERCIALLY PURE TITANIUM

TYPICAL CREEP PROPERTIES

Stress MPa to produce 0.1% plastic strain in IMI designation IMI 130

IMI 155

Temperature °C

1000 h

10 000 h

100 000 h

20 50 100 150 200 250 300 20 50 100 150 200 250 300

288 243 179 140 113 96 87 309 252 188 145 116 102 93

270 221 165 133 116 101 83 278 232 170 131 108 97 90

207 165 119 96 77 66 55 260 213 157 122 104 94 86

Table 3.20 TITANIUM ALLOYS IMI designation

Nominal composition %

IMI 230

Cu

2.5

TYPICAL CREEP PROPERTIES

Stress MPa to produce 0.1% total plastic strain in Condition Aged sheet

Annealed sheet

IMI 317

Al Sn

5.0 2.5

Annealed rod

IMI 318

Al V

60 4.0

Annealed rod

IMI 550

IMI 551

IMI 679

Al Mo Sn Si Al Mo Sn Sn Zr Al Mo Si

4.0 4.0 2.0 0.5 4.0 4.0 4.0 11.0 5.0 2.25 1.0 0.2

Fully heattreated bar

Fully heattreated rod Air-cooled and aged rod

Temperature °C

100 h

200 300 400 450 20 100 200 300 400 20 100 200 300 400 500 20 100 200 300 400 500 300 400 450 500 400 450

435 375 220 109 360 279 235 202 125 633 474 370 359 337 162 832 704 638 576 287 32 724 551 254 82 621 307

119 818 680 636 568 144 18 718 516 174 51 575 217

20 150 300 400 450 500

896 703 664 579 448 131

880 695 664 571 386 93

300 h

500 h

608 463

1000 h

593 458 370 359 337 88 788 676 635 102

540

710 471 101 31 501

880 672 649 526 247 62

Mechanical properties of light metals and alloys

63

Table 3.20 (continued )

IMI designation IMI 680

Nominal composition % Sn Mo Al Si

11.0 4.0 2.25 0.2

Stress MPa to produce 0.1% total plastic strain in Condition

Temperature °C

100 h

300 h

20 150 200 300 400 450 500 300 350 400 200 300 400 450 500 450 500 550 600

1127 945 862 804 555 298 88 570 540 490 599 551 497 461 408 478 420 300 130

1112 942 856 788 540 209 51

500 550 600

461 339 205

Quenched and aged rod

Furnace-cooled and aged rod IMI 685

Al Zr Mo Si

6.0 5.0 0.5 0.25

Heat-treated forgings

IMI 829

Al Sn Zr Nb Mo Si Al Sn Zr Nb Mo Si C

5.5 3.5 3.0 1.0 0.3 0.3 5.8 4.0 3.5 0.7 0.5 0.35 0.06

Fully heat treated rod

IMI 834

Heat-treated forgings

Table 3.21 TITANIUM AND TITANIUM ALLOYS

Condition

Tensile strength MPa

Commercial purity

Annealed rod

Room

354 354

IMI 125

Commercial purity

Annealed rod

Room

417 417

IMI 130

Commercial purity

Annealed rod

Room

550 550 550

IMI 115

1000 h

592 541 480 431 340

589 535 462 426

TYPICAL FATIGUE PROPERTIES

Temperature °C

IMI designation

Nominal composition %

500 h

550 550 550 550 589 589 589 589

Details of test Rotating bend Smooth Kt = 1 Notched Kt = 3 Rotating bend Smooth Kt = 1 Notched Kt = 3 Rotating bend Smooth Kt = 1 Notched Kt = 2 Notched Kt = 3.3 Direct stress (Zero mean) Smooth Kt = 1 Notched Kt = 1,5 Notched Kt = 2 Notched Kt = 3.3 Smooth Kt = 1 Notched Kt = 2 Notched Kt = 3 Notched Kt = 4

Endurance limit for 107 cycles stated) MPa

š 193 š 123 š 232 š 154 š 270 š 170 š 170 š š š š š š š š

263 247 170 116 278 147 123 116

continued overleaf

64

Smithells Light Metals Handbook

Table 3.21 (continued )

IMI designation

IMI 160 IMI 230

Nominal composition %

Commercial purity Cu 2.5

IMI 260

Pd

0.2

IMI 262

Pd

0.2

Condition

Temperature °C

Tensile strength MPa

Details of test

Endurance limit for 107 cycles stated) MPa

Direct stress (Zero mean) Smooth Kt

š 376

Annealed rod

Room

674

Annealed sheet Aged sheet

Room room

564 772

Aged sheet

room

761

Annealed rod

room 400

598

Annealed

Room

638

Aged rod

Room 400

700

Aged rod

Room

792

Reversed bend Reversed bend Direct stress (Zero minimum) Smooth Kt = 1 Rotating bend Smooth Kt = 1 Smooth Kt = 1 Direct stress (Zero mean) Smooth Kt = 1 Rotating bend Smooth Kt = 1 Smooth Kt = 1 Direct stress (Zero mean) Smooth Kt = 1 Notched Kt = 3.3

IMI 318

Al Sn

Al V

5.0 2.5

6.0 4.0

Annealed rod

Annealed rod

Room

Room

960 960

1015 1015

IMI 550

IMI 551

Al Mo Sn Si

Al Mo Sn Si

4.0 4.0 2.0 0.5

4.0 4.0 4.0 0.5

0!560 š 370 š 150 š 280 š 450 š 290

š 470 š 200

Similar to IMI 115 Similar to IMI 125 Rotating bend

IMI 317

š 390 š 490

Fully heattreated rod

Fully heattreated rod

Room

Room

1180 1180

Smooth Kt = 1.0 Notched Kt = 2.0 Notched Kt = 3.3 Direct stress (Zero mean) Smooth Kt = 1.0 Notched Kt = 1.5 Notched Kt = 2.0 Notched Kt = 3.3 Rotating bend Smooth Kt = 1 Notched Kt = 2.7 Direct stress (Zero minimum) Smooth Kt = 1 Notched Kt = 1 Direct stress (Zero minimum) Smooth Kt D 1 Notched Kt D 3

Rotating bend Rotating bend Smooth Kt D 1 Notched Kt D 2.4 Rotating bend Smooth Kt D 1 Notched Kt D 3.2

Limits for this alloy 108 cycles š 371 š 263 š 239

š š š š

433 278 201 154

š 470 š 230

0!750 0!325

0!850 0!350

š 587 š 394 š 750 š 430

Mechanical properties of light metals and alloys

65

Table 3.21 (continued )

IMI designation

Nominal composition %

Condition

Temperature °C

IMI 679

Sn Zr Al Mo Si

11.0 5.0 2.25 1.0 0.2

Air-cooled and aged rod

Room 200 400 450 500

IMI 680

Sn Mo Al Si

11.0 4.0 2.25 0.2

Quenched and aged rod

Room

Room

Tensile strength MPa

Rotating bend Smooth Kt D 1.0 Smooth Kt D 1.0 Smooth Kt D 1.0 Smooth Kt D 1.0 Smooth Kt D 1.0 Rotating bend 1272 1272 1272

1272

Room 200 400 Furnace-cooled rod

IMI 685

Al Zr Mo Si

6.0 5.0 0.5 0.25

Fully heattreated rod

Room

20 450 520

450 520

Fully heattreated forging

Room Room 475 475

IMI 829

Al Sn Zr Nb Mo Si

5.5 3.5 3.0 1.0 0.3 0.3

Fully heattreated rod

Room

IMI 834

Al Sn Zr Nb Mo Si C

5.8 4.0 3.5 0.7 0.5 0.35 0.06

Fully heattreated rod

Room

Ł Limits for 108 cycles.

Details of test

1100

Smooth Kt D 1 Notched Kt D 2 Notched Kt D 3.3 Direct stress (Zero mean Smooth Kt D 1 Notched Kt D 2 Notched Kt D 3.3 Rotating bend Smooth Kt D 1 Smooth Kt D 1 Smooth Kt D 1 Direct stress (Zero Smooth Kt D 1 Direct stress (Zero mean) Smooth Kt D 1 Smooth Kt D 1 Smooth Kt D 1 Direct stress (Zero minimum) Smooth Kt D 1 Smooth Kt D 1 Direct stress (Zero minimum) Smooth Kt D 1 Notched Kt D 3.5 Smooth Kt D 1 Notched Kt D 3.5 Direct stress (Zero minimum) Smooth Kt D 1 Notched Kt D 3

Direct stress (Zero minimum) Smooth Kt D 1 Notched Kt D 2

Endurance limit for 107 cycles stated) MPa š641Ł š510Ł š510Ł š 556 š 495 (Limits for 2 ð 107 cycles) š 710 š 340 š 293 (Limits for 2 ð 107 cycles) š 695 š 371 š 232 (Limits for 108 cycles) š 648 š 495 š 479 š 680

š 440 š 300 š 260

0!475 0!425

0!640 0!220 0!460 0!210

0!550 0!260

0!577 0!363

66

Smithells Light Metals Handbook

Table 3.22 IZOD IMPACT PROPERTIES OF TITANIUM AND TITANIUM ALLOYS IMI designation IMI 130† IMI 317 IMI 318 IMI 550

IMI designation IMI 551

IMI 679

IMI 680

IMI 685

Nominal composition % Condition Commercially pure Sn 5.0 Al 2.5 Al 6.0 V 4.0 Al 4.0 Mo 4.0 Sn 2.0 Si 0.5

196 ° C

78 ° C

20 ° C

100 ° C

200 ° C

300 ° C

400 ° C

500 ° C

17.6 (13) 13.5 (10)

62.4 (46) 20.3 (15) 14.9 (11)

61.0 (45) 27.1 (20) 20.3 (15) 19.0 (14)

62.4 (46) 35.2 (26) 25.7 (19)

72 (53) 52.8 (39) 40.6 (30)

82 (60 21 ) 63.7 (47) 65.0 (48)

84 (62) 70.5 (52) 83.5 (63)

82 (60 21 ) 71.8 (53) 92.0 (68)

196 ° C

78 ° C

20 ° C

100 ° C

200 ° C

300 ° C

400 ° C

500 ° C

Fully heattreated rod

13.5 (10)

19 (14)

20.3 (15)

21.7 (16)

24.4 (18)

26.5 (19 21 )

28.5 (21)

31.2 (23)

Air-cooled and aged

10.8 (8)

13.5 (10)

14.9 (11)

16.3 (12)

19 (14 21 )

25 (18 21 )

30 (22)

33.9 (25)

Quenched and aged rod

8.1 (6)

8.8 (6 12 )

10.8 (8)

12.2 (9)

14.9 (11)

17.6 (13)

20.3 (15)

25.7 (19)

Fully heattreated rod

31.2 (23)

39.3 (29)

43.4 (32)

Annealed rod Annealed rod Annealed rod Fully heattreated rod

Nominal composition % Condition Al 4.0 Mo 4.0 Sn 4.0 Si 0.5 Sn 11.0 Zr 5.0 Al 2.25 Mo 1.0 Si 0.2 Sn 11.0 Mo 4.0 Al 2.25 Si 0.2 Al 6.0 Zr 5.0 Mo 0.5 Si 0.25

Izod value Joules (ft lbf)Ł

Charpy value Joules (ft lbf)

Ł BSS 131 (1) 0.45 in diameter straight notched test pieces. † Izod values of commercial purity titanium are appreciably affected by variation in hydrogen content within commercial limits (0.008% maximum) in Ti 130 rod.

4

Aluminium and magnesium casting alloys

Aluminium casting alloys ALUMINIUM-SILICON ALLOYS

Specification BS 1490: 1988 Related British Specifications

LM6M(Ge) BS L33

LM20M(Ge)

Composition (%) (single figure indicates maximum) Copper Magnesium Silicon Iron Manganese Nickel Zinc Lead Tin Titanium Other Properties of material Suitability for: Sand casting Chill casting (gravity die) Die casting (press die) Strength at elevated temperature Corrosion resistance Pressure tightness Fluidity Resistance to hot shortness Machinability Melting range, C Casting temperature range, C Specific gravity

LM9M(SP) |

LM9TE(SP)

0.1 0.1 10.0 13.0 0.6 0.5 0.1 0.1 0.1 0.05 0.2

0.4 0.2 0.6 10.0 13.0 1.0 0.5 0.1 0.2 0.1 0.1 0.2

{z 0.1 0.2 10.0 13.0 0.6 0.3 0.7 0.1 0.1 0.1 0.05 0.2

E E G P E E E E F 565 575 710 740 2.65

EŁ E G P G E E E F 565 575 680 740 2.68

G E GŁ G E G G E F 550 575 690 740 2.68

LM9TE(SP) }

LM13TE(SP) |

LM13TF(SP) {z 0.7 1.5 0.8 1.5 10.0 12.0 1.0 0.5 1.5 0.5 0.1 0.1 0.2

G G FŁ E G F G E F 525 560 680 760 2.70

LM13TF7(SP) }

Smithells Light Metals Handbook

Table 4.1

68

4.1

Heat treatment Solution temperature, ° C Solution time, h Quench

520 535 2 8 Cold water

Precipitation temperature, ° C Precipitation time, h Stabilization temperature, ° C Stabilization time, h Special properties

150 170 16 (minimum)

Suitable for thin and intricate castings, readily welded

Pressure casting alloy

ŁŁ Or for such time to give required BHN.

190(12.3) 3 75 85 (4.9 5.5)

170(11.0) 1.5 110 130 (7.1 8.4)

240(15.5) 0 1 220 250 (14.2 16.2)

230(14.9) 2 150 170 (9.7 11.0)

295(19.1) 0 1 270 280 (17.5 18.1)

515 525 8 (minimum) Water, 70 80 ° C For pistons: 200 250 4 6ŁŁ

Low coefficient of expansion Good bearing properties Piston alloy

210(13.6) 1 HB90-120

Notes Association of Light Alloy Refiners and Smelters Grading: E Excellent, F Fair, G Good, P Poor, U Unsuitable, (Ge General purpose alloy; SP special purpose alloy as per BS 1490:1988).

170(11.0) 0.5 160 190 (10.4 12.3) HB 100 150

140(9.1) 1 130(8.4) HB 65 85

280(18.1) 1 270-300 (17.5-19.4) HB 100 150

200(12.9) 1 190(12.3) HB 65-85

Aluminium and magnesium casting alloys

units in brackets) 190(12.3) 5 70 80 (4.5 5.2)

Ł Not normally used in this form. † If Ti alone is used for grain refinement then Ti 6< 0.05%. ‡ Fully heat-treated. § Refine with phosphorus subject to examination under microscope.

160 180 4 16

Suitable for low-pressure cassting High strength and hardness

SI units (Imperial units in brackets) Mechanical properties sand cast Tensile stress min., MPa (tonf in 2 ) 160(10.4) Elongation min.% 5 Expected 0.2% proof stress, 60 70 2 MPa (tonf in ) (3.9 4.5) Mechanical properties chill cast SI units (Imperial Tensile stress min., MPa (tonf in 2 ) 190(12.3) Elongation, min. % 7 Expected 0.2% proof stress, 70 80 (4.5 5.2) MPa (tonf in 2 )

150 170 16 (minimum)

515 525 8 (minimum) Water, 70 80 ° C 160 180 4 16

69

LM18M(SP)

Composition % (Single figure indicates maximum) Copper Magnesium Silicon Iron Manganese Nickel Zinc Lead Tin Titanium Other Properties of material Suitability for: Sand casting Chill casting (gravity die) Die casting (press die) Strength at elevated temperature Corrosion resistance Pressure tightness Fluidity Resistance to hot shortness Machinability Melting range, C Casting temperature range, C Specific gravity

LM25M(Ge) |

LM25TE(Ge)

0.1 0.1 4.5 6.0 0.6 0.5 0.1 0.1 0.1 0.05 0.2

{z 0.20 0.20 0.60 6.5 7.0 0.5 0.3 0.1 0.1 0.1 0.05 0.2†

G G GŁ P E E G E F 565 625 700 740 2.69

G E GŁ G‡ E G G G F 550 615 680 740 2.68

LM25TB7(Ge)

LM25TF(Ge) }

LM29TE(SP) |

LM29TF(SP)

{z 0.8 1.3 0.8 1.3 22 25 0.7 0.6 0.8 1.3 0.2 0.1 0.1 0.2 Cr 0.6; Co 0.5, P§

P F U G G F F E P 520 770 At least 830 2.65

}

Smithells Light Metals Handbook

Specification BS 1490: 1988 Related British Specifications

70

Table 4.1 (continued )

Heat treatment Solution temperature, ° C Solution time, h Quench Precipitation temperature, ° C Precipitation time, h

525 545 4 12 Water, 70 80 ° C 155 175 8 12

Stabilization temperature, ° C Stabilization time, h Special properties

525 545 4 12 Water, 70 80 ° C 155 175 8 12

185 To produce HB requirement

495 505 4 Air blast 185 8

250 2 4 Readily welded

Mechanical properties sand cast SI units (Imperial 120(7.8) Tensile stress min., MPa (tonf in 2 ) Elongation min. % 3 Expected 0.2% proof stress, 55 60(3.6 3.9)

General purpose high-strength casting alloy units in brackets) 130(8.4) 2 80 100(5.2 6.5)

150(9.7)

160(10.4)

230(149)

120(7.8)

120(7.8)

1 120 150 (7.8 9.7)

2.5 80 110 (5.2 6.5)

0 2 200 250 (12.9 16.2)

0.3 120(7.8)

0.3 120(7.8)

HB 100 140

HB 100 140

MPa (tonf in 2 ) 190(12.3)

230(14.9)

280(18.1)

190(12.3)

190(12.3)

2 130200(8.4 12.9)

5 90 110(5.8 7.1)

2 220 260 (14.2 16.8)

0.3 170(11.0)

0.3 170 190 (11.0 12.3) HB 100 140

MPa (tonf in 2 ) Ł Not normally used in this form.

† If Ti alone is used for grain refinement then Ti 6< 0.05%. ‡ Fully heat-treated. § Refine with phosphorus-subject to examination under microscope. ŁŁ Or for such time to give required BHN.

HB 100 140 Note E Excellent. F Fair. G Good. P Poor. U Unsuitable. (Ge General purpose alloy; SP Special purpose alloy as per BS: 1490: 1988).

Aluminium and magnesium casting alloys

Mechanical properties chill cast SI units (Imperial units in brackets) 140(9.1) 160(10.4) Tensile stress min., MPa 2 (tonf in ) Elongation min. % 4 3 80 100(5.2 6.5) Expected 0.2% proof stress, 60 70(3.9 4.5)

More suited to chill (grav, die) casting Piston alloy

71

72

Smithells Light Metals Handbook

Table 4.2

ALUMINIUM-SILICON-COPPER ALLOYS

Specification BS 1490; 1988 Related British Specifications LM2M(Ge) Composition % (Single figures indicate maximum) Copper Magnesium Silicon Iron Manganese Nickel Zinc Lead Tin Titanium

0.7 2.5 0.30 9.0 11.5 1.0 0.5 0.5 2.0 0.3 0.2 0.2

Properties of material Suitability for: Sand casting Chill casting (gravity die) Die casting (press die) Strength at elevated temp. Corrosion resistance Pressure tightness Fluidity Resistance to hot shortness Machinability Melting range, ° C Casting temperature range, ° C Specific gravity

G† G† E G‡ G G G E F 525 570 2.74

LM4MTF LM4M(Ge) (Ge) |

{z 2.0 4.0 0.15 4.0 6.0 0.8 0.2 0.6 0.3 0.5 0.1 0.1 0.2

G G G G G G G G G 525 625 700 760 2.73

Heat treatment Solution temperature, ° C Solution time, h Quench

505 520 6 16 Water at 70 80 ° C 150 170 6 18

Precipitation temperature, ° C Precipitation time, h Special properties

}

Alloy for pressure die castings

Mechanical properties sand cast Tensile stress min. MPa (tonf in 2 ) Elongation min. % Expected 0.2% proof stress, MPa (tonf in 2 )

LM16TF LM16TB (SP) (SP) 3L78 |

{z 1.0 1.5 0.4 0.6 4.5 5.5 0.6 0.5 0.25 0.1 0.1 0.05 0.2Ł

LM21M(SP) }

G G F† G G G G G G 550 620 690 760 2.70 520 530 12 (min) Water at 70 80 ° C

3.0 0.1 5.0 1.0 0.2 0.3 2.0 0.2 0.1 0.2

5.0 0.3 7.0 0.6

G G G† G G G G G G 520 615 680 760 2.81

520 530 12 (min) Water at 70 80 ° C 160 170 8 10

General engineering alloy Pressure tight. High Can tolerate relatively strength alloy in TF high static loading in condition TF condition

Equally suited to all casting processes

SI units (Imperial units in brackets) 140(9.1) 2

230(14.9)

70 110 (4.5 7.1)

200 250 120 140 220 280 80 140 (12.9 16.2) (7.8 9.1) (14.2 18.1) (5.2 9.1)

Mechanical properties chill cast SI units (Imperial units in brackets) Tensile strength min. MPa 150(9.7) 160(10.4) 280(18.1) (tonf in 2 ) Elongation min. % 1 2 1 Expected 0.2% proof stress, MPa (tonf in 2 ) 90 130 80 110 200 300 (5.2 7.1) (12.9 19.4) (5.8 8.4) Ł 0.05% min. if Ti alone used for grain refinement. † Not normally used in this form. ‡ The use of die castings is usually restricted to only moderately elevated temperatures.

170(11.0) 230(14.9) 2

230(14.9) 280(18.1) 3

150(9.7) 1

170(11.0) 1

140 150 250 300 80 140 (9.1 9.7) (16.2 19.4) (5.2 9.1)

Aluminium and magnesium casting alloys

73

Table 4.2 (continued ) Specification BS 1490: 1988 LM22TB Related British Specifications (SP)

LM24M (Ge)

LM26TE (SP)

LM27M (Ge)

Composition % (Single figures indicate maximum)

|

Copper Magnesium Silicon Iron Manganese Nickel Zinc Lead Tin Titanium

2.8 3.8 0.05 4.0 6.0 0.6 0.2 0.6 0.15 0.15 0.1 0.05 0.2

3.0 4.0 0.1 7.5 9.5 1.3 0.5 0.5 3.0 0.3 0.2 0.2

2.0 4.0 0.5 1.5 8.5 10.5 1.2 0.5 1.0 1.0 0.2 0.1 0.2

1.5 2.5 0.3 6.0 8.0 0.8 0.2 0.6 0.3 1.0 0.2 0.1 0.2

Properties of material Suitability for: Sand casting Chill casting (gravity die) Die casting (press die) Strength at elevated temp. Corrosion resistance Pressure tightness Fluidity Resistance to hot shortness Machinability Melting range, ° C Casting temperature range, ° C Specific gravity

G† G G† G G G G G G 525 625 700 740 2.77

F† F† E G‡ G G G G F 520 580

G G F†

G E G†

E G F G F F 520 580 670 740 2.76

G G G G G G 525 605 680 740 2.75

Heat treatment Solution temperature, ° C Solution time, h Quench Precipitation temperature, ° C Precipitation time, h Special properties

2.79

515 530 6 9 Water at 70 80 ° C

LM30TS (SP) {z 4.0 5.0 0.4 0.7 16 18 1.1 0.3 0.1 0.2 0.1 0.1 0.2

Chill casting Alloy for Piston alloy, Excellent Alloy for pressure die alloy (grav. pressure retains castability casting automobile engine die) die castings strength cylinder blocks and hardness at elevated temps. sand cast SI units (Imperial units in brackets) 140(9.1) 1 80 90 (5.2 5.8)

chill cast

Tensile strength min., MPa (tonf in 2 ) Elongation min. % Expected 0.2% proof stress, MPa (tonf in 2 )

SI units (Imperial units in brackets) HB D 90 120

245(15.9) 8

180(11.7) 1.5

210(13.6) 1

110 120 (7.1 7.8)

100 120 (6.7 7.7)

160 190 90 110 150 200 160 200 (10.4 12.3) (5.8 7.1) (9.7 12.9) (10.4 12.9)

Note: E Excellent. F Fair. G Good. P Poor. U Unsuitable. (Ge General purpose alloy; Sp-Special purpose alloy as per BS 1490;1988).

160(10.4) 150(9.7) 2 0.5

}

U F G G G F G F P 505 650 Well above 650 ° C 2.73

Stress relief 175 225 8(minimum)

200 210 7 9

Mechanical properties Tensile stress min., MPa (tonf in 2 ) Elongation min. % Expected 0.2% proof stress, MPa (tonf in 2 ) Mechanical properties

LM30M (SP)

160(10.4) 0.5

LM12M(SP)

| {z Composition % (Single figures indicate maximum) Copper 9.0 11.0 Magnesium 0.2 0.4 Silicon 2.5 Iron 1.0 Manganese 0.6 Nickel 0.5 Zinc 0.8 Lead 0.1 Tin 0.1 Titanium 0.2

LM12TF(SP)Ł

[LM14-WP]†

[LM11-W]

[LM11-WP]

4L35

2L91

2L92

}

|

3.5 4.5 1.2 1.7 0.6‡ 0.6‡ 0.6 1.8 2.3 0.1 0.05 0.05 0.25

{z

4.0 5.0 0.10 0.25 0.25 0.10 0.10 0.10 0.05 0.05 0.25

361B

741A

4.0 5.0 0.10 0.25 0.25 0.10 0.10 0.10 0.05 0.05 Ti C Nb 0.05 0.30

3.5 4.5 1.2 2.5 0.5 0.5 0.1 0.1 0.1 0.1 0.05

}

Other Properties of material Suitability for: Sand casting Chill casting (gravity die) Die casting (press die) Strength at elevated temperature Corrosion resistance Pressure tightness Fluidity Resistance to hot shortness Machinability Melting range, C Casting temperature range, C Specific gravity

Co 0.5 1.0 Nb 0.05 0.3

F G U G P G F G E 525 625 700 760 2.94

F G U E F E G G G 530 640 700 750 2.82

F P U F F P F P G 545 640 680 700 2.80

F P U

F G

F P F P G 540 650 675 750 2.80

F F G G G 530 640 710 725 2.80

Smithells Light Metals Handbook

Specification BS 1490; 1988 Aerospace BSL series DTD series

74

Table 4.3 ALUMINIUM-COPPER ALLOYS

Heat treatment Solution temp., ° C Solution time, h Quench Precipitation temperature, ° C Precipitation time, h Special properties

Mechanical properties sand cast Tensile stress min., MPa (tonf in 2 ) Elongation % Expected 0.2% proof stress, min., MPa (tonf in 2 )

515 520 6

500 520 6

525 545 12 16

525 545 12 16

525 545 16 (minimum)

Water at 70 80 ° C 175 180 2 (minimum)

Boiling water

Water at 70 80 ° C 120 140 1 2

Water at 70 80 ° C 120 170 12 14

Water or oil

495 505 10 (minimum)†† Oil at 80 90 ° C

160 70 8 16

195 205 4 5

Piston alloy, now superseded by LM13 and LM26. Excellent machinability

95 103§ 2ŁŁ Excellent props. at elevated temperatures Grav. die alloy

Good shock resistance

High strength alloy

220(14.2)

220(14.2)

280(18.1)

324(21.0)

263(17.0)

210 240

7 165 200

4 200 240

310(20.1)

250(16.2)

(13.6 15.5)

(10.7 12.9)

(12.9 15.5)

280(18.1)

265(17.1)

310(20.1)

402(26.0)

340(22.0)

230 260

13 165 200

9 200 240

4 360(23.3)

260(16.8)

(10.7 12.9)

(12.5 15.5)

SI (Imperial units in brackets)

Ł Not included in BS 1490: 1988. † [ ] signifies obsolete specification. ‡ Si C Fe 1.0 max. § Or 5 days ageing at room temp. ŁŁ Can substitute stabilizing treatment at 200 250 ° C if used for pistons. †† Allow to cool to 480 ° C before quench.

(14.9 16.8) HB 100 130

Note: E Excellent. F Fair. G Good. P Poor. U Unsuitable. (Ge General purpose alloy; SP Special purpose alloy as per BS 1490: 1988).

Aluminium and magnesium casting alloys

Mechanical properties chill cast SI units (Imperial units in brackets) 170 278(18.0) Tensile stress min., MPa 2 (tonf in ) Elongation % Expected 0.2% proof stress, 140 170 139 170 min., MPa 2 (tonf in ) (9.0 11.0) HB 100 150

75

76

Smithells Light Metals Handbook

Table 4.4 MISCELLANEOUS ALUMINIUM ALLOYS Specification BS 1400; 1988 Aerospace BSL series DTD series

LM5M(SP)

4L53

L99

0.2 7.4 7.9 0.25 0.35 0.1 0.3 0.1 0.9 1.4 0.05 0.05 0.25

0.1 9.5 11.0 0.25 0.35 0.10 0.10 0.10 0.05 0.05 0.2†

0.1 0.20 0.45 6.5 7.5 0.20 0.10 0.10 0.10 0.05 0.05 0.20

F F

G E F‡

680 720 2.64

F F F‡ F E P F G G 450 620 680 720 2.57

425 435§ 8 Oil at 160 ° CŁŁ or boiling water

425 435 8 Oil at no more†† than 160 ° C

5018A

Composition % (Single figures indicate maximum) Copper 0.1 Magnesium 3.0 6.0 Silicon 0.3 Iron 0.6 Manganese 0.3 0.7 Nickel 0.1 Zinc 0.1 Lead 0.05 Tin 0.1 Titanium 0.2 Other Properties of material Suitability for: Sand casting Chill casting (gravity die) Die casting (press die) Strength at elevated temp. Corrosion resistance Pressure tightness Fluidity Resistance to hot shortness Machinability Melting range, ° C Casting temperature range, ° C Specific gravity

LM10TB(SP)

F F F‡ F E P F F G 580 642 680 740 2.65

Heat treatment Solution temperature, ° C Solution time, h Quench

F E P F G G

Precipitation temp., ° C Precipitation time, h

E G G G F 550 615 680 740 2.67 535 545 12 Water at 65 ° C min 150 160 4

Special properties

Good corrosion resistance in marine atmospheres

Mechanical properties Sand cast Tensile stress min, MPa (tonf in 2 ) Elongation % Expected 0.2% proof stress, min MPa (tonf in 2 )

SI units (Imperial units in brackets)

Mechanical properties chill cast Tensile stress min, MPa (tonf in 2 ) Elongation % Expected 0.2% proof stress, min MPa (tonf in 2 )

SI units (Imperial units in brackets)

Good shock resistance and high corrosion resistance ***

Excellent castability with good mech. props.

140(9.1) 3

278 3

280(18.0) 8

230(14.9) 2

90 110(5.8 7.1)

170(11.0)

170 190 (11.0-12.3)

185(12.0)

310(20.1) 12 170 200 (11.0 12.9)

280(18.1) 5 200(12.9)

170(11.0) 5 90 120(5.8 7.8)

309(20.0) 10 170(11.0)

Ł [ ] obsolete. † 0.05% min. if Ti alone used for grain refinement. †† Not normally used in this form. § Or 8 h at 435 445 C then raise to 490 500 C for further 8 h and quench as in table. ŁŁ Do not retain castings in oil for more than 1 h. ŁŁŁ Not generally recommended since occasional brittleness can develop over long periods.

Aluminium and magnesium casting alloys Table 4.4

77

(continued )

Specification BS 1400: 1988 Aerospace BSL series DTD series

LM28TE(SP)

LM28TF(SP)

[LM23P]Ł

[LM15WP]Ł

3L51

3L52 5008B

Composition % (Single figures indicate maximum) Copper 1.3 1.8 Magnesium 0.8 1.5 Silicon 17 20 Iron 0.7 Manganese 0.6 Nickel 0.8 1.5 Zinc 0.2 Lead 0.1 Tin 0.1 Titanium 0.2 Other Cr 0.6 Co 0.5 Properties of material Suitability for: Sand casting Chill casting (gravity die) Die casting (press die) Strength at elevated temp. Corrosion resistance Pressure tightness Fluidity Resistance to hot shortness Machinability Melting range, ° C Casting temp. range, ° C Specific gravity

P F F G F F G P 520 675 6<735 2.68

Heat treatment Solution temperature, ° C Solution time, h Quench

0.8 0.05 1.5 0.8 0.1 0.8 0.1 0.05 0.05 0.25

2.0 0.2 2.8 1.4 1.7

G G G‡ G G G F G G 545 635 680 750 2.77

495 505 4 Air blast

Precipitation temp, ° C

185

185

150 175

Precipitation time, h

To produce required HB

8

8 24

Special properties

Mechanical properties sand cast Tensile stress min, MPa (tonf in 2 ) Elongation % Expected 0.2% proof stress, min MPa (tonf in 2 )

Piston alloy

Aircraft engine castings

1.3 0.5 0.6 0.8 0.1 0.5 0.1 0.05 0.05 0.25

3.0 1.7 2.0 1.4 2.0

F G U E G F F G G 600 645 685 755 2.75 520 540 4 Water at 80 100 ° C Oil or air blast 150 180 (195 205) 8 24(2 5)

0.1 0.5 0.75 0.25 0.5 0.1 0.1 4.8 5.7 0.1 0.05 0.15 0.25 Cr 0.4 0.6

F P U‡ F E F F P G 572 615 730 770 2.81

175 185‡‡ (at least 24 h after cast) 10(at least 24 h after cast)

High mechanical props. at elevated temps.

Good strength without heat treatment. See‡‡

160(10.4) 2

280(18.1)

216(14.0) 4

125(8.1)

245(15.9)

150(9.7)

325(21.0)

232(15.0) 5

295(19.1)

180(11.7)

SI units (Imperial units in brackets) 120(7.8)

HB100 140 Mechanical properties chill cast SI units (Imperial units in brackets) Tensile stress min, 170(11.0) 190(12.3) 200(13.0) MPa (tonf in 2 ) 3 Elongation % Expected 0.2% proof stress min, MPa (tonf in 2 ) 160 190 140(19.1) HB 90 130 (10.4 12.3) HB 100 140

†† Can be furnace cooled to 385 395 ° C before quench. Do not retain in oil for more than 1 h. Further quench in water or air. ‡‡ Alternative-room temp. age-harden for 3 weeks. Note: E Excellent. F Fair. G Good. P Poor. U Unsuitable. (Ge General purpose alloy; SP Special purpose alloy as per BS 1490: 1988).

78 Smithells Light Metals Handbook

Table 4.5 HIGH STRENGTH CAST AL ALLOYS BASED ON AL-4.5 CU European Designation Al Assoc (USA) designation Cu Mg Si Fe Mn Ni Zn Sn Ti Ag Others each Others total

KO1

201.0 4.0 5.2 0.15 0.55 0.10 0.15 0.20 0.50

0.15 0.35 0.40 1.0 0.05 0.10

A-U5GT

201.2 A201.0 A201.2 4.0 5.2 4.0 5.0 4.0 5.0 0.20 0.55 0.15 0.35 0.20 0.35 0.10 0.05 0.05 0.10 0.10 0.07 0.20 0.50 0.20 0.40 0.20 0.40

0.15 0.35 0.40 1.0 0.05 0.10

0.15 0.35 0.40 1.0 0.03 0.10

0.15 0.35 0.40 1.0 0.03 0.10

204.0 4.2 5.0 0.15 0.35 0.20 0.35 0.10 0.05 0.10 0.05 0.15 0.30 0.05 0.15

204.2 4.2 4.9 0.20 0.35 0.15 0.10 0.20 0.05 0.03 0.05 0.05 0.15 0.25 0.05 0.15

206.0 4.2 5.0 0.15 0.35 0.10 0.15 0.20 0.50 0.05 0.10 0.05 0.15 0.3 0.05 0.15

206.2 A206.0 A206.2 4.2 5.0 4.2 5.0 4.2 5.0 0.20 0.35 0.15 0.35 0.20 0.35 0.10 0.05 0.05 0.10 0.10 0.07 0.20 0.50 0.20 0.50 0.20 0.50 0.03 0.05 0.03 0.05 0.10 0.05 0.05 0.05 0.05 0.15 0.25 0.15 0.30 0.15 0.25 0.05 0.15

0.05 0.15

0.05 0.15

Aluminium and magnesium casting alloys

79

Table 4.6 MINIMUM REQUIREMENTS FOR SEPARATELY CAST TEST BARS

Alloy

Sand/Die

TreatmentŁ

UTS MPa

201.0

Sand Sand Sand Die

T6 T7 T4 T4

414 414 311 331

204.0

0.2 PS MPa

EI% in 50 mm or 4 ð diam

345 345 194 220

5.0 3.0 6.0 8.0

Typical HB 500 kgf 10 mm 110 140 130 95

Ł For temper designations see Table 7.3.

Table 4.7 TYPICAL PROPERTIES OF SEPARATELY CAST TEST BARS

Alloy

Sand/Die

TreatmentŁ

201.0

Sand

T4 T43 T6 T7 T7

Sand Sand

Sand

T4 T7

Ł Elevated temperature properties.

0.2 PS MPa 215 255 380 435 415 360 345 275

EI% in 50 mm or 4 ð diam

Room 150CŁ

Temp. 0.5 100 h 1 000 h 10 000 h

365 414 448 485 460 469 380 360 315

205C

0.5 h 100 h 1 000 h 10 000 h

325 285 250 185

310 270 230 150

9 10 9 14

260C

0.5 h 100 h 1 000 h 0.5 h 100 h 1 000 h 10 000 h

195 150 125 140 85 70 60

185 140 110 130 75 60 55

14 17 18 12 30 39 43

20C 120C 175C

436 384 333

347 316 302

11.7 14.0 17.7

315C

A206.0

UTS MPa

20 17 7 8 4.5 5.5 6 8.5 8 7

Typical HB 500 kgf 10 mm 95 135 130

118HV 137HV

80

Magnesium alloys

Table 4.8 ZIRCONIUM-FREE MAGNESIUM ALLOYS Grain refined (0.05 0.2 mm chill cast) when superheated to 850 900 ° C or suitably treated with carbon (as hexachlorethane) Elektron designation ASTM designation Specifications BS 2970: 1989 BSS L series Equivalent DTD

A8 AZ81 MAG1MŁ (GP)†

Composition % (Single figures indicate maximum) Aluminium 7.5 9.0 Zinc 0.3 1.0 Manganese 0.15 0.4 Copper 0.15 Silicon 0.3 Iron 0.05 Nickel 0.01 CuCSiCFeC4Ni 0.40 Material properties Founding Characteristics Tendency to hot tearing Tendency to micro-porosity Castability§ Weldability (Ar-Arc process) Relative damping capacity¶ Strength at elevated temperatureŁŁ Corrosion resistance Density, g cm 3 Liquids, ° C Solidus, ° C Non-equilibrium solidus, ° C Casting temperature range, ° C

Good Sand and permanent‡ mould Little Appreciable A Good C C Moderate 1.81 600 475 420 680 800

MAG1TBŁ (GP) 3L. 112

A8 (High purity) AZ81 MAG2M(SP)†

MAG2TB(SP)

684A

690A

7.5 9.0 0.3 1.0 0.15 0.7 0.005 0.01 0.003 0.001

Good Special melting technique required Little Appreciable A Good C C Moderate 1.81 600 475 420 680 800

Smithells Light Metals Handbook

4.2

Heat treatment Solution: Time, h Temperature, ° C Cooling

12 (min) 435 (max)‡‡ Air, oil or water

Elektron designation ASTM designation Specifications BS 2970: 1989 BSS L series Equivalent DTD

AZ91 AZ91 MAG3M(GP)

Relative damping capacity¶ Strength at elevated temperatureŁŁ Corrosion resistance Density, g cm 3 Liquidus, ° C Solidus, ° C Non-equilibrium solidus, ° C Casting temperature range, ° C

MAG3TB(GP) 3L.124

C alloy MAG3TF(GP) 3L.125

MAG7M(GP)

MAG7TF(GP)

9.0 10.5 0.3 1.0 0.15 0.4 0.15 0.3 0.05 0.01 0.40

7.5 9.5 0.3 1.5 0.15 0.8 0.35 0.40 0.05 0.02 0.75

Good Sand, permanent mould and die (pressure) Little Less than MAG1 A Good, but some difficulty with die castings C C Moderate 1.83 595 470 420 680 800

Good Sand, permanent mould and die (pressure) Little Less than MAG1 A Good, but some difficulty with die castings C C Moderate 1.82 600 475 420 680 800

81

continued overleaf

Aluminium and magnesium casting alloys

Composition % (Single figures indicate maximum) Aluminium Zinc Manganese Copper Silicon Iron Nickel Cu C Si C Fe C Ni Material properties Founding Characteristics Tencency to hot tearing Tendency to micro-porosity Castability§ Weldability (Ar-Arc process)

12 (min) 435 (max)‡‡ Air, oil or water

82

Table 4.8

(continued )

16 (min) 435 (max)‡‡ Air, oil or water

Elektron designation ASTM designation

AZ91 (HP) AZ91E

Specifications BS 2970: 1989 BSS L series Equivalent DTD

ZC63 ZC63

AZ91D MAG11 (GP)

Composition % (Single figures indicate maximum) Aluminium Zinc Manganese Copper Silicon Iron Nickel Cu C Si C Fe C Ni Material properties Founding Characteristics Tendency to hot tearing Tendency to micro-porosity Castability§ Weldability (Ar-Arc process) Relative damping capacity¶ Strength at elevated temperatureŁŁ Corrosion resistance Density, g cm 3 Liquidus, ° C Solidus, ° C Non-equilibrium solidus, ° C Casting temperature range, ° C

16 (min) 435 (max)‡‡ Air, oil or water

Sand and permanent mould Good Little Less than MAG1 A Good C C Excellent 1.83 595 470 420 680 800

8.5 9.5 0.45 0.9 0.15 0.40 0.015 0.020 0.005 0.0010

High pressure die Good Little Little A Difficult C C Excellent 1.83 595 470 420 620 680

5.5 6.5 0.25 0.75 2.4 3.0 0.20 0.05 0.01

Sand, permanent and high pressure die Good Little Little B Good C B Moderate 1.84 635 465 700 810

Smithells Light Metals Handbook

Heat treatment Solution: Time, h Temperature, ° C Cooling

Heat treatment Time, h Temperature, ° C Cooling

16 (min) 435 (max) Air, oil or water

Elektron designation ASTM designation Specifications BS 2970: 1989 BSS L series Equivalent DTD Heat treatment continued Precipitation: Time, h Temperature, ° C Stress relief: Time, h Temperature, ° C

Not suitable

8 440 (max) oil or water

A8 AZ81 MAG1MŁ (GP)†

MAG1TBŁ (GP) 3L.122

2 4 250 330

A8 (High purity) AZ81 MAG2M(SP)†

MAG2TB(SP)

684A

690A

2 4 250 330 140 (9.1) 85 (5.5) 2

200 (13.0) 80 (5.2) 6

Mechanical properties chill cast (SI units first, Imperial units following in brackets) 185 (12.0) 230 (14.9) Tensile strength (min), MPa (tonf in 2 ) 2 0.2% proof stress (min), MPa 85 (5.5) 80 (5.2) p (tonf in ) Elongation % (min) (5.65 S0 ) 4 10

185 (12.0) 85 (5.5) 4

230 (14.9) 80 (5.2) 10

Applications

Automobile road wheels

Good ductility and shock resistance

High-purity alloy

offers good corrosion resistance

continued overleaf

Aluminium and magnesium casting alloys

Mechanical propefties sand cast (SI units first, Imperial units following in brackets) Tensile strength (min), MPa (tonf in 2 ) 140 (9.1) 200 (13.0) 2) 0.2% proof stress (min), MPa (tonf in 85 (5.5) 80 (5.2) p Elongation % (min) (5.65 S0 ) 2 6

83

84

Elektron designation ASTM designation Specifications BS 2970: 1989 BSS L series Equivalent DTD Precipitation: Time, h Temperature, ° C Stress relief: Time, h Temperature, ° C

AZ91

MAG3M(GP)

MAG3TB(GP) 3L.124

MAG3TF(GP) 3L.125

MAG7M(GP)

MAG7TB(GP)

8(min) 210(max) 2 4 250 330

MAG7TF(GP)

8(min) 210(max) 2 4 250 330

Mechanical properties sand cast (SI units first, Imperial units following in brackets) Tensile strength (min), MPa (tonf in 2 /†† 125 (8.1) 200 (13.0) 2 95 (6.2) 85 (5.5) 0.2% proof stress (min), MPa p (tonf in ) Elongation % (min) (5.65 S0 ) 4 Mechanical properties chill cast (SI units first, Imperial units following in brackets) Tensile strength (min), MPa (tonf in 2 ) 170 (11.0) 215 (13.9) 2 0.2% proof stress (min), MPa 100 (6.5) 85 (5.5) p (tonf in ) Elongation % (min) (5.66 S0 ) 2 5 Applications

C alloy

200 (13.0) 130 (8.4)

125 (8.1) 85 (5.5)

185 (12.0) 80 (5.2) 4

185 (12.0) 110 (7.1)

215 (13.9) 130 (8.4) 2

170 (11.0) 85 (5.5) 2

215 (13.9) 80 (5.2) 5

215 (13.9) 110 (7.1) 2

For pressure tight applications Increased proof stress after full heat treatment

Principal alloy for commercial usage

Smithells Light Metals Handbook

Table 4.8 (continued )

Elektron designation ASTM designation

AZ91(HP) AZ91E

Specifications BS 2970: 1989 BSS L series Equivalent DTD Precipitation: Time, h Temperature, ° C Stress relief: Time, h Temperature, ° C

ZC63 ZC63

AZ91D MAG11(GP)

16 (min) 200 (max)

Mechanical properties sand cast (SI units first, Imperial units following in brackets) Tensile strength (min), MPa (tonf in 2 ) 200 2 130 0.2% proof stress (min), MPa p (tonf in ) Elongation % (min) (5.65 S0 ) 2

Typical high pressure die-cast properties

210 125 3

Mechanical properties chill cast (SI units first, Imperial units following in brackets) Tensile strength (min), MPa (tonf in 2 ) 215 2) 0.2% proof stress (min), MPa (tonf in 130 p Elongation % (min) (5.65 S0 ) 2

200 150 1

210 125 3

High purity alloy

Ł M-as cast.

TS Stress relieved only. TE Precipitation treated only. TB Solution treated only. TF Solution and precipitation treated. † GP General purpose alloy. SP Special purpose alloy. ‡ Permanent mouldDgravity die casting. § Ability to fill mould easily. A, B, C, indicate decreasing castability.

offers excellent corrosion resistance. Max. temp. 120 ° C

Better foundability than AZ91 with superior elevated temperature properties

¶ Damping capacity ratings. ADOutstanding; better than grey cast iron. BDEquivalent to cast-iron. CDInfersior to cast-iron but better Al-base cast alloys. ŁŁ ADParticularly recommended. BDSuitable but not especially recommended. CDNot recommended where strength at elev. temps is likely to be an important consideration. †† 1 MPaD1 H m 2 D0 064 75 tonf in 2 . ‡‡ SO or CO atmosphere. 2 2

Aluminium and magnesium casting alloys

Not suitable

Applications

8 (min) 210 (max)

85

86

Table 4.9 MAGNESIUM-ZIRCONIUM ALLOYS Inherently fine grained (0.015 0.035 mm chill cast)

Specifications BS 2970: 1989 BSS L series Equivalent DTD Composition % (Single figures indicate maximum) Zinc Silver Rare earth metals Thorium Zirconium Copper Nickel Iron Silicon Manganese Material properties Founding characteristics Tendency to hot tearing Tendency to micro-porosity Castability¶ Weldability (Ar-Arc Process) Relative damping capacityŁŁ Strength at elevated temperature†† Resistance to creep at elevated temperature Corrosion resistance Density, g cm 3 (20 ° C) Liquidus, ° C Solidus, ° C Casting temperature range, ° C

Z5Z ZK51

RZ5 ZE41

ZRE1 EZ33

MAG4TEŁ (GP)† 2L.127

MAG5TE(SP) 2L.128

MAG6TE(SP) 2L.126

3.5 5.5

3.5 5.5

0.8 3.0

0.75 1.75

2.5 4.0

0.4 1.0 0.03 0.005

0.4 1.0 0.03 0.005

0.4 1.0 0.03 0.005

Good in sand and permanent moulds§ Marked Very appreciable B Not recommended B/C C Poor Moderate 1.81 640 560 720 810

Good in sand and permanent moulds Some Virtually none A Moderate B/C B Moderate Moderate 1.84 640 510 720 810

Excellent in sand and permanent moulds Little None A Very good B A Good up to 250 ° C Moderate 1.80 640 545 720 810

Smithells Light Metals Handbook

Elektron designation ASTM designation

Heat treatment Solution: Time, h Temperature, ° C Cooling Precipitation: Time, h Temperature, ° C

2 followed by 16 330 180 Air cool after each

8 200 Air cool

2 330 to precede precipitation treatment

Precipitation treatment affords s/relief

10 250 max Air cool

Mechanical properties sand cost SI units (Imperial units in brackets) Tensile strength min, MPa (tonf in 2 ) 230 (14.9) 2 0.2% proof stress min, 145 (9.4) p MPa (tonf in ) Elongation, % (5.65 S0 ) min 5

200 (13.0) 135 (8.7) 3

140 (9.1) 95 (6.2) 3

Mechanical properties chill cast SI units (Imperial units in brackets) 245 (15.9) Tensile strength min, MPa (tonf in 2 ) 2 0.2% proof stress min, 145 (9.4) p MPa (tonf in ) Elongation, % (5.65 S0 ) min 7

215 (13.9) 135 (8.7) 4

155 (10.0) 110 (7.1) 3

For high-strength pressure-tight applications

High degree of pressure tightness at room and elevated temperatures

Post weld stress relief: Time, h

Applications

High strength plus good ductility. Not suitable for spidery complex shapes

continued overleaf

Aluminium and magnesium casting alloys

16 180 Air cool

87

88

Table 4.9 (continued )

Specifications BS 2970: 1989 BSS L series Equivalent DTD

ZT1‡‡‡ HZ32

TZ6‡‡‡ ZH62

MAG8TE(SP)

MAG9TE(SP)

5005A

5015A

ZE63 ZE63

5045

Composition % (Single figures indicate maximum) Zinc Silver Rare earth metals Thorium Zirconium Copper Nickel Iron Silicon Manganese

1.7 2.5

5.0 6.0

5.5 6.0

0.10 2.5 4.0 0.4 1.0 0.03 0.005 0.01 0.01 0.15

0.20 1.5 2.3 0.4 1.0 0.03 0.005 0.01 0.01 0.15

2.0 3.0 0.4 1.0 0.03 0.005 0.01 0.01 0.15

Material properties Founding characteristics Tendency to hot tearing Tendency to micro-porosity Castability¶ Weldability (Ar-Arc process) Relative damping capacityŁŁ Strength at elevated temperature†† Resistance to creep at elevated temperature Corrosion resistance Density, g cm 3 (20 ° ) Liquidus, ° C Solidus, ° C Casting temperature range, ° C

As per MAG7 but more sluggish Little None C Very good B A Good up to 350 ° C Moderate 1.85 645 550 720 810

Similar to MAG5 Very little Low B Fair C B Fair Moderate 1.87 630 520 720 810

Good Negligible Virtually none A Very goodŁŁŁ B/C C Poor Moderate 1.87 625 516 720 810

Smithells Light Metals Handbook

Elektron designation ASTM designation

Heat treatment Solution: Time, h Temperature, ° C Cooling Precipitation: Time, h Temperature, ° C Post weld stress relief: Time, h Temperature, ° C

30 for 12 mm sctn. 70 for 25 mm sctn. 480††† Air blast or water spray 16 315 Air cool

48 or 72 138 127 Air cool

Pptn. treatment affords stress relief

255 (16.5) 155 (10.0) 5

275 (17.8) 170 (11.0) 5

255 (16.5) 155 (10.0) 5 For heavy duty structural usage

Sand Cast Alloy High strength with good ductility and excellent fatigue resistance. Structural parts aircraft, etc. continued overleaf

Aluminium and magnesium casting alloys

2 350 Air cool SI units (Imperial units in brackets) Mechanical properties sand cast 185 (12.0) Tensile strength min, MPa (tonf in 2 ) 2 0.2% proof stress min, 85 (5.5) p MPa (tonf in ) Elongation, % (5.65 S0 ) min 5 SI units (Imperial units in brackets) Mechanical properties chill cast Tensile strength min, MPa (tonf in 2 ) 185 (12.0) 0.2% proof stress min, 85 (5.5) p MPa 5 Elongation, % (5.65 S0 ) min Applications Creep resistant alloy

2 followed 16 330 by 180 Air cool after each

89

Specifications BS 2970: 1972 BSS L series Equivalent DTD

MSR-A

MSR-B

MTZ‡‡‡ HK31

MSR QE22

MAG12TF(SP) 5025A

Composition % (Single figures indicate maximum) Zinc 0.2 Silver 2.0 3.0 Rare earth metals 1.2 2.0‡ Thorium Zirconium 0.4 1.0 Copper 0.03 Nickel 0.005 Iron 0.01 Silicon 0.01 Manganese 0.15 Yttrium

5035A

EQ21 EQ21

WE54 WE54

MAG13TF(SP)

MAG14TF(SP)

WE43 WE43

5055

0.2 2.0 3.0 2.0 3.0‡

0.2 2.0 3.0 1.8 2.5‡

0.4 1.0 0.03 0.005 0.01 0.01 0.15

0.4 1.0 0.03 0.005 0.01 0.01 0.15

0.3 0.1 2.5 4.0 0.4 1.0 0.03 0.005 0.01 0.01 0.15

0.2 1.3 1.7 1.5 3.0‡ 0.4 1.0 0.05 0.10 0.005 0.01 0.01 0.15

0.2

0.2

2.0 4.0¶¶¶

2.4 4.4¶¶¶

0.4 1.0 0.03 0.005 0.01 0.01 0.15 4.75 5.5

0.4 1.0 0.03 0.005 0.01 0.01 0.15 3.7 4.3

Smithells Light Metals Handbook

Elektron designation ASTM

90

Table 4.9 (continued )

Elektron designation ASTM designation

MSR-A

Specifications BS 2970: 1989

MSR-B

MSR QE22

MTZ‡‡‡ MK31

MAG12TF (SP)

WE54 WE54

WE43 WE43

MAG13TF(SP)

MAG14TF(SP)

Good Little Slight B Very good B/C A

Good Very little Slight B Very good B/C A

Good Very little Slight B Very good B/C A

Good up to 200 ° C

Very good up to 250 ° C

Very good up to 250 ° C

Moderate 1.81 640 545 720 810

Excellent 1.85 640 550 720 810

Excellent 1.85 640 550 720 810

BSS L series Equipment DTD

5025A

5035A

5055

Material properties Founding characteristics

Good

Good

Good

Tendency to hot tearing Tendency to micro-porosity Cqstability¶ Weldability (Ar-Arc process) Relative damping capacityŁŁ Strength at elevated temperature†† Resistance to creep at elevated temperature

Little Slight B Very good B/C A

Little Slight B Very good B/C A

Little Slight B Very good B/C A

Good up to 200 ° C

Good up to 200 ° C

Good up to 200 ° C

Corrosion resistance Density, g cm 3 (20 ° C) Liquidus, ° C Solidus, ° C Casting temperature range, ° C Heat treatment Solution: Time, h Temperature, ° C Cooling Precipitation: Time, h Temperature, ° C

Moderate 1.81 640 550 720 810

Moderate 1.82 640 550 720 810

Moderate 1.81 640 550 720 810

Good up to 350 ° C for short time applications Moderate 1.84 645 590 720 810

8 525‡‡ Water or oil

8 525‡‡ Water or oil

8 525‡‡ Water or oil

2 565‡‡,¶¶ Air cool

8 520‡‡ Water or oil

8 525‡‡ Air cool

8 525‡‡ Water or oil

16 200 Air cool

16 200 Air cool

16 200 Air cool

16 200 Air cool

16 200 Air cool

16 250 Air cool

16 250 Air cool

Less easy to found than MSR types Very little Negligible C Very good B/C A

91

continued overleaf

Aluminium and magnesium casting alloys

EQ21 EQ21

Specifications BS 2970: 1989 BSS L series Equipment DTD

MSR-A

MSR-B

MSR QE22

EQ21 EQ21

WE54 WE54

MAG13TF(SP)

MAG14TF(SP)

Repeat above cycle

1 505 followed by above quench and age

1 510 followed by above aircool and age

1 510 followed by above quench and age

240 (15.5)

200 (13.0)

240

250

250

175 (11.3) 2

93 (6.0) 5

170 2

175 2

165 2

240

250

250

170 cast Similar to MSR alloys but less but less

175 2 Excellent strength up to 300 ° C for short time applications. Excellent corrosion resistance

165 2 Excellent strength up to 250 ° C for long time applications. Excellent corrosion resistance

MAG12TF(SP) 5025A

5035A

1 510 followed by above quench and age Mechanical properties sand cast SI units (Imperial units in brackets) Tensile strength min, MPa (tonf in 2 ) 240 (15.5) 240 (15.5) 0.2% proof stress min, MPa 2 (tonf in ) 170 (11.0) 185 (12.0) p 4 2 Elongation, % (5.65 S0 ) min Mechanical properties chill cast SI units (Imperial units in brackets) Tensile strength min, MPa 240 (15.5) 240 (15.5) (tonf in 2 ) 0.2% proof stress min, MPa 2 170 (11.0) 185 (12.1) (tonf in ) p 4 2 Elongation, % (5.65 S0 ) min Applications High strength in thick and thin section castings. Good elevated temperature (up to 250 ° C) short time tensile and fatigue props. Ł See footnote to Table 4.1. † See footnote to Table 4.1. ‡ Neodymium-rich rare rearths (others Ce-rich). ¶ See footnote to Table 4.1.

§ See footnote to Table 4.1.

WE43 WE43

5055

Post-weld stress relief: Time, h Temperature, ° C

ŁŁ See footnote to Table 4.1.

MTZ‡‡‡ MK31

240 (15.5) 175 (11.3) 2 Similar to MSRA-B

Usually sand 2 Superior short time tensile and creep resistance at temperatures around 300 ° C

†† See footnote to Table 4.1. ‡‡ SO or CO atmosphere. 2 2 ¶¶ Castings to be loaded into furnace at operating temperature. ŁŁŁ But only before hydriding treatment. ††† In hydrogen at atmospheric pressure. ‡‡‡ Thorium containing alloys are being replaced by alternative magnesium based alloys. ¶¶¶ Neodymium and heavy rare earths.

Smithells Light Metals Handbook

Elektron designation ASTM designation

92

Table 4.9 (continued )

5

5.1 Ag Ag Ag Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al Al

Equilibrium diagrams

Index of binary diagrams Al Mg Ti As Au B Ba Be Bi Ca Cd Ce Co Cr Cs Cu Dy Er Fe Ga Gd Ge Hf Hg Ho In K La Li Mg Mn Mo Na Nb Nd Ni Pb Pd Pr Pt Pu Re Ru Sb Sc Se Si Sm Sn Sr

94 95 95 96 96 97 97 98 98 99 99 99 100 101 102 102 103 103 104 105 105 105 106 106 107 107 108 108 109 109 110 110 111 111 112 112 112 113 113 114 115 116 116 117 117 118 118 118 119 119

Al Ta Al Te Al Th Al Ti Al Tl Al U Al V Al W Al Y Al Yb Al Zn Al Zr Au Mg Au Ti B Ti Ba Mg Be Ti Bi Mg Bi Ti C Ti Ca Mg Ca Ti Cd Mg Cd Ti Ce Mg Ce Ti Co Mg Co Ti Cr Ti Cu Mg Cu Ti Er Ti Fe Mg Fe Ti Ga Mg Gd Mg Gd Ti Ge Ti H Ti Hf Ti Hg Mg In Mg In Ti Ir Ti

120 120 120 121 121 122 122 123 123 124 124 125 126 126 127 127 128 128 129 129 130 130 131 131 131 132 132 133 133 134 134 135 135 136 136 137 137 138 138 139 139 140 140 141

K Mg La Mg Li Mg Mg Mn Mg Na Mg Ni Mg Pb Mg Pr Mg Pu Mg Sb Mg Sc Mg Si Mg Sn Mg Sr Mg Th Mg Ti Mg Tl Mg U Mg Y Mg Zn Mg Zr Mn Ti Mo Ti N Ti Nb Ti Nd Ti Ni Ti O Ti Os Ti Pb Ti Pd Ti Pt Ti Pu Ti Sc Ti Si Ti Sn Ti Ta Ti Th Ti Ti U Ti V Ti W Ti Y Ti Zn Ti Zr

141 142 142 143 143 144 144 144 145 145 146 146 147 147 148 148 148 149 149 150 150 151 152 152 153 153 154 154 155 155 156 156 157 157 158 158 159 159 160 160 161 161 161 162

94

Ag Al

Smithells Light Metals Handbook

Equilibrium diagrams

95

Ag Mg

Ag Ti

96

Al As

Al Au

Smithells Light Metals Handbook

Equilibrium diagrams

97

Al B

Al Ba

98

Al Be

Al Bi

Smithells Light Metals Handbook

Equilibrium diagrams

99

Al Ca

Al Cd

Al Ce

100

Al Co

Smithells Light Metals Handbook

Equilibrium diagrams

101

Al Cr

102

Al Cu

Al Cs

Smithells Light Metals Handbook

Equilibrium diagrams

103

Al Dy

Al Er

104

Al Fe

Al Fe

Smithells Light Metals Handbook

Equilibrium diagrams

105

Al Ga

Al Gd

Al Ge

106

Al Hf

Al Hg

Smithells Light Metals Handbook

Equilibrium diagrams

107

Al Ho

Al In

108

Al K

Al La

Smithells Light Metals Handbook

Equilibrium diagrams

109

Al Li

Al Mg

110

Al Mn

Al Mo

Smithells Light Metals Handbook

Equilibrium diagrams

111

Al Na

Al Nb

112

Smithells Light Metals Handbook

Al Ni

Al Nd

Al Pb

Al Ni

Equilibrium diagrams

113

Al Pd

Al Pr

114

Al Pt

Smithells Light Metals Handbook

Equilibrium diagrams

115

Al Pu

116

Al Re

Al Ru

Smithells Light Metals Handbook

Equilibrium diagrams

117

Al Sb

Al Sc

118

Al Se

Al Si

Al Sm

Smithells Light Metals Handbook

Equilibrium diagrams

119

Al Sn

Al Sr

120

Al Ta

Al Te

Al Th

Smithells Light Metals Handbook

Equilibrium diagrams

121

Al Ti

Al Tl

122

Al U

Al V

Smithells Light Metals Handbook

Equilibrium diagrams

123

Al W

Al Y

124

Al Yb

Al Zn

Smithells Light Metals Handbook

Equilibrium diagrams

125

Al Zn

Al Zr

126

Au Mg

Au Ti

Smithells Light Metals Handbook

Equilibrium diagrams

127

B Ti

Ba Mg

128

Be Ti

Bi Mg

Smithells Light Metals Handbook

Equilibrium diagrams

129

Bi Ti

C Ti

130

Ca Mg

Ca Ti

Smithells Light Metals Handbook

Equilibrium diagrams

131

Cd Mg

Cd Ti

Ce Mg

132

Ce Ti

Co Mg

Smithells Light Metals Handbook

Equilibrium diagrams

133

Co Ti

Cr Ti

134

Cu Mg

Cu Ti

Smithells Light Metals Handbook

Equilibrium diagrams

135

Er Ti

Fe Mg

136

Fe Ti

Ga Mg

Smithells Light Metals Handbook

Equilibrium diagrams

137

Gd Mg

Gd Ti

138

Ge Ti

H Ti

Smithells Light Metals Handbook

Equilibrium diagrams

139

Hf Ti

Hg Mg

140

In Mg

In Ti

Smithells Light Metals Handbook

Equilibrium diagrams

141

Ir Ti

K Mg

142

La Mg

Li Mg

Smithells Light Metals Handbook

Equilibrium diagrams

143

Mg Mn

Mg Na

144

Mg Ni

Mg Pb

Mg Pr

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Equilibrium diagrams

145

Mg Pu

Mg Sb

146

Mg Sc

Mg Si

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Equilibrium diagrams

147

Mg Sn

Mg Sr

148

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Mg Ti Mg Th

Mg Tl

Equilibrium diagrams

149

Mg U

Mg Y

150

Mg Zn

Mg Zr

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Equilibrium diagrams

151

Mn Ti

152

Mo Ti

N Ti

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Equilibrium diagrams

153

Nb Ti

Nd Ti

154

Ni Ti

O Ti

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Equilibrium diagrams

155

Os Ti

Pb Ti

156

Pd Ti

Pt Ti

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Equilibrium diagrams

157

Pu Ti

Sc Ti

158

Si Ti

Sn Ti

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Equilibrium diagrams

159

Ta Ti

Th Ti

160

Ti U

Ti V

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Equilibrium diagrams

161

Ti W

Ti Y

Ti Zn

162

Ti Zr

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6

Metallography of light alloys

Metallography can be defined as the study of the structure of materials and alloys by the examination of specially prepared surfaces. Its original scope was limited by the resolution and depth of field in focus by the imaging of light reflected from the metallic surface. These limitations have been overcome by both transmission and scanning electron microscopy (TEM, STEM and SEM). The analysis of X-rays generated by the interaction of electron beams with atoms at or near the surface, by wavelength or energy dispersive detectors (WDX, EDX), has added quantitative determination of local composition, e.g. of intermetallic compounds, to the deductions from the well-developed etching techniques. Surface features can also be studied by collecting and analysing electrons diffracted from the surface. A diffraction pattern of the surface can be used to determine its crystallographic structure (low-energy electron diffraction or LEED). These electrons can also be imaged as in a conventional electron microscope (Low-energy electron microscopy or LEEM). This technique is especially useful for studying dynamic surface phenomena such as those occurring in catalysis. X-rays photoelectron microscopy (XPS or ESCA) now enables the metallographer to analyse the atoms in the outermost surface layer to a depth of a few atoms (0.3 5.0 nm) and provides information about the chemical environment of the atom. Auger spectroscopy uses a low-energy electron beam instead of X-rays to excite atoms, and analysis of the Auger electrons produced provides similar information about the atoms from which the Auger electron is ejected. Nevertheless, the conventional optical techniques still have a significant role to play and their interpretation is extended and reinforced by the results of the electronic techniques.

6.1

Metallographic methods for aluminium alloys

PREPARATION

Aluminium and its alloys are soft and easily scratched or distorted during preparation. For cutting specimens, sharp saw-blades should be used with light pressure to avoid local overheating. Specimens may be ground on emery papers by the usual methods, but the papers should preferably have been already well used, and lubricated or coated with a paraffin oil (‘white spirit’ is suitable), paraffin wax or a solution of paraffin wax in paraffin oil. Silicon carbide papers (down to 600-grit) which can be well washed with water are preferred for harder alloys, the essential point being to avoid the embedding of abrasive particles in the metal. For pure soft aluminium, a high viscosity paraffin is needed to avoid this. Polishing is carried out in two stages: initial polishing with fine ˛-alumina, proprietary metal polish, or diamond, and final polishing with -alumina or fine magnesia, using a slowly rotating wheel (not above 150 rev. min 1 ). It is essential to use properly graded or levigated abrasives and it is preferable to use distilled water only; it is an advantage to boil new polishing cloths in water for some hours in order to soften the fibres. Many aluminium alloys contain hard particles of various intermetallic compounds, and polishing times should in general be as short as possible owing to the danger of producing excessive relief. Relief may be minimized by experience and skill in polishing; blanket felt may with advantage be substituted for velveteen or selvyt cloth as a polishing pad, while the use of parachute silk on a cork pad is also useful for avoiding relief in the initial stages of the process, but a better general alternative is to use diamond polishing, followed by a very brief final polishing with magnesia. Many aluminium alloys contain the reactive compound Mg2 Si. If this constituent is suspected, white spirit should be substituted for water during all but the initial stages of wet polishing, to avoid loss of the reactive particles by corrosion.

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Table 6.1 MICROCONSTITUENTS WHICH MAY BE ENCOUNTERED IN ALUMINIUM ALLOYS Microconstituent Al3 Mg2 Mg2 Si CaSi2 CuAl2 NiAl3 Co2 Al9 .1/ FeAl3 MnAl6

Appearance in unetched polished sections Faint, white. Difficult to distinguish from the matrix. Slate grey to blue. Readily tarnishes on exposure to air and may show irridescent colour effects. Often brown if poorly prepared. Forms Chinese script eutectic. Grey. Easily tarnished Whitish, with pink tinge. A little in relief; usually rounded Light grey, with a purplish pink tinge

CrAl7

Light grey Lavender to purplish grey; parallel-sided blades with longitudinal markings Flat grey. The other constituents of binary aluminium-manganese alloys (MnAl4 , MnAl3 and ‘υ’) are also grey and appear progressively darker. May form hollow parallelograms Whitish grey; polygonal. Rarely attacked by etches

Silicon ˛(AlMnSi).2/ ˇ(AlMnSi).2/ Al2 CuMg Al6 Mg4 Cu

Slate grey. Hard, and in relief. Often primary with polygonal shape use etch to outline Light grey, darker and more buff than MnAl6 Darker than ˛(AlMnSi), with a more bluish grey tint. Usually occurs in long needles Like CuAl2 but with bluish tinge Flat, faint and similar to matrix

(AlCuMn).3/ ˛(AlFeSi).4/ ˇ(AlFeSi).4/ (AlCuFe).5/ (AlFeMn).6/

Grey Purplish grey. Often occurs in Chinese-script formation. Isomorphous with ˛(AlMnSi) Light grey. Usually has a needle-like formation Grey ˛ phase lighter than ˇ phase (see Note 5) Flat grey, like MnAl6

(AlCuNi) (AlFeSiMg).7/ FeNiAl9 (AlCuFeMn) Ni4 Mn11 Al60 MgZn2

Purplish grey Pearly grey Very similar to and difficult to distinguish from NiAl3 Light grey Purplish grey Faint white; no relief

In Table 10.1 constituents are designated by symbols denoting the compositions upon which they appear to be based, or by the elements, in parentheses, of which they are composed. The latter nomenclature is adopted where the composition is unknown, not fully established, or markedly variable. The superscript numbers in column 1 refer to the following notes: (1) On very slow cooling under some conditions, FeAl3 decomposes into Fe2 Al7 and Fe2 Al5 . The former is micrographically indistinguishable from FeAl3 . The simpler formula is retained for consistency with most of the original literature. (2) ˛(AlMnSi) is present in all slowly solidified aluminium-manganese-silicon alloys containing more than 0.3% of manganese and 0.2% of silicon, while ˇ(AlMnSi), a different ternary compound, occurs above approximately 3% of manganese for alloys containing more than approximately 1.5% of silicon. ˛(AlMnSi) has a variable composition in the region of 30% of manganese and 10 15% of silicon. The composition of ˇ(AlMnSi) is around 35% of manganese and 5 10% of silicon. (3) (AlCuMn) is a ternary compound with a relatively large range of homogeneity based on the composition Cu2 Mn3 Al20 . (4) ˛(AlFeSi) may contain approximately 30% of iron and 8% of silicon, while ˇ(AlFeSi) may contain approximately 27% of iron and 15% of silicon. Both constituents may occur at low percentages of iron and silicon. (5) The composition of this phase is uncertain. Two ternary phases exist. ˛(AlCuFe) resembles FeAl3 ; ˇ(AlCuFe) forms long needles. (6) The phase denoted as (AlFeMn) is a solid solution of iron in MnAl6 . (7) This constituent is only likely to be observed at high silicon contents.

It should be noted that some aluminium alloys are liable to undergo precipitation reactions at the temperatures used to cure thermosetting mounting resins; this applies particularly to aluminiummagnesium alloys, in which grain boundary precipitates may be induced. ETCHING

The range of aluminium alloys now in use contains many complex alloy systems. A relatively large number of etching reagents have therefore been developed, and only those whose use has become more or less standard practice are given in Table 6.2. Many etches are designed to render the distinction between the many possible microconstituents easier, and the type of etching often depends on the magnification to be used. The identification of constituents, which is best accomplished by using cast specimens where possible, depends to a large extent on distinguishing between the

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165

Table 6.2 ETCHING REAGENTS FOR ALUMINIUM AND ITS ALLOYS No. 1

Reagent

Remarks

Hydrofluoric acid (40%) 0.5 Hydrochloric acid (1.19) 1.5 Nitric acid (1.40) 2.5 Water 95.5

ml ml ml ml

(Keller’s etch)†

15 s immersion is recommended. Particles of constituents are outlined. Colour indications: Mg2 Si and CaSi2 : ˛(AlFeSi) and (AlFeMn): ˇ(AlCuFe): MgZn2 , NiAl3 , (AlCuFeMn), Al2 Cu Mg and Al6 CuMg: ˛(AlCuFe) and (AlCuMn): Al3 Mg2 :

all common microblue to brown darkened light brown brown to black

blackened heavily outlined and pitted The colours of other constituents are little altered. Not good for high Si alloys

2

Hydrofluoric acid (40%) 0.5 ml Water 99.5 ml

15 s swabbing is recommended. This reagent removes surface flowed layers, and reveals small particles of constituents, which are usually fairly heavily outlined. There is little grain contrast in the matrix. Colour indications: blue Mg2 Si and CaSi2 : slightly darkened FeAl3 and MnAl6 : NiAl3 : brown (irregular) ˛(AlFeSi): dull brown (AlCrFe): light brown dark brown Co2 Al9 : (AlFeMn): brownish tinge ˛(AlCuFe), (AlCuMg) and (AlCuMn): blackened ˛(AlMnSi), ˇ(AlMnSi) and (AlCuFeMn) may appear light brown to black ˇ(AlFeSi) is coloured red brown to black The remaining possible constituents are little affected

3

Sulphuric acid (1.84) Water

20 ml 80 ml

30 s immersion at 70 ° C; the specimen is quenched in cold water. Colour indications: violently attacked, Mg2 Si, Al3 Mg2 and FeAl3 : blackened and may be dissolved out blue CaSi2 : ˛(AlMnSi) and ˇ(AlMnSi): rough and attacked slightly darkened NiAl3 and (AlCuNi): ˇ(AlFeSi): slightly darkened and pitted ˛(AlFeSi), (AlCuMg) and (AlCuFeMn): outlined and blackened Other constituents are not markedly affected

4

Nitric acid (1.40) Water

25 ml 75 ml

Specimens are immersed for 40 s at 70 ° C and quenched in cold water. Most constituents (not MnAl6 ) are outlined. Colour indications: ˇ(AlCuFe) is slightly darkened Al3 Mg2 and AlMnSi: attacked and darkened slightly Mg2 Si, CuAl2 , (AlCuNi) and (AlCuMg) are coloured brown to black

5

Sodium hydroxide Water

1 g 99 ml

Specimens are etched by swabbing for 10 s. All usual constituents are heavily outlined, except for Al3 Mg2 (which may be lightly outlined) and (AlCrFe) which is both unattacked and uncoloured. Colour indications: slightly darkened FeAl3 and NiAl3 : (AlCuMg): light brown ˛(AlFeSi): dull brownŁ ˛(AlMnSi): rough and attacked; slightly darkenedŁ MnAl6 and (AlFeMn): coloured brown to blue (uneven attack) tends to be darkened MnAl4 : The colours of other constituents are only slightly altered continued overleaf

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Table 6.2 (continued ) No. 6

7

Reagent Sodium hydroxide Water

Remarks

10 g 90 ml

Specimens immersed for 5 s at 70 ° C, and quenched in cold water. Colour indications: ˇ(AlFeSi): slightly darkened light brown Mn11 Ni4 Al60 : ˇ(AlCuFe): light brown and pitted light to dark brown CuAl2 : FeAl3 : dark brown (FeAl3 is more rapidly attacked in the presence of CuAl2 than when alone) MnAl6 , NiAl3 , (AlFeMn), CrAl7 and AlCrFe: blue to brown ˛(AlFeSi), ˛(AlCuFe), CaSi2 and (AlCuMn): blackened

Sodium hydroxide Sodium carbonate (in water)

3% 5%

8

Nitric acid Hydrofluoric acid Glycerol

20 ml 20 ml 60 ml

9

Nitric acid, 1% to 10% by vol. in alcohol

Recommended for aluminium-magnesium alloys. Al3 Mg2 is coloured brown. 5 20% chromium trioxide can be used

10

Picric acid Water

4 g 96 ml

Etching for 10 min darkens CuAl2 , leaving other constituents unaffected. Like reagent 4

11

Orthophosphoric acid Water

9 ml 91 ml

12

Nitric acid

13

Nitric acid (density 1.2) Water Ammonium molybdate, (NH4 )6 Mo7 O24 , 4H2 O

3% 5%

Useful for sensitive etching where reproducibility is essential. In general, the effects are similar to those of Reagent 5, but the tendency towards colour variations for a given constituent is diminished. Particularly useful for distinguishing FeNiAl9 (dark blue) from NiAl3 brown). Potassium salts can be used. A reliable reagent for grain boundary etching, especially if the alternate polish and etch technique is adopted. The colours of particles are somewhat accentuated

The reagent is used cold. Recommended for aluminium-magnesium alloys in which it darkens any grain boundaries containing thin ˇ-precipitates. Specimen is immersed for a long period (up to 30 min). Mg2 Si is coloured black, Al3 Mg2 a light grey, and the ternary (AlMnFe) phase a dark grey 10 s immersion colours Al6 CuMg4 greenish brown and distinguishes it from Al2 CuMg, which is slightly outlined but not otherwise affected

20 ml 20 ml

20 ml of reagent are mixed with 80 ml alcohol. Specimens are immersed, and well washed with alcohol after etching. Brilliant and characteristic colours are developed on particles of intermetallic compounds. The effects depend on the duration of etching, and for differentiation purposes standardisation against known specimens is advised

3 g

14

Sodium hydroxide (various strengths, with 1 ml of zinc chloride per 100 ml of solution)

Generally useful for revealing the grain structure of commercial aluminium alloy sheet67

15

Hydrochloric acid (37%) Hydrofluoric acid (38%) Water

Recommended (30 s immersion at room temperature) for testing the diffusion of copper through claddings of aluminium, aluminiummanganese-silicon, or aluminium-manganese on aluminiumcopper-magnesium sheet. Zinc contents up to 2% in the clad material do not influence the result68

16

Ammonium oxalate Ammonium hydroxide, 15% in water

15.3 ml 7.7 ml 77.0 ml 1 g

Develops grain boundaries in aluminium-magnesium-silicon alloys. Specimens are etched for 5 min at 80 ° C in a solution freshly prepared for each experiment

100 ml

Ł These are isomorphous and the colour depends on the proportion of Mn and Fe. † Sodium fluoride can be used in place of HF in mixed acid etches.

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167

colours of particles, so that the illumination should be as near as possible to daylight quality. It is recommended that a set of specially prepared standard specimens, containing various known metallographic constituents, be used for comparison. It is very easy to obtain anomalous etching effects, such as ranges of colour in certain types of particles, and carefully standardized procedure is necessary. It should be remembered that the form and colour of the microconstituents may vary according to the degree of dispersion brought about by mechanical treatments, and also that the etching characteristics of a constituent may vary according to the nature of the other constituents present in the same section. Some etching reagents for aluminium require the use of a high temperature; in such cases the specimen should be preheated to this temperature by immersion in hot water before etching. For washing purposes, a liberal stream of running water is advisable. Electrolytic etching for aluminium alloys. In addition to the reagents given for aluminium in Table 6.2 the following solutions have been found useful for a restricted range of aluminium-rich alloys: 1.

2.

3.

4.

5.

6.

The following solution has been used for grain orientation studies: Orthophosphoric acid (density 1.65) 53 ml Distilled water 26 ml Diethylene glycol monoethyl ether 20 ml Hydrofluoric acid (48%) 1 ml The specimen should be at room temperature and electrolysis is carried out at 40 V and less than 0.1 A dm 2 . An etching time of 1.5 2 min is sufficient for producing grain contrast in polarized light after electropolishing. The solution below is also used for the same purpose and is more reliable for some alloys: Ethyl alcohol 49 ml Water 49 ml Hydrofluoric acid 2 ml (quantity not critical) The specimen is anodized in this solution at 30 V for 2 min at room temperature. A glass dish must be used. Not suitable for high-copper alloys. For aluminium alloys containing up to 7% of magnesium: Nitric acid (density 1.42) 2 ml 40% hydrofluoric acid 0.1 ml Water 98 ml Electrolysis is carried out at a current density of 0.3 A dm 2 and a potential of 2 V. The specimen is placed 7.6 cm from a carbon cathode. For cast duralumin: Citric acid 100 g Hydrochloric acid 3 ml Ethyl alcohol 20 ml Water 977 ml Electrolysis is carried out at 0.2 A dm 2 and a potential of 12 V. For commercial aluminium: Hydrofluoric acid (40%) 10 ml Glycerol 55 ml Water 35 ml This reagent, used for 5 min at room temperature, with a current density of 1.5 A dm 2 and a voltage of 7 8 V, is suitable for revealing the grain structure after electropolishing.72 For distinguishing between the phases present in aluminium-rich aluminium-coppermagnesium alloys, electrolytic etching in either ammonium molybdate solution or 0.880 ammonia has been recommended. In both cases, Al2 CuMg is hardly affected, CuAl2 is blackened, Al6 Mg4 Cu is coloured brown, while Mg2 Al3 is thrown into relief without change of colour.73

GRAIN-COLOURING ETCH

For many aluminium alloys containing copper, and especially for binary aluminium-copper alloys, it is found that Reagent No. 1 of Table 6.2 gives copper films on cubic faces which are subject to preferential attack and greater roughening of the surface. Subsequent etching with 1% caustic soda solution converts the copper into bronze-coloured cuprous oxide, and a brilliant and contrasting

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representation of the underlying surfaces is obtained. The technique is of use in orientation studies in so far as the films are dark and unbroken on (100) surfaces, but shrink on drying on other surfaces. In particular (111) faces have a bright yellow colour with a fine network on drying, which has no preferred orientation, while (110) faces develop lines (cracks in film) which are parallel to a cube edge.

6.2

Metallographic methods for magnesium alloys

PREPARATION

1. Magnesium is soft and readily forms mechanical twins and so deformed layers should be avoided. 2. Abrasives and polishing media tend to become embedded. Therefore use papers well-covered with paraffin making sure the deformed layer is removed. 3. Some phases in magnesium alloys are attacked by water. If these are present use paraffin or ethanol as lubricant. 4. Some very hard intermetallics can be present. Therefore keep polishing times short to avoid relief. The recommended procedure is to grind carefully to 600-grit silicon carbide papers. Then polish with fine ˛-alumina slurry or 4 6 µm diamond paste. This is followed by polishing on a fine cloth using light magnesia paste made with distilled water or a chemical attack polish of 1 g MgO, 20 ml ammon. tartrate soln. (10%) in 120 ml of distilled water. In reactive alloys, white spirit replaces distilled water and chemical attack methods avoided. ETCHING

The general grain structure is revealed by examination under cross-polars. This will also detect mechanical twins formed during preparation. A selection of etching reagents suitable for magnesium and its alloys is given in Table 6.3. Of these, 4 and 1 are the most generally useful reagents for cast alloys, while 16 is a useful macro-etchant and, followed by 4, is invaluable for showing up the grain structure in wrought alloys. Table 6.3 No.

ETCHING REAGENTS FOR MAGNESIUM AND ITS ALLOYS

Etchant

Remarks

1

Nitric acid Diethylene glycol Distilled water

1 ml 75 ml 24 ml

This reagent is recommended for general use, particularly with cast, die-cast and aged alloys. Specimens are immersed for 10 15 s, and washed with hot distilled water. The appearance of common constituents following this treatment is outlined in Table 6.4. Mg-RE and Mg-Th alloys also

2

Nitric acid Glacial acetic acid Water Diethylene glycol

1 20 19 60

Recommended for solution-heat-treated castings, and wrought alloys. Grain boundaries are revealed. The proportions are somewhat critical. Use 1 10 s

3

Citric acid Water

5 g 95 ml

4

Nitric acid, 2% in alcohol

A generally useful reagent

5

Nitric acid, 8% in alcohol

Etching time 4 6 s. Recommended for cast, extruded and rolled magnesium-manganese alloys

6

Nitric acid, 4% in alcohol

Used for magnesium-rich alloys containing other phases, which are coloured light to dark brown

7

Nitric acid, 5% in water

Etching time 1 3 s. Recommended for cast and forged alloys containing approximately 9% of aluminium

8

Oxalic acid 20 g l 1 in water

Etching time 6 10 s. Used also for extruded magnesiummanganese alloys

9

Acetic acid, 10% in water

Etching time 3 4 s. Used for magnesium-aluminium alloys with 3% of aluminium

ml ml ml ml

This reagent reveals grain boundaries, and should be applied by swabbing. Polarized light is an alternative

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169

Table 6.3 (continued ) No. 10 11 12

Etchant

Remarks

 Etching time 6 s  These regants are recommended for magnesium-aluminium alloys with 3 to 6% of  Orthophosphoric acid, 13% in glycerol Etching time 12 s aluminium Tartaric acid Used for wrought alloys. Mg2 Si is roughened and pitted. 10 s to 2 min for Mg-Mn-Al-Zn alloys. Grain contrast in cast alloys 100 g l 1 of water

Tartaric acid 20 g l 1 of water

13

Citric acid and nitric acid in glycerol

Used for magnesium-cerium and magnesium-zirconium alloys. The magnesium-rich matrix is darkened and the other phases left white

14

Orthophosphoric acid Picric acid Ethyl alcohol

Recommended for solution-heat-treated castings. The specimen is lightly swabbed, or immersed with agitation for 10 20 s. The magnesium-rich matrix is darkened, and other phases (except Mg2 Sn) are little affected. The maximum contrast between the matrix and Mg17 Al12 is developed. The darkening of the matrix is due to the development of a film, which must not be harmed by careless drying

0.7 ml 4 g 100 ml

15

Picric acid saturated in 95% alcohol 10 ml Glacial acetic acid 1 ml

A grain boundary etching reagent; especially for Dow metal (Al 3% Zn 1%, Mn 0.3%). Reveals cold work and twins

16

Picric acid, 5% in ethyl alcohol 50 ml Glacial acetic acid 20 ml Distilled water 20 ml

Useful for magnesium-aluminium-zinc alloys. On etching for 15 s an amorphous film is produced on the polished surface. When dry, the film cracks parallel to the trace of the basal plane in each grain. The reagent may be used to reveal changes of composition within grains, and other special purposes

17

Picric acid, 5% in ethyl alcohol 50 ml Glacial acetic acid 16 ml Distilled water 20 ml

As for Reagent 16, but suitable for a more restricted range of alloy composition

18

Picric acid, 5% in ethyl alcohol 100 ml Glacial acetic acid 5 ml Nitric acid (1.40) 3 ml

General reagent

19

Picric acid, 5% in ethyl alcohol 10 ml Distilled water 10 ml

Mg2 Si is coloured dark blue and manganese-bearing constituents are left unaffected

20

Hydrofluoric acid (40%) Distilled water

Useful for magnesium-aluminium-zinc alloys. Mg17 Al12 is darkened, and Mg3 Al2 Zn3 is left unetched. If the specimen is now immersed in dilute picric acid solution (1 vol. of 5% picric acid in alcohol and 9 vol. of water) the matrix turns yellow, and the ternary compound remains white

10 ml 90 ml

21

Picric acid, 5% in ethyl alcohol 100 ml Distilled water 10 ml Glacial acetic acid 5 ml

Reveals grain-boundaries in both cast and wrought alloys. This reagent is useful for differentiating between grains of different orientations, and for revealing internally stressed regions

22

Nitric acid conc.

Recommended for pure metal only. Specimen is immersed in the cold acid. After 1 min a copious evolution of NO2 occurs, and then almost ceases. At the end of the violent stage, the specimen is removed, washed and dried. Surfaces of very high reflectivity result, and grain boundaries are revealed

The appearance of constituents after etching. The micrographic appearances of the commonly occurring microconstituents in cast alloys are as given in Table 6.4. ELECTROLYTIC ETCHING OF MAGNESIUM ALLOYS

This has been recommended for forged alloys. The specimen is anodically treated in 10% aqueous sodium hydroxide containing 0.06 g l 1 of copper. A copper cathode is used, and a current density of

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Table 6.4 THE MICROGRAPHIC APPEARANCE OF CONSTITUENTS OF MAGNESIUM ALLOYS Microconstituent .1/

Mg17 Al12 .2/ MgZn2 .3/ Mg3 Al2 Zn3 Mg2 Si.4/

Appearance in polished sections, etched with Reagent 1 (zirconium-free alloys)

Manganese.5/ (MgMnAl).5/

White, sharply outlined and brought into definite relief Appearance very similar to that of Mg17 Al12 Appearance similar to those of Mg17 Al12 and MgZn2 Watery blue green; the phase usually has a characteristic Chinese-script formation, but may appear in massive particles. Relief less than for manganese Tan to brown or dark blue, depending on duration of etching. Individual particles may differ in colour Grey particles, usually rounded and in relief. Little affected by etching Grey particles, angular in shape and in relief. Little affected by etching

Microconstituent

Appearance in polished sections etched with Reagent 4 (zirconium-bearing alloys)

Primary Zr (undissolved in molten alloy) Zinc-rich particles.6/

Hard, coarse, pinkish grey rounded particles, readily visible before etching

Mg2 Sn.4/

Mg9 Ce Mg5 Th Mg-Th-Zn MgZn2

Fine, dark particles, loosely clustered and comparatively inconspicuous before etching Compound or divorced eutectic in grain boundaries. Appearance hardly changed by few per cent of zinc or silver Compound or divorced eutectic in grain boundaries (bluish). Appearance hardly changed by few per cent of zinc if Zn exceeds Th Brown acicular phase. Appears in Mg-Th-Zn-Zr alloys when Th ½ Zn Compound or divorced eutectic in grain boundaries. Absent from alloys containing RE or Th

The superscript numbers in column 1 refer to the following notes: (1) This is the -phase of the magnesium-aluminium system; it is also frequently called Mg4 Al3 or Mg3 Al2 . (2) Although the phase MgZn may be observed in equilibrium conditions, MgZn2 is frequently encountered in cast alloys. (3) This ternary compound occurs in alloys based on the ternary system magnesium-aluminium-zinc, and may be associated with Mg17 Al12 . (4) Blue unetched. (5) These constituents are best observed in the unetched condition. (6) Alloys of zirconium with interfering elements such as Fe, Al, Si, N and H, separating as a Zr-rich precipitate in the liquid alloy. Co-precipitation of various impurities makes the particles of indefinite composition. Note: The microstructure of all zirconium-bearing cast alloys with satisfactory dissolved zirconium content is characterised by Zr-rich coring in the centre of most grains. In the wrought alloys zirconium is precipitated from the cored areas during preheating or working, resulting in longitudinal striations of fine precipitate which become visible on etching.

0.53 A dm 2 is applied at 4 V. After etching, the specimen is successively washed with 5% sodium hydroxide, distilled water and alcohol, and is finally dried. NON-METALLIC INCLUSIONS IN MAGNESIUM-BASE ALLOYS

The detection and identification of accidental flux and other inclusions in magnesium alloys involves the exposure of a prepared surface to controlled conditions of humidity, when corrosion occurs at the site of certain inclusions, others being comparatively unaffected. The corrosion product or the inclusion may then be examined by microchemical techniques. The surface to be examined should be carefully machined and polished by standard procedures. The polishing time should be short, and alcohol or other solvent capable of dissolving flux must be avoided. As soon as possible the prepared specimens are placed in a humidity chamber, having been protected in transit by wrapping in paper. A suitable degree of humidity is provided by the air above a saturated solution of sodium thiosulphate. The presence of corrosive inclusions is indicated by the development of corrosion spots. At this stage the corroded area may be lightly ground away to expose the underlying structure for microexamination so that the micrographic features which are holding the flux become visible. With other specimens, or with the same specimens re-exposed to the humid conditions, identification of the inclusions may be proceeded with, as follows: 1. Detection of chloride

The corrosion product is scraped off, and dissolved on a microscope slip in 5% aqueous nitric acid. A 1% silver nitrate solution is then added, and a turbidity of silver chloride indicates the presence

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171

of the chloride ion. The solution of the corrosion product should preferably be heated before adding the silver nitrate to remove any sulphide ion, which also gives rise to turbidity. Alternatively, a 10% solution of chromium trioxide may be added directly to the corrosion spot, when chloride is indicated by an evolution of gas bubbles from the metal surface, and the development of a brown stain. This method is less specific than the silver nitrate method, and may give positive reactions in the presence of relatively large amounts of sulphates and nitrates. 2. Detection of calcium

Scrapings of corrosion product are dissolved in a small watch glass on a hot plate in 2 ml water and one drop of glacial acetic acid. To the hot solution a few drops of saturated ammonium oxalate solution are added. The presence of calcium is indicated by turbidity or precipitation. Spectroscopic identification of calcium in the solution is also possible. 3. Detection of boric acid in inclusions

Scrapings of corrosion product and metal are placed in a test tube with 1 ml of water. The inclusion dissolves, and complete solution of the sample is effected by adding a small portion of sulphuric acid (density 1.84) from 9 ml carefully measured and contained in a graduated cylinder. When solution is complete, the remainder of the acid is added and the mixture is well shaken; 0.5 ml of a 0.1% solution of quinalizarin in 93% (by wt.) of sulphuric acid is now added, mixed in, and allowed to stand for 5 min. A blue colour indicates the presence of boric acid. The colour in the absence of boric acid varies from bluish violet to red according to the dilution of the acid, which must thus be carefully controlled as described. 4. Detection of nitride

A drop of Nessler’s solution applied directly to the metal surface in the presence of nitride, gives an orange brown precipitate, which may take about 1 min to develop. This test should be made on freshly prepared surfaces on which no water has been used, since decomposition of nitride to oxide occurs in damp air. 5. Detection of sulphide

The corrosion product is added to a few drops of water slightly acidified with nitric acid. A drop of the solution placed on a silver surface gives rise to a dark stain if sulphide was present in the corrosion product. Sulphur printing may also be applied. 6. Detection of iron

The corrosion product is dissolved in hydrochloric acid. A drop of nitric acid is added with several drops of distilled water. In the presence of iron, the addition of a crystal of ammonium thiocyanate develops a blood-red colouration. In all the above tests, a simultaneous blank test should be carried out. Iron-printing, analogous to sulphur-printing, can be applied using cleaned photographic paper impregnated with a freshly prepared solution of potassium ferricyanide and potassium ferrocyanide acidified with nitric or hydrochloric acid.

6.3

Metallographic methods for titanium alloys

PREPARATION

The preparation of titanium samples by ordinary methods of grinding is straightforward but needs care; final polishing is difficult. Specimens are easily scratched, and mechanical working of the surface during polishing causes twin-formation which may obscure other metallographic features. Other ‘false’ structures may be caused by the presence of local, randomly dispersed areas of cold work, which give a duplex appearance to homogeneous specimens. Electrolytic polishing of surfaces ground wet by ordinary methods to the 000 grade of emery paper is therefore recommended. Mechanical polishing, if preferred, may be carried out with diamond preparation, with a final fine polish (if required) with alumina, both with a trace of hydrofluoric acid. Examination for hydride is carried out in polarised light between crossed polaroids; the hydride then appears bright and anisotropic. This also reveals the grain structure of ˛-titanium.

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Smithells Light Metals Handbook

ETCHING

The presence of surface oxide films on titanium and its alloys necessitates the use of strongly acid etchants. Those given in Table 6.5 are useful. Table 6.5 ETCHING REAGENTS FOR TITANIUM AND ITS ALLOYS No. 1

2

3

4

5

6

7

Etchant

Conditions

Hydrofluoric acid (40%) Nitric acid (1.40) Lactic acid

1 3 ml

Hydrofluoric acid (40%) Nitric acid (1.40) Lactic acid

1 ml

Hydrofluoric acid (40%) Nitric acid (1.40) Water (Kroll’s reagent)

Remarks

5 30 s

Mainly unalloyed titanium; reveals hydrides

5 30 s

As Etchant 1

3 10 s

Most useful general etch

5 30 s

Chemical polish and g.b. etch

3 20 s

Useful for ˛/ˇ alloys. ˛ is attacked or stained. ˇ unattacked

5 15 s

General purpose, TiAlSn alloys

3 20 s

TiAlSn alloys

10 ml 30 ml

30 ml 30 ml 1 3 ml 2 6 ml to 100 ml

Hydrofluoric acid (40%) Nitric acid (1.40) Lactic acid

10 ml

Potassium hydroxide (40%) Hydrogen peroxide (30%) Water (can be varied to suit alloy)

10 ml

10 ml 30 ml

5 ml 20 ml

Hydrofluoric acid (40%) Nitric acid Glycerol

20 ml 40 ml

20 ml

Hydrofluoric acid Nitric acid (1.40) Glycerol Water

1 25 45 20

ml ml ml ml

7

Heat treatment of light alloys

7.1

Aluminium alloys

7.1.1

Annealing

For softening aluminium alloys that have been hardened by cold work: Alloys 1080A, 1050, 1200, 5251, 5154A, 5454, 5083 360 ° C for 20 min. Alloys 3103, 3105 400 425 ° C for 20 min. Heat-treatable alloys that have not been heat treated 360 ° C š 10 ° C for 1 h and cool in air. Alloys that have been heat treated 400 425 ° C for 1 h and cool at 15 ° C/h to 300 ° C. For Al-Zn-Mg alloys of the 7000 series, after cooling in air, reheat to 225 ° C for 2 4 h.

7.1.2

Stabilizing

To relieve internal stress. Normally heat to 250 ° C followed by slow cooling is adequate.

7.1.3

Hardening

Conditions for solution treatment and ageing for both cast and wrought aluminium alloys are given in Tables 7.1 and 7.2. For the alloy designation system and compositions see Chapter 3. Temper designations are given in Table 7.3.

Table 7.1

HEAT TREATMENT DATA FOR ALUMINIUM CASTING ALLOYS

Solution treatment Material designation and temper

Alloy type

Precipitation treatment

Temperature °C

Time1

Quench2

h

medium

505 520

6 16

Hot water

520 535 425 435

2 8 8

Water Oil at 160 ° C max4

515 515 520 520 515

8 8 12 12 6 9

Hot Hot Hot Hot Hot

Temperature °C

Time3 h

150 170 150 170 150 170

6 18 16 16

160 180 160 180 200 250

4 16† 4 16 4 16

160 179

8 10

BS 1490 LM 4 TF LM 9 TE TF LM 10 TB LM 13 TE TF TF7 LM 16 TB TF LM 22 TB

Al Si5 Cu3 Al Si12 Mg Al Mg10 Al Si11 Mg Cu Al Si5 Cu1 Mg Al Si6 Cu3 Mn

525 525 530 530 530

water water water water water

continued overleaf

174

Smithells Light Metals Handbook

Table 7.1 (continued ) Solution treatment Material designation and temper LM 25 TB7 TE TF LM 26 TE LM 28 TE TF LM 29 TE TF LM 30 TS

Alloy type Al Si7 Mg

Precipitation treatment

Temperature °C

Time1 h

Quench2 medium

525 545

4 12

Hot water

525 545

4 12

Hot water

495 505

4

Air blast

495 505

4

Air blast

Temperature °C 250 155 175 155 175 200 210 185 185 185 185 175 225

Al Si9 Cu3 Mg Al Si19 Cu Mg Ni Al Si23 Cu Mg Ni Al Si17 Cu4 Mg

Time3 h 2 8 8 7

4 12 12 9 † 8 † 8 8

BS ‘L’ series (4L 35)

Al Cu4 Ni2 Mg2

500 520

6

Boiling water

3L 51 (3L 52)

Al Si2 Cu Ni Fe Mg Al Cu2 Ni Si Fe Mg

520 540

4

Water at 30 100 ° C

(4L 53) 3L 78 (2L 91) 2L 92 (L 99) (L 119)

Al Al Al Al Al Al

425 435 520 530 525 545 525 545 535 545 542 š 5

8 12 12 16 12 16 12 5

L 154 L 155

Al Cu4 Si1 Al Cu4 Si1

510 š 5 510 š 5

16 16

540 š 5

4 12

540 š 5

4 12

430 š 5

8

440 š 5 495 š 5

8 8

Mg10 Si4 Cu1 Cu4 Cu4 Si6 Cu5 Ni1

Oil at 160 ° C max4 Hot water Hot water Hot water Hot water Boiling water or oil at 80 ° C Water (50 70 ° C) Water (50 70 ° C)

95 110 or room temperature 150 175 150 180 or 195 205

2 5 days

160 170 120 140 120 170 150 160 215 š 5

8 10 1 2 12 14 4 12 16

140 š 10

30 days 16

165 š 10 130 š 10

8 12 1 2

165 š 10 180 š 5

8 12 10

8 24 8 24 2 5

DTD specifications 722B 727B

Al Si5 Al Si5

735B 5008B 5018A

Al Si5 Al Zn5 Mg Al Mg7 Zn

or then

Water (80 100 ° C) or oil Water (80 100 ° C) Oil > 160 ° C > 1 h then oil at room temperature, or air Boiling water

1 Single figures are minimum times at temperature for average castings and may have to be increased for particular castings. 2 Hot water means water at 70 80 ° C unless otherwise stated. 3 The exact number of hours depends on the mechanical properties required. 4 The castings may be allowed to cool to 385 395 ° C in the furnace before quenching. The castings shall be allowed to stay in the oil for not more than 1 h and may then be quenched in water or cooled in air. † The duration of the treatment shall be such as will produce the specified Brinell hardness in the castings. Ł For temper designation see Table 7.2. () Specification now withdrawn.

Table 7.2 TYPICAL HEAT TREATMENT DATA FOR WROUGHT ALUMINIUM ALLOYS Times and temperatures within the limits shown. some specifications give tighter limits Solution treatment Material designation 2011

Alloy type

Temper‡

Temperature °C

Al Cu5.5 Pb Bi

T 3 (TD) T 6 (TF)

510 š 5 510 š 5

Quench medium†

Ageing temperature °C

Time at temperature h

Water Water

Room 155 165

48 12

Heat treatment of light alloys

175

Table 7.2 (continued ) Solution treatment Material designation 2014A

Temper‡

Alloy type Al Cu4 Si Mg

2024

Al Cu4 Mg1

2031 2117 2618A 6061

Al Al Al Al

6063

Al Mg Si

Cu2 Ni1 Mg Te Si Cu2 Mg Cu2 Mg15 Te1 Ni1 Mg1 Si Cu

6082

Al Si1 Mg Mn

6101A

Al Mg Si

6463

Al Mg Si

7010

Al Zn6 Mg2 Cu2

7014

Al Zn5.5 Mg2 Cu Mn

7075

Al Zn6 Mg Cu

Temperature °C

Quench medium†

T T T T T T T T T T T T T T T T T T T T T T T T

3 (TD) 4 (TB) 6 (TF) 651 351 4 (TB) 42 4 (TB) 4 (TB) 6 (TF) 4 (TB) 6 (TF) 4 (TB) 5 (TE) 6 (TF) 4 (TB) 6 (TF) 651 4 (TB) 6 (TF) 4 (TB) 6 (TF) 351 7651

505 š 5 505 š 5 505 š 5 505 š 5 495 š 5 495 š 5 495 š 5 525 š 10 495 š 5 530 š 5 525 š 15 525 š 15 525 š 5

Water Water Water Water Water Water Water Water or oil Water Water Water Water Water

525 š 5 530 š 10 530 š 10 525 š 15 525 š 5 525 š 5 525 š 5 525 š 5 475 š 10 475 š 10

T T T T T T

73651 6 (TF) 6510 6 (TF) 651 73

465 š 10 460 š 10 460 š 10 460 š 10 460 š 10 465 š 5

Water Water Water Water Water Water Water Water Water Water or followed by Water Water 85 ° C or oil Water or oil Water Water Water (60 80 ° C) or followed by Water followed by Water 70 ° C or followed by

T 7351

465 š 5

T 7352

465 š 5

Ł Heating to temperature at not more than 20 ° C/h. † Water below 40 ° C unless otherwise stated. ‡ For temper designation see Table 7.3

Table 7.3 ALUMINIUM ALLOY TEMPER DESIGNATIONS Symbol

Condition

Casting alloys BS 1490 M TB TB7 TE TF TF7 TS

As cast Solution treated and naturally aged Solution treated and stabilized Artificially aged Solution treated and artificially aged Solution treated, artificially aged and stabilized Thermally stress relieved continued overleaf

Ageing temperature °C

Time at temperature h

Room Room 155 190 155 190 Room Room Room 155 205 Room 160 200 Room 165 195 Room 160 180 160 180 Room 175 185 165 195 Room 170 š 10 Room 170 š 10

48 48 5 5 48 48 48 2 96 16

172 š 3Ł 120 š 3 172 š 3 172 š 3Ł 135 š 5 135 š 5 135 š 5 135 š 5 110 š 5 120 š 5 177 š 5 110 š 5 177 š 5 110 š 5 120 š 5 177 š 5

6 24 6 10 12 12 12 12 6 20 6 6 5 6 20 6

20 20

20 24

3 12 5 15 5 15 1 20 7 12 3 12 1 20 1 20 5 15 15 15 24

24 30 10 24 12 24 30 10

176

Smithells Light Metals Handbook

Table 7.3 (continued ) Symbol

Condition

BSEN515 T T T T T T T T T T

1 2 3 (TD) 4 (TB) 5 (TF) 6 7 8 (TH) 9 10

Cooled from elevated temperature shaping process and naturally aged to stable condition As T 1 but cold worked after cooling from elevated temperature Solution treated, cold worked and naturally aged to stable condition Solution treated and naturally aged to stable condition Cooled from elevated temperature shaping process and artificially aged Solution treated and artificially aged Solution treated and stabilized (over-aged) Solution treated, cold worked and then artificially aged Solution treated, artificially aged and then cold worked Cooled from elevated temperature shaping process artificially aged and then cold worked

Ł British equivalents in parenthesis.

7.2

Magnesium alloys

7.2.1

Safety requirements

A potential fire hazard exists in the heat treatment of magnesium alloys. Overheating and direct access to radiation from heating elements must be avoided and the furnace must be provided with a safety cutout which will turn off heating and blowers if the temperature goes more than 6 ° C above the maximum permitted. In a gastight furnace a magnesium fire can be extinguished by introducing boron trifluoride gas through a small opening in the closed furnace after the blowers have been shut down. 7.2.2

Environment

For temperature over 400 ° C, surface oxidation takes place in air. This can be suppressed by addition of sufficient sulphur dioxide, carbon dioxide or other suitable oxidation inhibitor. In the case of castings to MEL ZE63A and related specifications, solution treatment should be carried out in an atmosphere of hydrogen and quenching of castings from solution treatment temperature of MEL QE22 is to be done in hot water. If microscopic examination reveals eutectic melting or high temperature oxidation, rectification cannot be achieved by reheat-treatment. Quench from solution treatment should be rapid, either forced air or water quench. From ageing treatment, air cool. 7.2.3

Conditions for heat treatment of magnesium alloys castings

These are shown in Table 7.4 and for some wrought magnesium alloys in Table 7.5. Stress relief treatments are given in Table 7.6. Table 7.4 HEAT TREATMENT OF MAGNESIUM CASTING ALLOYS Solution treatment Specifications

Composition

MEL ZRE1 BS 2L126 BS 2970 MAG 6 ASTM EZ33A UNS M12330

Zn2.5 Zr0.6 RE3.5

Temperature (° C)

Time (h) quench

Ageing Temperature (° C)

Time (h) quench

250

16 AC

Heat treatment of light alloys

177

Table 7.4 (continued ) Solution treatment

Temperature (° C)

Time (h) quench

330 +170 180

2 AC 10 16 AC

140

48 AC

Zn2.2 Zr0.7 Th3.0

315

16 AC

MEL TZ6 DTD 5015A BS 2970 MAG 9 ASTM ZH62A UNS M16620

Zn5.5 Zr0.7 Th1.8

330 +170 180

2 AC 10 16 AC

MEL EQ21A

Ag1.5 Zr0.7 Cu0.07 Nd(RE)2.0

520

8 WQ

200

12 16 AC

MEL MSR-B DTD 5035A

Ag2.5 Zr0.6 Nd(RE)2.5

520 530

4 8 WQ

200

8 16 AC

MEL QE22 (MSR) DTD 5055 ASTM QE22A UNS M18220

Ag2.5 Zr0.6 Nd(RE)2.0

520 530

4 8 WQ Hot WQ

200

8 16 AC

MEL A8 BS 3L122 BS 2970 MAG1 ASTM AZ81A UNS M11818

Al8.0 Zn0.5 Mn0.3

380 390 410 420

8 AC 16 AC

MEL AZ91 (ST) BS 3L124 BS 2970 MAG 3

Al9.0 Zn0.5 Mn0.3 Be0.0015

380 390 410 420

8 AC 16 AC

ASTM AZ91C (ST&PT) UNS M11914

Al9.0 Zn0.5 Mn0.3 Be0.0015

380 390 410 420

8 AC 16 AC

200

10 AC

MEL MAG 7 (ST) BS 2970 MAG 7

Al7.5/9.5 Zn0.3/1.5 Mn0.15

380 390 410 420

8 AC 16 AC

MEL MAG 7 (ST&PT)

Al7.5/9.5 Zn0.3/1.5 Mn0.15

380 390 410 420

8 AC 16 AC

200

10 AC

Specifications

Composition

MEL RZ5 BS 2L128 BS 2970 MAG 5 ASTM ZE41A UNS M16410

Zn4.2 Zr0.7 RE1.3

MEL ZE63A DTD 5045 ASTM ZE63A

Zn5.8 Zr0.7 RE2.5

MELZT1 DTD 5005A BS 2970 MAG 8 ASTM HZ32A

Temperature (° C)

480Ł

Time (h) quench

Ageing

10 72 WQ

Ł In hydrogen. Max 490 ° C.

Table 7.5 HEAT TREATMENT OF MAGNESIUM WROUGHT ALLOYS Solution treatment Specifications

Composition

Form

MEL AZ80 ASTM AZ80A UNS M11800

Al8.5 Zn0.5 Mn0.12

Ex F

Temperature (° C)

400

Time (h) quench

2-4 WQ

Ageing Temperature (° C)

Time (h) quench

177

16 AC

177

16-24 AC continued overleaf

178

Smithells Light Metals Handbook

Table 7.5 (continued ) Solution treatment Specifications

Composition

Form

ASTM HM31A UNS 13310

Th2.5-4.0 Zn0.3 Zr0.4-1.0

Ex

ASTM 60A UNS 16600

Zn5.5

F T6 F T4 F T5

Notes: Ex extrusions, F aged, AC air cool, WQ

Temperature (° C)

500 500

forgings, T4 solution treated, T5 water quench.

Ageing

Time (h) quench

2 WQ 2 WQ

cooled and artificially aged, T6

Table 7.6 STRESS RELIEF TREATMENTS FOR WROUGHT MAGNESIUM ALLOYS

Specifications

Composition

Form

Temperature (° C)

Time (min)

MEL AZM ASTM Al61A UNS 11610

Al6.0 Zn1.0 Mn0.3

Ex&F SH SA

260 204 343

15 60 120

MEL AZ80 ASTM AZ80 UNS 11311

Al8.5 Zn0.5 Mn0.12 min

Ex&F Ex&FŁ

260 204

15 60

MEL AZ31 ASTM AZ31B UNS 11311

Al3.0 Zn1.0 Mn0.3

Ex&F SH SA

260 149 343

15 60 120

Notes: Ex extrusions, F and artificially aged.

forgings, SH

sheet hard rolled, SA

sheet annealed, Ł

cooled

Temperature (° C)

Time (h) quench

232

16 AC

150

24 AC

150

24 AC

solution treated and artificially

8

Metal finishing

The processes and solutions described in this section are intended to give a general guide to surface finishing procedures. To operate these systems on an industrial scale would normally require recourse to one of the Chemical Supply Houses which retail properietary solutions.

8.1

Cleaning and pickling processes

VAPOUR DEGREASING

Used to remove excess oil and grease. Components are suspended in a solvent vapour, such as trior tetrachloroethylene. Note: Both vapours are toxic and care should be taken to ensure efficient condensation or extraction of vapours. EMULSION CLEANING

An emulsion cleaner suitable for most metals can be prepared by diluting the mixture given below with a mixture of equal parts of white spirit and solvent naphtha. Pine oil Oleic acid Triethanolamine Ethylene glycol-monobutyl ether

62 g 10.8 g 7.2 g 20 g

This is used at room temperature and should be followed by thorough swilling. Table 8.1

ALKALINE CLEANING SOLUTIONS

Metal to be cleaned All common metals other than aluminium and zinc, but including magnesium

Composition of solution

Sodium hydroxide (NaOH) Sodium carbonate (Na2 CO3 ) Tribasic sodium phosphate (Na3 PO4 .12H2 O) Wetting agent

Temperature

oz gal 1

gl 1

°F

°C

Remarks

6

37.5

180 200

80 90

For heavy duty

4

25.0

1 1 4

6.2 1.5 continued overleaf

180

Smithells Light Metals Handbook

Table 8.1 (continued ) Metal to be cleaned

Composition of solution gl 1

°F

°C

2 4

12.5 25.0

180 200

80 90

For medium duty

2

12.5

2 1 8

12.5

4 4 1 8

25.0 25.0

180 200

80 90

For light duty

2 4 1 8 2

12.5 25.0

180 200

80 90

12.5

180 200

80 90

4

25.0

1 4

1.5

6 1

37.5 6.25

2

12.5

2 1 1 8

12.5 6.25

Sodium hydroxide Sodium carbonate Tribasic sodium phosphate Sodium metasilicate (Na2 SiO3 .5H2 O) Wetting agent Tribasic sodium phosphate Sodium metasilicate Wetting agent Aluminium and zinc

Tribasic sodium phosphate Sodium metasilicate

Most common metals

Sodium carbonate Tribasic sodium phosphate

Wetting agent

Wetting agent

Most common metals

Temperature

oz gal 1

Sodium carbonate Sodium hydroxide Tribasic sodium phosphate Sodium cyanide (NaCN) Sodium metasilicate Wetting agent

Remarks

0.75

0.75

0.75 Electrolytic cleaner, 6 V Current density 100/A ft 2 (10/A dm 2 ) Article to be cleaned may be made cathode or anode or both alternately Room

Room

May be used electrolytically

0.75

Table 8.2 PICKLING SOLUTIONS Metal to be pickled Aluminium (wrought)

Aluminium (cast and wrought)

Composition of solution

For etching Sodium hydroxide (NaOH)

Nitric acid, s.g. 1.42 Hydrofluoric acid (52%) Water

Temperature

oz gal 1

gl 1

8

°F

°C

56

104 176

40 80

Articles dipped until they gas freely, then swilled, and dipped in nitric acid 1 part by vol. to 1 of water (room temperature)

1 gal 1 gal

11 11

Room

Room

Articles first cleaned in solvent degreaser. Use polythene or PVC tanks

8 gal

81

Remarks

Metal finishing

181

Table 8.2 (continued ) Composition of solution

Metal to be pickled

Temperature

oz gal 1

gl 1

°F

Bright dip Chromic acid Ammonium bifluoride Cane syrup Copper nitrate Nitric acid (s.g. 1.4) Water (distilled) to

0.84 oz 0.72 oz 0.68 oz 0.04 oz 4.8 oz 1 gal

5.2 g 4.5 g 4.2 g 0.25 g 30 ml 11

195

90

Immerse for 1 21 min. Solution has limited life. AR chemicals and deionized or distilled water should be used

Aluminium and other nonferrous metals

Bright dip Phosphoric acid (s.g. 1.69) Nitric acid (s.g. 1.37)

8.4 gal 0.6 gal

9.41 0.61

195

90

Immerse for several min. Agitate work and solution. Good ventilation necessary. Addition of acetic acid

Magnesium and magnesium alloys

General cleaner Chromic acid

16 32

100 200

Up to b.p.

Up to b.p.

For removal of oxide films, corrosion products, etc. Should not be used on oily or painted material

Sulphuric acid pickle Sulphuric acidŁ

3%

Room

Room

Should be used on rough castings or heavy sheet only. Removes approx. 0.002 in. in 20 30 s

Nitro-sulphuric pickle Nitric acid Sulphuric acidŁ

8% 2%

Room

Room

Bright pickle for wrought products Chromic acid Sodium nitrate

°C

Remarks

23 4 1 8

150 25 3 4

Room

Room

37 21 3 41

235 20

Room

Room

1

6.2

Acetic acid

8 approx.

50 approx.

Room

Room

Special purpose pickles

Citric acid

8 approx.

50 approx.

Room

Room

Special purpose pickles

Calcium or magnesium fluoride Bright pickle for castings Chromic acid Concentrated nitric acid (70%) Hydrofluoric acid (50%)

Lustrous appearance. Involves metal removal

Note: It is almost universal practice to use an inhibitor in the pickling bath. This ensures dissolution of the scale with practically no attack on the metal. Inhibitors are usually of the long chain amine type and often proprietary materials. Examples are Galvene and Stannine made by ICI.

182

8.2

Anodizing and plating processes

Composition of solution

Temperature

oz gal 1

gl 1

°F

°C

Chromic acid (CrO3 ), chloride content must not exceed 0.2 g l 1 sulphate less than 0.5 g l 1 (After Bengough- Stuart)

5 16

30 100

103 108

38 42

Sulphuric acid (s.g. 1.84)

32

200

60 75

Hard anodizing Hardas process Sulphuric acid

32

200

23 41

Eloxal GX process Oxalic acid (COOH)2 .2H2 O

12.8

15 24

5 C 5

80

70

20

Current density amp ft 2 (A dm 2 )

Time and voltage

Cathodes

Vat

Hangers

Remarks

Pure aluminium or titanium

Slight agitation is required

Current controlled by voltage. Average 3 4 (0.3 0.4) d.c.

† 1 10 min 0 40 V increased in steps of 5 V 5 35 min Maintain at 40 V 3 5 min Increase gradually to 50 V 4 5 min Maintain at 50 V

Tank or stainless steel

10 20 (1 2) d.c.

12 18 V 20 40 min

Aluminium or lead plates (tank if lead lined)

Lead lined steel

Pure aluminium or titanium

The current must not exceed 0.2 Al 1 of electrolyte

25 400 (2.5 40) d.c.

40 120 V

Lead

Lead lined steel

Aluminium or titanium

Agitation required. Gives coating 1 3 thou. thick

10 20 (1 2) d.c.

50 V 30 60 min

Vat lining

Lead lined steel

Aluminium or titanium

Oxalic acid processes are more expensive than sulphuric acid anodizing; but coatings are thicker and are coloured.

Steel (exhausted)

This process cannot be used with alloys containing more than 5% copper

Smithells Light Metals Handbook

Table 8.3 ANODIZING PROCESSES FOR ALUMINIUM Good ventilation above the bath and agitation of the bath is advisable in all cases.

Eloxal WX process Oxalic acid

12.8

80

75 95

25 35

20 30 (2 3) a.c.

20 60 V 40 60 min

Vat lining

Lead lined steel

Aluminium or titanium

Integral colour Anodizing Kalcolor process Sulphuric acid Sulphosalicylic acid

0.8 16

5 100

72

22

30 (3) d.c.

25 60 V 20 45 min

Lead

Lead lined steel

Aluminium or titanium

Aluminium level in solution must be maintained between 1.5 and 3 g l 1

† Period according to degree of protection Complete cycle normally 40 min.

Metal finishing 183

184

Table 8.4 ANODIZING PROCESSES FOR MAGNESIUM ALLOYS Temperature

oz gal 1 g l 1 HAE process Potassium hydroxide Aluminium Potassium fluoride Trisodium phosphate Potassium manganate Dow 17 process Ammonium bifluoride Sodium dichromate Phosphoric acid 85% H3 PO4 Cr 22 process Chromic acid Hydrofluoric acid (50%) Phosphoric acid H3 PO4 (85%) Ammonia solution MEL process Fluoride anodize Ammonium bifluoride

19.2

120

1.7 5.5 5.5

10.4 34 34

3.2

20

39

232

16

100

14

88

4 4 13.5

25 25 84

25 30

160 180

16

100

Current density A ft 2 (A dm 2 )

Time and voltage

Cathodes

12 15 (1.2 1.5)

90 min at 85 V approx. a.c. preferred

Mg alloy for a.c. Mg or steel if d.c. used

Mild steel or rubber lined

Mg alloy

Matt hard, brittle, corrosion resistant, dark brown 25 50 µm thick, abrasion resistant

160 180 70 85

5 50 (0.5 5)

10 100 min up to 110 V a.c. or d.c.

Mg alloy for a.c. Mg or steel for d.c.

Mild steel or rubber lined

Mg alloy

Matt dark green, corrosion resistant, 25 µm thick approx., abrasion resistant

165 205 75 95

15 (1.5)

12 min 380 V a.c.

Mild steel

Mg alloy

Matt dark green, corrosion resistant, 25 µm thick approx.

<86

5 100 (0.5 10)

30 min 120 V a.c. preferred

Rubber lined

Mg alloy

Principally a cleaning process to improve corrosive resistance by dissolving or ejecting cathodic particles from the surface

F

C

<95

<35

<30

Mg alloy for a.c. Mg or steel for d.c.

Vat

Hangers

Remarks

Smithells Light Metals Handbook

Composition of solution

Metal finishing

8.3

185

Plating processes for magnesium alloys

DOW PROCESS (H. K. DELONG)

This process depends on the formation of a zinc immersion coat in a bath of the following composition:

Component Tetrasodium pyrophosphate Zinc sulphate Potassium fluoride

Concentration gl oz gal 1 16 5.3 1.0

1

120 40 7

The treatment time is 3 5 min at a temperature of 175 185 F (80 85 ° C) with mild agitation. The pH of the bath should be 10 10.4. The steps of the complete process are: 1. 2. 3. 4. 5.

Solvent or vapour degreasing. Hot caustic soda clean or cathodic cleaning in alkaline cleaner. Pickle 41 1 12 min in 1% hydrochloric acid and rinse. Zinc immersion bath as above without drying off from the rinse. Cold rinse and immediately apply copper strike as under.

Component Copper cyanide Potassium cyanide Potassium carbonate Potassium hydroxide Potassium fluoride Free cyanide pH Temperature

Concentration gl oz gal 1 4.2 7.4 2.4 1.2 4.8 1.2 12.8 13.2 140 ° F (60 ° C)

1

26 46 15 7.5 30 7.5

CONDITIONS

30 40 A ft 2 (3 4 A dm 2 ) for 12 1 min, reducing to 15 20 A ft 2 (1.5 2 A dm 2 ) for 5 min or longer. If required, the copper thickness from the above strike can be built up in the usual alkaline or proprietary bright plating baths. Following the above steps, further plating may be carried out in conventional electroplating baths. ELECTROLESS PLATING ON MAGNESIUM

Deposits of a compound of nickel and phosphorus can be obtained on magnesium alloy components by direct immersion in baths of suitable compositions. Details of the process may be obtained from the inventors. The Dow Chemical Co. Inc., Midland, Michigan, USA. ‘GAS PLATING’ OF MAGNESIUM (VAPOUR PLATING)

Deposits of various metals on magnesium components (as on other metals) can be produced by heating the article in an atmosphere of a carbonyl or hydride of the metal in question.

9

Superplasticity of light metal alloys

Superplasticity is the name given to the ability of a material to sustain extremely large deformations at low flow stresses at a temperature around half the melting point expressed in Kelvin. It is only found in metals and alloys, which have, and can maintain during forming, a very fine grain structure. A parameter which indicates the degree of superplasticity is the strain rate sensitivity m, given by the high temperature flow equation: D KPem , is the stress for plastic flow, eP the applied strain rate and K is a constant. Superplastic materials have m values normally between 0.4 and 0.6, while most other metals and alloys at elevated temperatures have m values of 0.2; viscous materials (e.g. glass) behave like a Newtonian fluid and have m values of 1. A full discussion of the mechanism of superplasticity, including methods for determining m, can be found in K. A. Padmanabhan and G. J. Davies, ‘Superplasticity’, Berlin, Springer-Verlag, 1980. The tables in this chapter give alloy systems with the temperature range over which they show superplasticity, the maximum possible percentage elongation, and the m value. The values of about 10 4 quoted under remarks are preferred strain rates.

Table 9.1 NON-FERROUS-SYSTEMS (LIGHT METAL ALLOY)

Temperature range ° C

Maximum elongation %

m

Al (commercial) Al 7.6Ca Al 7.6Ca

380 580 400 600 ¾500

6 000 850 570

0.2 0.78 0.32

Al 5Ca 5Zn Al 17Cu Al 32:74Cu

450 400 520 ¾510

600 >160

0.35 0.7

Al 33Cu Al 6Cu 0.5Zr Al 2.59Cu 2.26Li 0.16Zr(2090)

380 520 400 500 450 480

1 150 2 000 1 800

0.9 0.5

Al 4.40Cu 0.70Mg 0.80Si 0.75Mn(2014) + 15%SiC

450 480

160

0.4

Al 25 33Cu 7 11Mg Al Ga Ti Al 4Ge Al 2.4Li 2.0Cu 0.70Mg 0.08Zr(8091 Al 2.5Li 1.2Cu 0.6Mg 0.1Zr(8090)

420 480 RT 400 500 490 550

>600

0.72 0.3 0.5

230 1 350

0.6

520 530

660 1200

0.65

Alloy system

Remarks

Euratom alloy Optimum 500 ° C at 4.16 ð10 4 Alcan 08050 After 25% pre-deformation at 510 ° C TI Supral Optimum 520 ° C at 5 ð10 4 Elong% 350% at 5.25 MPa hydrostatic pressure

Optimum 530 ° C at 10 3 10 4 2 3 mm sheet at 2 5 ð10 4

Superplasticity of light metal alloys

187

Table 9.1 (continued )

Temperature range ° C

Maximum elongation %

m

Remarks

¾530

>1 000

0.68

2 mm sheet at 5 ð 10 4 and 5 10 micron grain size

1.56Mg 5.6Zn 3Mg 6Zn 0.93Mg 10.72Zn 0.42Zr 5.8Mg 0.37Zr + others 4.89 Mg 1.19Cr

530 340 360 550 520 482 520

500 400 1 550 >800 >1 000

0.7 0.35 0.9 0.6

Al 8.0Mg 1.0Li 0.15Zr Al 5.70Zn 2.30Mg 1.50Cu 0.22Cr(7475) + 15% SiC

300 495 515

>1 000 97

Al 5.70Zn 2.30Mg 1.50Cu 0.22Cr(7475)

¾530

1 300

350 400 180

Mg 9Li Mg 9Li

Alloy system Al 2.4Li 1.2Cu 0.60Mg 0.12Zr(8090) Al Al Al Al Al

Mg 33Al Mg 9Li

Mg Mg Mg Mg Ti Ti Ti Ti

4.3Al 3Zn 0.5Mn 30.7Cd 5.5Zn 0.5Zr 0.5Zr

(commercial) 4Al 0.2502 5Al 2.5Sn 6Al 4V

Ti 6Al 5Zr 4Mo 1Cu 0.25Si Ti 8Mn Ti 15Mo Ti 11Sn 5Zr 2.25Al 1Mo 0.25Si

TI BA 480 Optimum 520 ° C at 1.6 ð10 2

0.43

Elong% 310% at 5.25 MPa hydrostatic pressure Optimum 530 ° C at 2.8 ð10 4

2 100 460

0.8 0.52

200

445

0.47

250

310

0.44

Eutectic At 3 ð10 4 ; 6.1 micron grain size At 1 ð10 3 ; 7.1 micron grain size At 1 ð10 4 ; 14.2 micron grain size Russian MA 15

450 270 310 500

250 1 000 150

0.6 0.3

ZK 60

900 950 1 050 900 1 100 750 1 000

RC 70

450 1 000

0.8 0.6 0.72 0.85

800 580 900 580 900 800

300 140 450 500

Commercial alloy used throughout world IMI 700

0.95 0.6 IMI 679

10

Light metal-matrix composites

Metal-matrix composites are engineered materials comprising reinforceants of high elastic modulus and high strength in a matrix of a more ductile and tougher metal of lower elastic modulus and strength. The metal-matrix composite has a better combination of properties than can be achieved by either component material by itself. The objective of adding the reinforceant is to transfer the load from the matrix to the reinforceant so that the strength and elastic modulus of the composite are increased in proportion to the strength, modulus and volume fraction of the added material. The reinforcement can take one of several forms. The least expensive and most readily available on the market are the particulates. These can be round but are usually irregular particles of ceramics, of which SiC and Al2 O3 are most frequently used. Composites reinforced by particulates are isotropic in properties but do not make best use of the reinforceant. Fine fibres are much more effective though usually more costly to use. Most effective in load transfer are long parallel continuous fibres. Somewhat less effective are short parallel fibres. Long fibres give high axial strength and stiffness, low coefficients of thermal expansion and, in appropriate matrices, high creep strength. These properties are very anisotropic and the composites can be weak and brittle in directions normal to that of the fibres. Where high two-dimensional properties are needed, cross-ply or interwoven fibres can be used. Short or long randomly oriented fibres provide lower efficiencies in strengthening (but are still more effective than particulates). These are most frequently available as SiC whiskers or as short random alumina (‘Saffil’) fibres or alumino-silicate matts. Long continuous fibres include drawn metallic wires, mono-filaments deposited by CVD or multifilaments made by pyrolysis of polymers. The properties of some typical fibres are compared in Table 10.1. The relative prices are given as a very approximate guide. Because most composites are engineered materials, the matrix and the reinforceant are not in thermodynamic equilibrium and so at a high enough temperature, reaction will occur between them which can degrade the properties of the fibre in particular and reduce strength and more especially fatigue resistance. As many composites are manufactured by infiltration of the liquid metal matrix into the pack of fibres, reaction may occur at this stage. Some typical examples of interaction are listed in Table 10.2. In order to obtain load transfer in service, it is essential to ensure that the reinforceant is fully wetted by the matrix during manufacture. In many cases, this requires that the fibre is coated with a thin interlayer which is compatible with both fibre and matrix. In many cases, this also has the advantage of preventing deleterious inter-diffusion between the two component materials. The data on most coatings are proprietary knowledge. However, it is well known that silicon carbide is used as an interlayer on boron and on carbon fibres to aid wetting by aluminium alloys. The routes for manufacturing composites are still being developed but the most successful and lowest cost so far is by mixing particulates in molten metal and casting to either foundry ingot or as billets for extrusion or rolling. This is applied commercially to aluminium alloy composites. Another practicable route is co-spraying in which SiC particles are injected into an atomized stream of aluminium alloy and both are collected on a substrate as a co-deposited billet which can then be processed conventionally. This is a development of the Osprey process and can be applied more widely to aluminium and other alloys. Other routes involve the infiltration of molten metal into fibre pre-forms of the required shape often contained within a mould to ensure the correct final shape. This can be done by squeeze casting or by infiltrating semi-solid alloys to minimize interaction between the fibre and metal. Fibres can also be drawn through a melt to coat them and then be consolidated by hot-pressing.

Table 10.1 PROPERTIES OF REINFORCING FIBRES AT ROOM TEMPERATURE

Fibre

Preparation route

Cont. mono-filament Cont. multi-filament Whisker (random, short) Multi-filament Random short fibres Cont. multi-filament Cont. multi-filament

Chemical vapour depos. Polymer fibre pyrolysis Polymer fibre pyrolysis Oxide/salt fibre pyrolysis Polymer fibre pyrolysis Polymer fibre pyrolysis

150 10 15 0.1 2.0 15 25 2 4 10 8

Density g cm 3 3.4 2.6 3.2 3.9 3.5 2.0 1.9

3 800 2 500 10 000 1 500 2 000 3 000 4 200

Elastic modulus GPa

Coefficient of thermal expansion K 1 ð 106

Price relative to glass fibre

450 200 700 380 300 600 300

4.5 4.5 4.5 7.0 7.0 0 0

500 100 150 100 25 1 000 100

Light metal-matrix composites

SiC SiC SiC ¾Al2 O3 ¾Al2 O3 C(high modulus) C(med. strength)

Form

Diameter µm

Fracture stress MPa

189

190

Smithells Light Metals Handbook

Table 10.2 TYPICAL INTERACTIONS IN SOME FIBRE-MATRIX SYSTEMS

System

Potential interaction

Al C

Formation of Al4 C3 at interface. Degradation of C fibre properties.

Al Al2 O3

No significant reaction at normal fabrication temperatures

Al oxide (Al2 O3 SiO3 B2 O3 )

B2 O3 reacts with Al to form borides.

Al B

Boride formation; interlayer of SiC needed.

Al/Li Al2 O3

Interfacial layer of LiAl5 O8 on liquid infiltration.

Al SiC

No significant reaction below melting point. Al4 C3 and Si can form in liquid Al.

Al steel

Formation of iron aluminides.

Mg(AZ91) C

No significant reaction at m.p. of alloy provided O and N avoided during infiltration.

Ti B

Formation of TiB2 . Formation of TiC, TiSi2 and Ti5 Si3 .

Ti SiC

Temperature of significant interaction ° C 550 ¾495

770 500 ¾650 m.p. 660 >700 500

750 700

Table 10.3 MECHANICAL PROPERTIES OF ALUMINIUM ALLOY COMPOSITES AT ROOM TEMPERATURE

Form

Heat treatment

% particulate

0.2% proof stress MPa

1.0 0.6 0.2 0.25

Extrusion

T6

4.4 0.7 0.8 0.75

Extrusion

T6

Nil 10% Al2 O3 15% Al2 O3 20% Al2 O3 13% SiC 20% SiC 30% SiC Nil 10% Al2 O3 15% Al2 O3 20% Al2 O3 10% SiC

276 297 317 359 317 440 570 414 483 476 483 457

310 338 359 379 356 585 795 483 517 503 503 508

20.0 7.6 5.4 2.1 4.9 4.0 2.0 13.0 3.3 2.3 0.9 1.8

69.9 81.4 87.6 98.6 89.5 120.0 140.0 73.1 84.1 91.7 101.4 91.2

Sheet Extrusion

T6 T6

8.2% SiC Nil 15% Al2 O3 20% Al2 O3

448 290 359 359

516 414 428 421

4.5 10.0 3.8 3.1

82.5 73.1 88.3 91.7

Base Alloy

Nominal composition

6061

Mg Si Cu Cr

2014A

Cu Mg Si Mn

Tensile stress MPa

Elongation %

Elastic modulus GPa

Fracture toughness MPa m 1/2 29.7 24.1 22 21.5 17.9

2.71 2.81 2.86 2.94

25.3 18.0 18.8

2.80 2.92 2.97 2.98

Cu Mn V

6.0 0.3 0.1

2618

Cu Mg Si Fe Ni

2.0 1.5 0.9 0.9 1.0

Sheet Extrusion Extrusion

T6 T6 T6

¾10% SiC Nil 13% SiC

396 320 333

468 400 450

3.3 6.0

93.6 75.0 89.0

Zn Mg Cu Cr Li Cu Mg Zr

5.6 2.2 1.5 0.2 2.5 1.3 0.95 0.1

Extrusion

T6

Nil 12% SiC

617 597

659 646

11.3 2.6

71.1 92.2

Extrusion (18 mm)

T6 T6

Nil 12% SiC

480 486

550 529

5.0 2.6

79.5 100.1

7075

8090

17.7

28.9

Light metal-matrix composites

2219

Density g cm 3

191

192

Smithells Light Metals Handbook

Table 10.4 MECHANICAL PROPERTIES OF ALUMINIUM ALLOY COMPOSITES AT ELEVATED TEMPERATURES

Base Alloy

Nominal composition

6061

Mg Si Cu Cr

1.0 0.6 0.2 0.25

2014A

Cu Mg Si Mn

4.4 0.7 0.8 0.75

Temperature °C

0.2% proof stress MPa

Tensile strength MPa

Heat treatment

% particulate

Extrusion

T6

15% 15% 15% 15% 15% 15% 15%

Al2 O3 Al2 O3 Al2 O3 Al2 O3 Al2 O3 Al2 O3 Al2 O3

22 93 150 204 260 316 371

317 290 269 241 172 110 62

359 331 303 262 179 117 69

Extrusion

T6

15% 15% 15% 15% 15% 15% 15%

Al2 O3 Al2 O3 Al2 O3 Al2 O3 Al2 O3 Al2 O3 Al2 O3

22 93 150 204 260 316 371

476(413) 455(393) 407(352) 317(283) 200(159) 103(62) 55(35)

503(483) 490(434) 434(379) 338(310) 214(172) 110(76) 55(41)

Form

Figures in parentheses are for basic alloy without particulate.

Table 10.5 MECHANICAL PROPERTIES OF MAGNESIUM ALLOY COMPOSITES AT ROOM TEMPERATURE

Base Alloy ZK60A

Nominal composition

Tensile strength MPa

Elongation %

Elastic modulus GPa

260

325

15.0

44

330 370 450 405

420 455 570 490

4.7 3.9 2.0 2.0

68 74 83 83

80

8.0

12% Al2 O3 (fibre)

200

3.5

24% Al2 O3 (fibre)

280

2.0

75

10.0

45

338

0.8

112

% reinforcement

Form

Mg 5.5Zn 0.5Zr

Extruded rod

Nil 15% 20% 15% 20%

Mg 12Li

Squeeze infiltration Squeeze infiltration Squeeze infiltration Extruded rod Extruded rod

0.2% proof stress MPa

SiC(partic.) SiC(partic.) SiC(whisker) B4 C(partic.)

Nil

Nil 20% SiC(whisker)

Table 10.6 MECHANICAL PROPERTIES OF TITANIUM ALLOY COMPOSITES

Base Alloy Ti-6Al-4V

Form Forging

% particulate

Temperature °C

10% TiC 10% TiC 10% TiC 10% TiC 10% B4 C

21 427 538 649 21

Figures in parentheses are for basic alloy without particulate.

0.2% proof stress MPa 800 476(393) 414(359) 369(221)

Tensile strength MPa 806 524(510) 455(441) 317(310) 1055(890)

Elongation % 1.13 1.70(11.6) 2.40(8.5) 2.90(4.2)

Elastic modulus GPa 106 120

205

Index

Alkaline cleaning solutions, 179 80 Alloy designation systems, 14 15 Aluminium: anodizing processes, 182 3 mechanical properties, 17, 30, 34 physical properties, 5, 6, 7 Aluminium alloy composites, mechanical properties, 191, 192 Aluminium alloys: creep data, 36 8 etching, 164 7 fatigue strength, 38 9 heat treatment, 173 6 mechanical properties, 30 34, 34 6 metallographic methods, 163 7 microconstituents, 164 miscellaneous, 76 8 physical properties, 6, 7 9 stabilizing treatment, 173 superplasticity properties, 186 7 temper designation systems, 15 16, 175 see also cast and wrought aluminium alloys Aluminium copper alloys, 74 6 Aluminium silicon alloys, 68 71 Aluminium silicon-copper alloys, 72 3 Annealing treatment, aluminium alloys, 173 Anodizing processes: aluminium, 182 3 magnesium alloys, 184 Binary diagrams, index, 93 4 Cast aluminium alloys: high strength, 78, 79 mechanical properties, 26 9, 33 4 Cleaning solutions, alkaline, 179 80 Delong, H.K. see Dow (plating) process Dow (plating) process, 185 Electroless plating process, magnesium, 185 Emulsion cleaning process, 179 Etching process: aluminium alloys, 164 7 electrolytic, 169 70

magnesium alloys, 168 71 titanium alloys, 172 Fibre-matrix systems, 188, 190 Finishing processes, 179 85 Gas plating process, magnesium, 185 Grain-colour etch, 167 8 Hardening treatment, aluminium alloys, 173 Heat treatment: aluminium alloys, 173 6 magnesium alloys, 173 6 Magnesium: electroless plating process, 185 gas plating process, 185 mechanical properties, 40, 44 physical properties, 5, 10 12 Magnesium alloy composites, mechanical properties, 192 Magnesium alloys: anodizing processes, 184 etching, 168 71 fatigue and impact strengths, 50 52 heat treatment of castings, 53, 176 8 heat treatment of wrought alloys, 177 8 high temperature, 46 9 long-term creep resistance, 47 8 mechanical properties, 40 41, 42 3, 44 5 metallographic methods, 168 71 microconstituents, 170 non-metallic inclusions, 170 71 physical properties, 10 12 plating processes, 185 safety requirements, 176 short-term creep resistance, 49 specifications, 3 stress relief treatments, 178 superplasticity properties, 187 zirconium-free, 80 85 Magnesium-zirconium alloys, 86 92 Metal-matrix composites, 188 Metallography, techniques available, 163

194

Index

Pickling solutions, 180 81 Plating processes, magnesium alloys, 185 Reinforcing fibres, properties, 189 Stabilising treatment, aluminium alloys, 173 Superplasticity properties, 186 7 Temper designation systems, 15 16, 175 Test bar properties, high strength cast aluminium alloys, 79 Titanium: creep properties, 62 fatigue properties, 63 4 Izod impact properties, 66 mechanical properties, 55 physical properties, 5, 13 specifications, 3 Titanium alloy composites, mechanical properties, 192 Titanium alloys: Charpy values, 66 creep properties, 62 3

etching, 172 fatigue properties, 64 5 Izod impact properties, 66 mechanical properties, 56 7 metallographic methods, 171 2 physical properties, 13 specifications, 3 4 superplasticity properties, 187 temperature effect on properties, 59 61 Titanium sheet, temperature effect on properties, 58 Vapour degreasing process, 179 Vapour plating see gas plating process Wrought aluminium alloys: compositional specifications, 14 designation system, 14 15 mechanical properties, 17 26, 30 32, 34 6 physical properties, 7 9 specifications, 2