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Wabash Alloys
The Aluminum Association and its member companies assume no responsibility or liability for the use of information contained
herein. The Aluminum Association and its member companies assume no responsibility for its use. No warranties, express or
implied, by The Aluminum Association or its member companies accompany this information.
1. Introduction 2
7. References 17
1
1.
Introduction
Automotive aluminum use has Aluminum — even unpainted and wealth of advantages to
been growing for years (from an uncoated — resists corrosion by automotive engineers developing
average of 87 pounds per car in water and road salt and, in non- new car designs of the future.
1976 to 248 pounds in 1999), cosmetically critical parts, its use
mainly to reduce weight and can avoid the substantial extra
improve fuel economy. Each costs of galvanizing, coating and
pound of aluminum used can painting required for steel.
reduce vehicle weight as much as Aluminum does not rust like steel
1.5 pounds. Automotive frames if the paint is scratched or
and bodies can make even further chipped. Nor is it weakened or
use of aluminum’s unique embrittled, as some plastics may
combination of strength, light be, by desert heat, northern cold,
weight, crash-energy absorption, or the ultraviolet radiation in
corrosion resistance, and thermal sunlight. For its new delivery
and electrical conductivity. vans, the U.S. Postal Service
specified aluminum bodies
As new car prices increase (they designed to last 24 years!
roughly quadrupled between 1978
and 1999), durability and corrosion Finally, when a car must be
resistance take on new importance. scrapped aluminum is readily
Buyers want vehicles that will recycled with a high residual
retain their appearance and keep a scrap value, providing both
high resale value. That is economic and environmental
something that aluminum can benefits.
provide, as automakers offer longer
warranties against component Aluminum, with its wide choice
failure and body rust-out. of alloys and tempers, offers a
2
2.
Aluminum in Automobiles
A Brief History
During the past 25 years, the use newcomer to the automobile; in Bouton. (Figure 1) Substantial
of aluminum in automobiles has fact, it has a long and successful use of aluminum in automobiles
increased steadily, both in history in automotive applications. was reported in 1900 in both
absolute quantity per car and as a Aluminum crankcases were used France and the United States, twin
percentage of vehicle weight. on the 1897 Clark (a three- cradles of the modern aluminum
However, aluminum is hardly a wheeler) and the 1898 De Dion industry. (Figure 2)
3
A number of aluminum parts
turned up on cars exhibited in the
second New York automobile
show, in 1901. Aluminum body
panels were replacing wood, the
traditional coach-body material, in
automobiles around the same
time. By 1903, the Gordon
Bennett Napier had an aluminum
cylinder block; the 1904
Lanchester’s rear axle housing
was made of aluminum. And,
automotive uses of aluminum
multiplied during the early 1900s,
showing up in gear housings, fan
cowls, oil pans, water pumps,
steering boxes, steering wheels,
radiators, dashboards and FIGURE 3 –– Henry Ford with the last and first of his Model T Fords.
other parts.
hood. (Figure 3) In 1913, W.O. famous British engineer. The
Before World War I, the auto Bentley pioneered the use of Pomeroy car weighed only about
industry was aluminum’s biggest aluminum pistons in racing cars. two-thirds as much as a standard
single market, absorbing up to automobile, and proved to be
half of the aluminum produced. What may have been the first extremely durable.
“AIV” (aluminum-intensive
The popular Ford Model T used vehicle) was designed and built In mass-production cars steel
aluminum in its transmission and in 1923 by L.H. Pomeroy, a became predominant, largely for
economic reasons. However, the
advantages of aluminum
continued to give it a prominent
role in transportation —
particularly in aircraft, railroad
cars, trucks and buses where
aluminum’s combination of
light weight, strength, and
corrosion-resistant durability were
highly valued.
4
standard production cars would be military aircraft; after the war, this pistons have been standard on U.S.-
rediscovered after World War II, expanded production capacity made made automobiles since 1955.
and particularly after the sudden aluminum available for new and Aluminum trim, virtually unknown
rise in gasoline prices that began renewed markets, including in the early 1950s, was in
in 1973. automobiles. widespread use by the end of that
decade; by the mid-60s, most U.S.
The U.S. aluminum industry The first U.S. fluid drive cars had aluminum grilles.
expanded rapidly during World War transmission, in 1948, had an
II to meet the nation’s need for aluminum housing. Aluminum Since then, automotive applications
have multiplied: aluminum
bumpers since the early 1970s,
aluminum intake manifolds since
1977; aluminum engine heads,
engine blocks, wheels, radiators,
driveshafts, and in recent years, a
significant number of auto body
closure panels. More than a
hundred types of auto parts are
made of aluminum and the list
keeps growing.
5
overheating and so reduces brake
3.
“fading” in severe use, an
important safety factor.
Since the mid-1970s, the in large production volume Charge Air Coolers — In addition
percentage of aluminum use in models of passenger cars, pickup to its good heat exchange and
automobiles has increased almost trucks, vans and sport utility corrosion resistance characteristics,
three-fold. Today, more than a vehicles. aluminum can be readily formed,
hundred different auto parts are cast or extruded into complex
made of engineered alloy Brackets — Aluminum’s hollow shapes, as required for this
aluminum and the list is still combination of strength, application.
growing. While lighter weight resilience, and durability makes it
and efficient function were the an excellent material for engine Complete Bodies — Aluminum
primary reasons for selecting mounting and accessory brackets. has been used successfully for
aluminum, extended life through It is widely used for power complete auto bodies,
better corrosion resistance steering brackets, pump-mounting demonstrating strength, light
provided an added benefit that is brackets, air conditioner mounting weight, durability, and excellent
highly important in achieving the brackets, steering column brackets crashworthiness. It is the
desired useful life of the vehicle. and similar applications. preferred body material for large
trucks, buses and other utility
A sampling of those wide-ranging Brake Cylinders and Pistons — vehicles and was selected for the
applications is depicted on Light weight, corrosion resistance, current U.S. Postal Service van,
these pages. economy, and reliability explain with a projected body life of 24
the choice of aluminum in this years.
Air Conditioners — Aluminum is important application.
an excellent conductor of heat and Driveshafts — This relatively new
is widely used in automotive air Brake Drums — Strength and application of aluminum was
conditioner condensers, durability under exposure to prompted by the metal’s
evaporators, liquid lines, and water, road salt and dirt are combination of high strength,
compressor housings. among the advantages of light weight, and corrosion
aluminum in this application. In resistance in a severely exposed
Body Panels — Aluminum has addition, the heat-transfer location. Aluminum’s light
been successfully used in hoods, capability of aluminum helps to weight not only improves general
deck lids and other exterior parts keep brake linings from vehicle performance and
6
economy, but also reduces become the material of choice for been used in the radiators of
driveline vibration and noise. these parts. selected cars. Now, with new
production techniques,
Engine Heads and Blocks — The Load Floors — This application automakers are equipping most
engine is one of the heaviest demonstrates the versatility of models with aluminum radiators
single units in an automobile and aluminum. Its combination of to take advantage of their light
offers one of the greatest light weight, strength, and weight, heat-transfer capacity, and
opportunities for weight saving corrosion resistance provides a corrosion resistance. Aluminum is
through the use of aluminum. part that can take contact with formable, machinable, and can be
Many car engines have aluminum various materials, weights and brazed, soldered or welded.
heads and some have aluminum impacts, without special
engine blocks as well. protection or maintenance. Seat Tracks, Shells and Headrests —
The mechanical properties of
Fuel Injection Systems — Luggage Racks and Air Deflectors — lightweight aluminum alloys and
Aluminum offers weight savings, In these parts, aluminum combines their ease of fabrication make
corrosion resistance, machinability esthetic appearance and styling them an advantageous choice for
and extrudability, as manufacturers with function and durability in these safety-sensitive parts.
continue to make fuel injection environmental exposure without
systems smaller and lighter. painting or coatings. Spare Tire Carrier Parts — These
Aluminum is used for pump parts are both functional and styled
housings, tubing and cylinder Oil Coolers — Auxiliary engine oil for appearance. Aluminum
parts. coolers and transmission oil provides both the necessary
coolers make use of aluminum for functional strength and durability
Heater Cores — Aluminum is an efficient heat exchange, durability, plus the desired styling.
appropriate material for heater and light weight.
core applications, since it is an Splash and Heat Shields —
excellent conductor of heat and is Pistons — These moving parts Aluminum’s resistance to water,
formable, and can be brazed, must last for the life of the vehicle road salt, hydrocarbons and dirt,
soldered or welded. in a demanding environment of and its ability to reflect and
high heat, stress, and potentially conduct away heat provides for
Intake Manifolds — Aluminum corrosive compounds. Aluminum durable shields to protect auto
allows the production of intake meets these demands, with the parts made of more vulnerable
manifolds in more advanced added advantage that its light materials.
shapes and with thinner walls than weight makes engines more
are practical in iron. In addition, responsive and efficient in Suspension Parts — Aluminum
aluminum engine parts of all converting fuel energy into has proven its value for suspension
kinds present an attractive “high- vehicle performance. Aluminum parts, where strength, light
tech” appearance under the hood has been the standard material for weight, and corrosion resistance
which effectively conveys a sense automobile pistons since the 1950s. are vital, in a popular “high-
of the vehicle’s quality to performance” car. It has been used
potential purchasers. As a result of Radiators — Throughout in such parts as the upper and
all these factors, aluminum has automobile history, aluminum has lower control arms, front and rear
7
steering knuckles, trailing arms, problems and provided an configurations, aluminum wheels
wheel spindle control rods, tie rod attractive and durable appearance now have become standard
sockets, drive line support, wheel for several generations of equipment on many makes and
shafts and axle cover beams. automobile designers and owners. models.
Anodized aluminum exterior trim
Transmission Housings — In a has been used for more than thirty Wheel Covers — These visually
part requiring strength, corrosion years, with excellent outdoor attractive parts must be light
resistance, ease of fabrication and durability, corrosion performance weight and formable, and must
economy, aluminum meets all of and a bright finish. retain their good appearance over
the requirements, while the expected life of the vehicle.
substantially reducing vehicle Wheels — Aluminum wheels Aluminum is an excellent material
weight. Transmission housings greatly reduce a car’s unsprung for this application. Its natural
were one of the earliest weight, improving ride and corrosion resistance ensures that
applications of aluminum in handling. They are not susceptible the esthetic styling given to the
automobiles, for those very same to rusting. Aluminum wheels were part will last.
reasons. introduced as optional equipment
for styling reasons. Produced as
Trim Moldings — Aluminum trim castings, forgings, fabricated sheet
moldings have solved corrosion and hybrid cast and wrought
8
Aluminum in Today’s Automobile
9
minimized by the appropriate
4.
choice of alloy, component design,
and protective measures.
10
Aluminum conducts heat about radiant heat striking its surface. Its
1.8 times better than copper, Reflectivity — Smooth high reflectivity gives aluminum a
pound for pound and more than aluminum is highly reflective of decorative appearance; it also
three times better than steel. This the electro-magnetic spectrum, makes aluminum a very effective
makes aluminum an excellent from radio waves through visible barrier against thermal radiation,
material for heat exchangers. light and on into the infrared and suitable for use in automotive heat
Aluminum heat exchangers are thermal range. Aluminum bounces shields.
widely used in automotive away about 80 percent of the
radiators, air conditioning systems visible light and 90 percent of the
and similar types of equipment.
11
coatings, aluminum is an excellent
5.
substrate for paints and other
coatings, often applied for esthetic
reasons as well as for additional
corrosion protection.
12
aluminum oxide while the part Chemical conversion coatings are For many applications, such as
being anodized is the anode in an excellent for: interior decorative parts, the
electrolytic cell. coating may be applied directly to
Improved adhesion of organic a clean surface. However, a
The basic process steps to coatings; suitable wash primer or zinc
accomplish anodizing are: Mild wear resistance; chromate primer usually improves
the performance of the finish coat.
Enhanced drawing or forming
1) Chemical cleaning of the (Note that chrome-free primers are
operations;
surface to remove soils and now recommended and are
contaminants; Decorative purposes when replacing the chromate primers).
colored or dyed;
2) Etching to remove the existing
oxide; Improved corrosion resistance For applications involving exterior
under supplementary organic exposure, surface treatments such
3) Electrolytically treating the
finishes or films of oil or as anodizing or chemical
part in chromic acid, sulfuric
wax; and conversion coating are required
acid or another appropriate
prior to the application of a primer
solution to build a thick new Adhesive bonding.
or finish coat. As noted earlier,
oxide coating; and
sulfuric acid or chromic acid
The sequence of operations for
4) Sealing the resultant coating in anodic coatings provide excellent
applying satisfactory conversion
hot water, a hot dichromate surfaces for organic coatings.
coatings includes:
solution, or some other Usually only thin anodic coatings
suitable agent. are required as a pre-paint
1) Removal of organic
treatment.
contaminants and oxide or
Such anodic treatments provide
corrosion products;
both corrosion resistant surfaces Conversion coatings are less
and surfaces amenable to 2) Conditioning the surface with expensive pretreatments than
additional protective finishes if acid or alkaline solutions; anodic coatings, provide a good
they are needed. 3) Conversion coating with oxide- base for paint, and improve the
type, phosphate or chromate life of the paint by retarding
5.2.2 - Chemical processes; and corrosion of the substrate.
Conversion Coatings Adequate coating of the entire
4) Rinsing followed by
supplemental coating if surface is very important for
Chemical conversion coatings are paint bonding. The conventional
required. The final step can be
adherent surface layers of low- automotive finishing system
omitted if no-rinse conversion
solubility metal oxide, phosphate, consisting of a) cleaning with a
coatings are applied.
or chromate compounds produced dilute alkali, b) followed by zinc
by the reaction of suitable reagents 5.2.3 – Painting phosphate as the pretreatment, and
with the metal surface. They differ c) the cathodic electrocoat which
from anodic coatings in that The only difference between provides excellent corrosion
conversion coatings are formed by painting aluminum and steel is the resistance.
a chemical oxidation-reduction surface preparation. Aluminum is
reaction at the aluminum surface, an excellent substrate for organic It is useful to note that many
whereas anodic coatings are coating if the surface has been vehicles now have aluminum
formed by an electrolytic reaction. properly cleaned and prepared. closure panels made from alloys
13
6016 and 6111 which have them from splash greatly reduce alloys are resistant to stress
exhibited excellent corrosion the risk of corrosion. corrosion cracking. However,
resistance and paint adhesion aluminum alloys containing more
performance in service. Filiform corrosion — Filiform than three percent of magnesium
corrosion can occur on painted (Mg) may become sensitized
5.3 - Anti-corrosion surfaces where a defect or scratch (susceptible) to stress corrosion
Enhancement in the coating occurs allows cracking if exposed for long
access. This type of corrosion periods at temperatures above
In automotive applications, manifests itself as thin filaments about 75°C (150°F). Therefore
appropriate designs and that grow under the coating from their use in exposed structural
precautions can protect aluminum scratch lines. The filaments are applications, where there is
against the most likely forms of fine tunnels of corrosion product continuous or intermittent
corrosive attack: galvanic, crevice, trailing the active cell. Using an exposure to engine heat or other
filiform, poultice and intergranular appropriate conversion coating high temperatures, should be
stress corrosion. and ensuring the consistency and avoided. If the advantages of the
quality of coatings best prevents 5xxx (Al-Mg) alloys are needed in
Galvanic corrosion — When filiform corrosion. Filiform such situations, the selection of
dissimilar metals are held in corrosion is really only of concern alloys such as 5454 and 5754 with
contact in the presence of for painted exterior panels, and lower Mg levels is recommended.
moisture, galvanic corrosion is the alloys now used for these It should be noted that paint-bake
possible. Aluminum is anodic applications have been developed cycle aging has no deleterious
(i.e., has a more negative solution to minimize their susceptibility to effect upon the corrosion
potential) to steel and many other this type of corrosion. resistance of 5xxx alloys. Heat
common metals, except zinc and treatable 2xxx and 6xxx alloys
magnesium, and so is vulnerable Poultice corrosion — Surface may show some minor
to galvanic corrosion because the accumulations (“poultices”) that susceptibility to intergranular
more anodic material corrodes retain moisture promote corrosion corrosion when partially aged (as
preferentially to the other. in much the same way as crevices. in the paint-bake condition) but
Protection is afforded by: a) The design of metal components this is of no concern after the
keeping bimetallic junctions dry and their surfaces should be such paint coating is applied.
and, b) separating dissimilar as to shed dirt and liquids;
metals with coatings or other permanent contact between metal
insulators. Anodizing also helps surfaces and absorptive materials
combat galvanic corrosion by should be avoided. If these
thickening the protective measures are insufficient or
aluminum oxide film. impossible, the metal may be
given a protective coating.
Crevice corrosion —
Unprotected crevices at mating Intergranular and stress
surfaces can collect and retain corrosion cracking — Stress
moisture that may form a pathway corrosion cracking (scc) is unlikely
for corrosive electric currents. with the combinations of alloys
Measures that eliminate or seal and products in most automotive
crevices, and designs that shield applications. Most 5xxx and 6xxx
14
dissimilar metals as well can
6.
increase protection. Sealants
should be applied to crevices for
best results.
15
6.3 - Controlling 6.5 - Design and coating as shown in previous
Entrapment Areas Orientation of Structural column. If possible, the steel
Members and plate should be galvanized or
Reinforcements painted and sealants should be
applied to joints. Steel rivets are
better than aluminum in such a
joint; coated steel or stainless
steel rivets are preferred.
The proper location of the
opening in lower doors can
minimize chances of plugging and
can enhance drainage. The design
above right tends to plug with
debris more easily than the design
at left. Sealants in tight joints Hat section and H- or I-beam Drain openings should be properly
further improve corrosion reinforcements are good designs located to enhance drainage and to
resistance. but the hat section should be open prevent entry of road contaminants.
at the bottom for easy drainage. Sealant in joint crevices enhances
corrosion resistance.
16
7.
References
Automotive Aluminum Extrusion, Mozelewski, EA. Summary of The Aluminum Design Manual,
AT5, The Aluminum Association, Corrosion Testing of Aluminum The Aluminum Association,
Washington, DC, 1998. ABS Alloys, Alcoa Laboratories Washington, DC, 2000.
Report No. XC-528,1980.
Aluminum, Vol. 1-Properties and Aluminum and Aluminum Alloys,
Physical Metallurgy Edited by Godard, H.P. The Corrosion of Editor, J. R. Davis, ASM
John E. Hatch. American Society Light Metals, John Wiley & International, 1993.
for Metals, 1984, Metals Park, Sons, Inc, 1967.
Ohio.
Handbook of Corrosion Data,
Schlitt, R.P and R.K. Eschebach. Bruce D. Craig, Editor, ASM
“Material Selection and International, 1989.
Corrosion protection for Bi-
Metallic Systems in Automotive
Environments.” S.A.E. Paper
831831, 1983.
Aluminum: Technology,
Applications and Environment, by
Dietrich Altenpohl, The
Aluminum Association,
Washington, DC, 1998.
17
Appendix A
Properties of Commonly Used
Aluminum Automotive Alloys
The Aluminum Association has stampings. The compositions, followed by a baked electro-
published several comprehensive typical mechanical properties, coating), the lower magnesium
manuals describing the typical physical properties, and alloys such as 5454-O and 5754-O
compositions, properties and comparative characteristics of the are considered the leading choices
applications for both the most commonly used sheet alloys for structural stampings. Alloy
aluminum sheet and extrusion are presented in Tables 1 5754-O is the material that has
alloys that have been developed or through 4. been almost exclusively used for
optimized for automotive adhesively bonded unibody
applications. Respectively, these The 5xxx (Al-Mg) alloys are non- sheet structures.
are entitled “Aluminum for heat treatable. Their formability
Automotive Body Sheet Panels” - generally increases with Heat treatable alloys 6009, 6111,
AT3, and “Automotive Aluminum increasing magnesium content. and 6022 have been developed
Extrusion Manual” - AT5. The However, 5xxx alloys with primarily for closure panels. They
reader is therefore strongly nominal magnesium contents are characterized by high ductility
advised to obtain copies of these greater than about three weight in the T4 temper in which they are
two documents as well as percent are subject to formed, and high strength in the
“Aluminum Standards and Data” “sensitization”, whereby, with a finished application because they
for detailed information. combination of cold work (as in strengthen during the paint-bake
However, to aid the reader, the stamping) and long-term elevated cycle. There are also certain
following basic information is temperature exposure (as would applications where they may be
provided to give guidance on the arise in proximity to the engine used advantageously in vehicle
composition and typical properties compartment), precipitation structures. However, it is
of the materials most commonly occurs at grain boundaries. inadvisable to use them where
used in vehicle structures. Consequently the material may they will be continuously exposed
become susceptible to to elevated temperatures during
A1 - Aluminum Sheet intergranular forms of corrosion, vehicle service since this will
Alloys including stress corrosion continue the age hardening
cracking. Although the high process and potentially lead to
Various non-heat treatable and heat magnesium alloy 5182-O has been loss of ductility which may
treatable aluminum alloys have successfully used in a production compromise the energy
been successfully utilized in application (with an appropriate absorption capability.
fabricating prototype unibody pretreatment and a protective
structures in sheet metal paint coating, e.g., chromating
18
TABLE 1 CHEMICAL COMPOSITION LIMITS
OF ALUMINUM BODY SHEET ALLOYS(1,2)
AA Si Fe Cu Mn Mg Cr Zn Ti Others Others Note
Alloy Each Total
Desig-
nation
5182 0.20 0.35 0.15 0.20-0.50 4.0-5.0 0.10 0.25 0.10 0.05 0.15 ––
5454 0.25 0.40 0.10 0.50 -1.0 2.4 -3.0 0.05-0.20 0.25 0.20 0.05 0.15 ––
5754 0.40 0.40 0.10 0.50 (3)
2.6-3.6 0.30 (3)
0.20 0.15 0.05 0.15 ––
6009 0.60 -1.0 0.50 0.15- 0.60 0.2- 0.8 0.4- 0.8 0.10 0.25 0.10 0.05 0.15 ––
6022 0.8 -1.5 0.05-- 0.20 0.01-- 0.11 0.02-- 0.10 0.45-- 0.7 0.10 0.25 0.15 0.05 0.15 ––
6111 0.6 -1.1 0.40 0.5-0.9 0.10 - 0.45 0.50 - 1.0 0.10 0.15 0.10 0.05 0.15 ––
Notes:
(1) Maximum limit unless a range is shown
(2) Shown as a percent by weight
(3) Mn + Cr = 0.10-0.6
Alloy & MPa (ksi) MPa (ksi) % MPa (ksi) GPa (ksi) 10 3
Temper
19
TABLE 3 TENTATIVE TYPICAL PHYSICAL PROPERTIES
OF ALUMINUM BODY SHEET ALLOYS
Alloy Average Melting Range Thermal Electrical Density
Coefficient of Approx.(1) Conductivity at Conductivity at
Thermal 25°C. 20°C (68°F),
Expansion MS/m (%)
x10-6 (Percent of Int’l
Annealed Copper
Standard)
5182-0 24.1 (13.4) 575-640 121 (840) 18 (31) 64 (110) 2.65 (0.096)
(1070-1185)
5454-0(2) 23.6 (13.1) 600-645 134 (930) 20 (34) 66 (113) 2.69 (0.097)
(1115-1195)
5754-0 23.8 (13.2) 590-645 132 (916) 19 (33) 66 (113) 2.67 (0.097)
(1095-1195)
6009-T4 23.4 (13.0) 605-650 167 (1160) 26 (44) 84 (144) 2.71 (0.098)
(1120-1205)
6111- T4 23.4 (13.0) 585-650 –– 23 (40) 76 (131) 2.71 (0.098)
(1090-1200)
6022-T4 23.4 (13.0) 580-650 –– –– –– 2.69 (0.097)
(1075-1205)
Notes:
(1) Eutectic melting may be eliminated by homogenization
(2) Typical per Aluminum Standards & Data, 1997
5182-O A A A C
5454-O A B A B
5754-O A A A C
6009-T4 A B B A
6111-T4 A B B A
6022-T4 A B B A
A=Best B=Better C=Good
Notes:
(1) Ratings are for original bare aluminum alloy sheet; ratings may vary dependent upon combination of forming and paint bake cycle.
20
A2 - Aluminum Extrusion The compositions, typical For automotive space frame
Alloys mechanical properties, typical structures, however, the 6xxx (Al-
physical properties, and Mg-Si) alloys are the preferred
Aluminum extrusions in both the comparative characteristics of the ones due to ease of extrusion,
6xxx and 7xxx alloy series are most commonly used sheet alloys good formability, excellent
routinely used today in a wide are presented in Tables 5 corrosion resistance and good
range of automotive applications. through 8. weldability. These alloys provide
6005 0.60-0.9 0.35 0.10 0.10 0.40-0.6 0.10 0.10 0.10 0.05 0.15 ––
6005A 0.50-0.9 0.35 0.30 0.50 0.40-0.7 0.30 0.20 0.10 0.05 0.15 (4)
6061 0.40-0.8 0.7 .015-0.40 0.15 0.8-1.2 0.04-0.35 0.25 0.15 0.05 0.15 ––
6063 0.20 -0.6 0.35 0.10 0.10 0.45-0.9 0.10 0.10 0.10 0.05 0.15 ––
7004 0.25 0.35 0.05 0.20-0.7 1.0-2.0 0.05 3.8-4.6 0.05 0.05 0.15 (5)
7005 0.35 0.40 0.10 0.20-0.7 1.0-1.8 0.06-0.20 4.0-5.0 0.01-0.06 0.05 0.15 (6)
7029 0.10 0.12 0.50-0.9 0.03 1.3-2.0 — 4.2-5.2 0.05 0.03 0.10 (7)
7116 0.15 0.30 0.50 -1.1 0.05 0.8-1.4 –– 4.2-5.2 0.05 0.05 0.15 (7,8)
7129 0.15 0.30 0.50-0.9 0.10 1.3-2.0 0.10 4.2-5.2 0.05 0.05 0.15 (7,8)
Notes:
(1) Maximum limit unless a range is shown
(2) Shown as a percent; remainder is aluminum.
(3) The sum of those “others” metallic elements: expressed to the second decimal place before determining sum.
(4) Mn + Cr = 0.12-0.50
(5) Zr = 0.10-0.20
(6) Zr = 0.08-0.20
(7) V = 0.05 max.
(8) Ga = 0.03 max.
21
good strength at low cost, are the 6xxx extrusions alloys when improves the ductility, toughness
readily formed in the T4 temper used for the crash energy and minimizes any tendency to
and yet can be aged to the T5 or management structural members crack on impact crushing while
T6 temper to give quite high in locations where these will be providing stable properties, even
strengths. Of the commonly subjected to elevated temperature with long exposure to above
produced alloys, 6063 has the during vehicle service. This can ambient temperatures.
lowest strength, followed by 6005, lead to changes in strength and, in
6005A and 6061. some instances, to a tendency to It should be noted that the
develop cracking upon impact chemical composition limits for
The most commonly used alloys collapse. However, this problem these alloys are relatively wide
in space frames for crash energy can be overcome by overaging the and individual suppliers have
management are 6063, 6005A and materials to the T7 temper versions of these alloys and
6061. As with the 6xxx sheet (e.g. 8 hr. at 210°C). This reduces tempers optimized for automotive
materials, consideration must be the strength level from the fully structural applications.
given to the thermal stability of age hardened condition (T6) but
Alloy & MPa (ksi) MPa (ksi) % MPa (ksi) GPa (ksi) 103
Temper
22
TABLE 7 TYPICAL PHYSICAL PROPERTIES
ALUMINUM EXTRUSION ALLOYS
Alloy Average Melting Range Thermal Electrical Density
Temper Coefficient of Approx.(1) Conductivity at Conductivity at
Thermal 25°C 20°C (68°F),
Expansion MS/m(%)
x10-6 (Percent of Int’l
Annealed Copper
Standard)
6005-T5(2) 23.4 (13.0) 605-655(1) 188 (1310) 28 (49) 93 (161) 2.70 (0.097)
(1125-1205)
(2)
6005A-T5 — — — — — 2.70 (0.098)
6061-T6 23.6 (13.1) 580-650 (1)
167 (1160) 25 (43) 82 (142) 2.70 (0.098)
(1080-1205)
6063-T5 23.4 (13.0) 615-655 209 (1450) 33 (55) 105 (181) 2.70 (0.097)
(1140-1210)
6063-T6 23.4 (13.0) 615-655 201 (1390) 32 (53) 102 (175) 2.70 (0.097)
(1140-1210)
7004-T5(2) 23.8 (13.2) — –– –– –– 2.77 (0.100)
7005-T53 (2)
23.8 (13.2) 605-645 — 22 (38) 72 (135) 2.77 (0.100)
(1125-1195)
7029-T5(2) 22.8 (12.6) — 163 (1130) 25 (42) 77 (133) 2.77 (0.100)
7116-T5 (2)
23.4 (13.0) — — 27 (46) 86 (148) 2.78 (0.101)
7129-T5 (2)
22.8 (12.6) — 163 (1130) 25 (42) 77 (133) 2.78 (0.100)
Notes:
(1) Eutectic melting may be eliminated by homogenization
(2) Tentative
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TABLE 8 COMPARATIVE CHARACTERISTICS OF ALUMINUM EXTRUSION ALLOYS
Alloy Resistance to Formability(2) Fusion Weldability(3)
General
Corrosion(1)
6005-T5(4) A B-C A
6005A-T5 (4)
B B-C A
6061-T6 B B-C A
6063-T5 A A-A A
6063-T6 A B-B A
7005-T53 (4)
C A-B A
7029-T5 (4)
C A-B (5)
7116-T5 (4)
C A-B (5)
7129-T5 (4)
C A-B (5)
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