CHARACTERISTICS
A relatively light metal compared to steel, nickel, brass, and copper with a specific gravity of 2.7. Aluminum is
easily machinable and can have a wide variety of surface finishes.
At high temperatures (200-250°C) aluminum alloys tend to lose some of their strength. However, at subzero
temperatures strength increases while retaining their ductility, making aluminum an extremely useful low-
temperature alloy, high flying commercial aircraft commonly fly at -50°C so they profit from this property.
It also has good electrical (ground for aircraft antenna) and thermal conductivities and is highly reflective to
heat and light. Aluminum connectors have a tendency to become loose after repeated usage and this can lead to
arcing and fire, which requires extra precaution and special design when using aluminum wiring in buildings.
Aluminum alloys also have a good strong resistance to corrosion which is a result of an oxide skin that forms as
a result of reactions with the atmosphere. These reactions occur very quickly, usually within minutes. This
corrosive skin protects aluminum from most chemicals, weathering conditions, and even many acids, however
alkaline substances are known to penetrate the protective skin and corrode the metal.
It is a very versatile metal and can be cast in any form. It can be rolled, stamped, drawn, spun, roll-formed,
hammered and forged. The metal can be extruded into a variety of shapes and can be turned, milled, and bored
in the machining process. Aluminum can riveted, welded, brazed, or resin bonded (aluminum/composite
aircraft are a good example). For most applications, aluminum needs no protective coating as it can be finished
to look good, however it is often anodized to improve color and strength.
PROCESSING
The secret to aluminum’s strength comes down to chemistry. Pure aluminum is mixed with other elements to
create high-strength alloys. Common additives used to increase the strength and formability of aluminum include
silicon, magnesium and copper. Aluminum-zinc alloys are some of the strongest alloys available today and
are commonly used by the automotive and aerospace industries. Aluminum can be further strengthened through
processing – hot rolling or cold rolling. Some alloys are made stronger by heat-treating followed by rapid
cooling. This process freezes the atoms in place strengthening the final metal. Alternatively, some aluminum is
“cold worked” -- usually by rolling, stretching forging or drawing -- to make it stronger. This process inhibits the
movement of atoms relative to each other, strengthening the finished product. The strongest aluminum alloys –
7000-series alloys – can reach strengths in excess of 72,000 pounds per square inch. A 1.2-inch aluminum wire
made from this alloy could suspend a fully-loaded tractor-trailer in the air.
Casting, or pouring molten aluminum into a mold, is used for high-volume parts requiring minimal machining,
such as automotive parts. Sheet rolling is used to make long flat pieces of aluminum often used in transportation
applications such as cars, planes and trains and also in consumer packaging for cans and foil. When strength and
precision are needed, aluminum can be forged using compressions and dies to produce parts such as racecar
wheels. Extrusion is used to form longer, thinner pieces of aluminum called rod, bar or wire, often used in the
building industry.
GENERAL APPLICATIONS
The Wright brothers
In 1903, the Wright brothers used aluminum to make the engine crankcase for their first wood-frame biplane.
For defense in WWII
In 1942, WOR-NYC broadcast the radio show “Aluminum for Defense” to encourage Americans to contribute
scrap aluminum to the war effort.
Apollo Command Module
The Apollo Command Model was made of an aluminum honeycomb-sandwich bonded between sheets of
aluminum alloy.
The Orion spacecraft
Lockheed Martin has chosen an aluminum-lithium alloy for the primary structures of NASA’s new Orion
spacecraft.
Aircraft : The airframe of a typical modern commercial transport aircraft is 80 percent aluminum by
weight. Aluminum alloys are the overwhelming choice for the fuselage, wing, and supporting
structures of commercial airliners and military cargo/transport aircraft. Structural components of
current United States Navy aircraft are made of fabricated wrought aluminum (forged, machined and
assembled parts). Attention is now focused toward aluminum casting technology, which offers lower
manufacturing costs, the ability to form complex shapes and the flexibility to incorporate innovative
design concepts.
Space flight: Ever since the launch of Sputnik a half-century ago, aluminum has been the material
of choice for space structures of all types. Chosen for its light weight and its ability to withstand the
stresses that occur during launch and operation in space, aluminum has been used on Apollo
spacecraft, the Skylab, the space shuttles and the International Space Station. Aluminum alloys
consistently exceed other metals in such areas as mechanical stability, dampening, thermal
management and reduced weight.
Aluminium was used as the primary propellant for the space shuttle’s solid rocket booster motor because it
has a high volumetric energy density and is difficult to ignite accidentally.
ALUMINUM ALLOY DESIGNATIONS
The aluminum industry uses a four-digit index system for the designation of its wrought aluminum alloys.
As outlined below, the first digit indicates the alloy group according to the major alloying elements.
1xxx Series- In this group. minimum aluminum content is 99%. and there is no major alloying element.
The second digit indicates modifications in impurity limits. If the second digit is zero, there is no special
control on individual impurities. Digits 1 through 9, which are assigned consecutively as needed, indicate special
control of one or more individual impurities.
The last two digits indicate specific minimum aluminum content. Although the absolute minimum aluminum
content in this group is 99% the minimum for certain grades is higher than 99%, and the last two digits represent
the hundredths of a per cent over 99.
Thus, 1030 would indicate 99.30% minimum aluminum. without special control on individual impurities. The
designations 1130, 1230, 1330, etc.. indicate the same purity with special control on one or more impurities.
Likewise. 1100 indicates minimum aluminum content of 99.00% with individual impurity control.
2xxx through 9xxx Series
The major alloying elements are indicated by the first digit, as follows:
2xxx Copper
3xxx Manganese
4xxx Silicon
5xxx Magnesium
6xxx Magnesium and silicon
7xxx Zinc
8xxx Other element
9xxx Unused series
The second digit indicates alloy modification. If the second digit is zero. it indicates the original alloy: digits 1
through 9, which are assigned consecutively, indicate alloy modifications. The last two digits have no special
significance, serving only to identify the different alloys in the group.
Experimental alloys are designated according to the four digit system, but they are prefixed by the letter X.
Properties and examples :
2024-T3
This is the most common of the the high-strength aluminum alloys. It is aircraft quality. 2024-T3 aluminum sheet
is thought of as the aircraft alloy because of its strength. It has excellent fatigue resistance. Welding is generally
not recommended. Typical uses for 2024-T3 Alclad aluminum sheet are aircraft skins, cowls, aircraft structures,
and also for repair and restoration because of its shiny finish (2024-T3 Alclad).
Ultimate strength is 62000 PSI with a shearing strength of 40000 PSI.
6061-T6
This alloy has a very good corrosion resistance and finishing ability, welding goes good too. The strength level of
6061-T6 aluminum sheet is about that of mild steel. 6061-T6 aluminum sheet can be fabricated by most of the
commonly used techniques. Typical uses are aircraft landing mats, truck bodies and frames, structural components
and more.
Ultimate strength is 45000 PSI with a shearing strength of 30000 PSI.
5052-H32
This one has the highest strength in the NON-heatable alloys. It is not structural. 5052 aluminum sheet has higher
fatigue strength than most alloys. 5052 aluminum sheet has excellent corrosion resistance, particularly in marine
applications and has excellent workability. 5052 aluminum sheet is commonly used to make fuel tanks.
3003-H14
Most widely used of aluminum alloys, pure aluminum with manganese added for strength, approx 20% stronger
than the 100 series. 3003-H14 aluminum sheet has great workability and may be deep drawn, spun, welded or
brazed. 3003 aluminum sheet is NON-heat treatable. This aluminum sheet is widely used for cowls and baffle
plating.
Ultimate strength is 21000 PSI with a shearing strength of 14000 PSI.
7075
Aircraft manufacturers use high-strength alloys (principally alloy 7075) to strengthen aluminum aircraft structures.
Aluminum alloy 7075 has Copper (1.6%), Magnesium (2.5%) and zinc (5.6%) added for ultimate strength, but the
copper content makes it very difficult to weld. On the other hand it anodizes really beautifully. 7075 has the best
machinability and it will result in a very nice finish.
Ultimate strength is 33000 PSI (-0) and 82000 PSI (-T6) with a shearing strength of 22000 PSI (-0) and 49000 PSI
(-T6).
