SURFACE J451

REAF.
JAN89
VEHICLE
400 Commonwealth Drive, Warrendale, PA 15096-0001
INFORMATION Issued 1934-01
REPORT Reaffirmed 1989-01

Superceding J451b

ALUMINUM ALLOYS - FUNDAMENTALS

ForewordThis Document has not changed other than to put it into the new SAE Technical Standards Board
Format.

1. Scope

1.1 PurposeThis information report is intended to give general data on the properties of aluminum and
information on working, joining, forming, machining, finishing, and heat treating of aluminum.

2. References

2.1 Applicable PublicationThe following publication forms a part of the specification to the extent specified
herein. Unless otherwise indicated the lastest revision of SAE publications shall apply.

2.1.1 SAE PUBLICATIONAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.

SAE J454 AUG87General Data on Wrought Aluminum Alloys

3. PropertiesCommercially pure aluminum is a face-centered cubic metal with a specific gravity of about 2.71
(0.098 lb/in3), a thermal conductivity of about 0.52 cgs units (at 25C), and a melting point of approximately
1215 F. Its coefficient of thermal expansion (approximately 0.000013 per F) is about twice that of steel or
cast iron and about one-third greater than that of copper or brass. The electrical conductivity of pure
aluminum is about 62% of the International Annealed Copper Standard. In the form of cast test bars, the
commercially pure metal has a typical tensile strength of 14 000 psi and a typical elongation of 30% in 2 in,
while sheet in the annealed temper has a typical tensile strength of about 13 000 psi and a typical elongation
of about 45% in 2 in. The modulus of elasticity, for all practical purposes, is 10 000 000 psi. The commercially
pure metal and many of its alloys are highly resistant to atmospheric corrosion and to attack by many
chemicals, with the notable exception of strong alkalis. Because it is so high in the electrochemical series,
however, it is subject to galvanic attack if coupled with metals such as the copper alloys in the presence of an
electrolyte.

SAE Technical Standards Board Rules provide that: This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely
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SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.

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Copyright 1989 Society of Automotive Engineers, Inc.

All rights reserved. Printed in U.S.A.
 SAE J451 Reaffirmed JAN89

4. Alloying ElementsAdditions of alloying elements usually increase the specific gravity (silicon and
magnesium lower it), decrease the electrical and thermal conductivity and the melting point, increase the
strength, and have a rather slight effect on the coefficient of thermal expansion and the modulus of elasticity.
Some alloying elements, alone or in combination, produce alloys that respond to heat treatment. The addition
of alloying elements can increase or decrease corrosion resistance, depending on the alloying element, heat
treatment, and service environment. Aluminum alloys which are adversely affected by such additions are often
protected by metallurgical cladding with a sacrificial alloy. The alloying elements commonly used in this
country are copper, silicon, magnesium, manganese, and zinc.

5. Working And Heat TreatingAluminum and its commercial alloys, being rather ductile materials, can be hot
or cold worked into most of the common manufactured forms. The commercially pure metal and some of the
alloys are not heat treatable compositions, and attain their strengths either by virtue of the alloy content or
because of strain hardening resulting from cold work. The strength of many of the alloys, however, can be
further increased by suitable heat treatments.

The response of an aluminum alloy to heat treatment depends on the presence of one or more alloying
elements substantially more soluble in aluminum at temperatures of about 900 1000F than at room
temperature. By heating the material for a sufficient time at the proper solution treating temperature, the
alloying elements are substantially dissolved by the aluminum; and by quenching rapidly from the solution
treating temperature, the elements are retained in solid solution. Longer heating times are required for
castings than for wrought products, and for heavy as compared to light sections. Alloys which are susceptible
to intergranular corrosion should be quickly quenched after solution heat treatment to prevent reprecipitation
along grain boundaries.

Certain of the heat treatable alloys, notably the so-called duralumin (Cu, Mg, Si) type alloys, age harden
considerably at room temperature within a few days after quenching; the others, although they harden slowly at
room temperature, must be heated to about 300F for a few hours to attain their maximum strengths. With a
few exceptions, most alloys which age harden substantially at room temperature can be made to develop even
greater strength by a precipitation treatment at 300 500F. It is generally agreed that precipitation treatments
or age hardening result from lattice strains and the precipitation of alloying elements or compounds from the
supersaturated solid solution in the form of minute particles. Recent studies indicate that the strengthening of
heat treatable aluminum alloy by aging is due to both the uniform dispersion of a finely dispensed
submicroscopic precipitate and the distortion of the lattice structure by these particles before they reach a
visible size. It is believed that these particles, because of their critical size and location in the crystal structure,
impede or prevent slip and thus increase the strength of the metal. Because of this phenomenon, these aging
treatments are normally referred to as precipitation treatments. Room temperature aging, on the other hand, is
believed to be the result of zone hardening. In this connection, it is interesting to note that the better workability
of the as-quenched material can be retained in those alloys which age at room temperature by the simple
expedient of storing the quenched material at about 0F.

The effects of either cold work or heat treatment on the strength and workability of the materials can be
removed by annealing at temperatures of about 600 800F, depending on the alloy and temper. It must be
remembered, however, that the strength of a non-heat treatable alloy can be regained, after annealing, only by
the introduction of additional cold work.

6. JoiningAluminum and its alloys can be joined by fusion welding, resistance welding, soldering, brazing, and
adhesive bonding. The choice of process is dependent on alloy composition, material thickness, joint
configuration, and expected service environment. The inert gas shielded metal arc process (MIG) and inert
gas shielded tungsten arc process (TIG) are the most widely used fusion welding processes. Oxygas and
coated electrode welding techniques are sometimes used, but the fluxes required with these processes, if not
completely removed after welding, can promote corrosion. Brazing techniques now in common use include
torch, dip, and furnace brazing.

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All aluminum alloys can be joined by one or more of the available processes. Heat treated aluminum alloys
(like the ferrous base alloys) are subject to reductions in strength after welding. Heat treating after welding will
restore most of the prewelded mechanical properties. Work hardened aluminum alloys provide good as-
welded mechanical properties and are used for applications such as storage tanks, boats, ships, and railroad
cars.

7. FormingAluminum and its alloys can be formed hot or cold with considerable ease, although the bend radii
for cold forming and the allowance for spring-back must be increased as the strength of the material increases.
For severe forming, very deep drawing, or spinning, the annealed (0) temper usually is employed; while for the
less drastic operations, the intermediate, cold-worked temper (H12, H22, H32; or H14, H24, or H34), or the T3
or T4 type temper immediately after quenching usually is selected. The full hard (H18, H28, or H38) or the
heat treated and aged (T6) tempers are not usually used where more than slight forming is required. Heat
treatable alloys, however, can often be formed in the annealed or the as-quenched tempers and subsequently
heat treated to the desired temper.

8. MachiningThe aluminum alloys can generally be machined easily, if suitable practices and proper tools are
used. Substantial tonnages of aluminum alloy rods and bars are regularly used for making screw-machine
products.

9. Finishing And CoatingThe aluminum alloys can be given a wide variety of mechanical, chemical,
electrochemical, or paint finishes. The more common mechanical finishes include sand or grit blasting, scratch
brushing, and buffing, while the chemical finishes may be a simple dip coating or an etching treatment. The
possibility of generating an explosive mixture of finely powdered metal and air should be borne in mind in
connection with mechanical finishing operations. Paint coatings may be either a clear lacquer or a pigmented
coating and may be applied to secure either decoration or protection, or both. Paint adhesion is generally
enhanced by the application of chemical conversion coatings prior to painting. Electroplating, although not
extensively practiced in the past, is now gaining increased commercial use.

Anodic coatings can be produced to provide good protection against corrosion and are also good bases for
subsequent paint coatings. These coatings can be dyed, and they make possible a variety of colored surfaces
suitable for many decorative applications. Their hard, wear resistant surfaces are made use of in many
applications.

The appearance of automotive bright anodized trim parts produced from 5252 or the 5X57 type sheet or a
6463 extrusion is dependent upon the alloy, the temper, the finishing procedure, the aluminum producers'
controls of their fabrication procedures, and the metal handling and forming techniques used. Strength
requirements and formability considerations generally dictate alloy selections. Variations of temper within the
bright sheet trim alloys offer further opportunity to adjust mechanical and formability properties. However, the
relationship between alloy, temper, and appearance must be given careful consideration. Alloy 5457-0, widely
used, has excellent formability associated with the annealed temper. It offers a good and acceptable finish for
many decorative trim parts, but lacks the image clarity or brightness of the less workable strain hardened
tempers, such as the H25 and H28 tempers of all 5X57 type automotive trim alloys. Alloy 5657, when supplied
in a modified strain hardened temper to achieve a higher minimum elongation, may have formability and
finishing capabilities intermediate between the annealed and H25 tempers. Partially recrystallized structures,
which may be experienced when material is produced to significantly higher minimum elongation requirements
than those specified herein for the H25 temper, may give, under some conditions, an undesirable appearance
after forming and finishing. Adequate control of finishing procedures is required to provide the highly lustrous
and good image clarity possible using the 5X57 type decorative aluminum trim alloys. "Out-of-control" finishing
procedures used after forming can produce trim parts having an unfavorable appearance or corrosion
resistance. Improper handling and forming techniques can also contribute to an undesirable appearance
(scratches, gouges, strains, etc.) of the final automotive trim part.

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 SAE J451 Reaffirmed JAN89

To simplify presentation of information about the aluminum alloys, the materials have been grouped under the
general headings of casting alloys and wrought alloys. Generally speaking, a given composition is not used
commercially for both wrought and cast products, and the casting alloys usually contain a somewhat greater
total alloy content than the wrought alloys. When yield strength is specified, it is that stress at which the stress-
strain curve deviates 0.2% from the modulus line (normally referred to as 0.2% offset).

Additional information on aluminum alloys and commercially available forms can be found in SAE J454.

PREPARED BY THE SAE WROUGHT ALUMINUM COMMITTEE

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 SAE J451 Reaffirmed JAN89

RationaleNot applicable

Relationship of SAE Standard to ISO StandardNot applicable.

ApplicationThis information report is intended to give general data on the properties of aluminum and
information on working, joining, forming, machining, finishing, and heat treating of aluminum.

Reference Section

SAE J454 AUG87General Data on Wrought Aluminum Alloys

Developed by the SAE Wrought Aluminum Committee