Browse Topic: Aluminum alloys

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Effect of the Flow Forming Process on the Mechanical properties and Microstructure of GDC & LPDC cast aluminum alloy wheels.2026-26-02981/16/2026
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel production technique, offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only reduces overall wheel weight but also enhances strength and
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, SUNDARAM, RAGHUPATHI, Paua, Ketan
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-02961/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Jichkar, Pawan
Aluminum Alloy Castings, Permanent Mold, 5.0Si - 1.2Cu - 0.5Mg (355.0-T71), Solution Heat Treated and OveragedAMS4280K (Current)12/9/2025
This specification covers an aluminum alloy in the form of permanent mold castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Investment Castings, 7.0Si - 0.32Mg (356.0-T6), Solution and Precipitation Heat TreatedAMS4260H (Current)12/9/2025
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, 7.0Si - 0.55Mg - 0.12Ti (F357.0-T6), Solution and Precipitation Heat TreatedAMS4289A (Current)12/9/2025
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, Permanent Mold, 5.0Si - 1.2Cu - 0.50Mg (355.0-T6), Solution and Precipitation Heat TreatedAMS4281H (Current)12/9/2025
This specification covers an aluminum alloy in the form of permanent mold castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Castings 4.7Cu - 0.60Ag - 0.35Mn - 0.25Mg - 0.25Ti (B201.0-T7) Solution Heat Treated and Overaged AMS4242D (Current)12/9/2025
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Castings 4.5Cu - 0.70Ag - 0.30Mn - 0.25Mg - 0.25Ti (A201.0-T4) Solution Heat Treated and Naturally Aged AMS4223F (Current)12/9/2025
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, High Strength 4.5Cu - 0.70Ag - 0.30Mn - 0.25Mg - 0.25Ti (A201.0-T7) Solution Heat Treated and Overaged AMS4229H (Current)12/9/2025
This specification covers an aluminum alloy in the form of sand, permanent mold, and composite mold castings.
AMS D Nonferrous Alloys Committee
Hard Anodic Coating on Aluminum and Aluminum AlloysAMS2469J (Current)12/8/2025
This specification establishes the requirements for a hard anodic coating on aluminum and aluminum alloys.
AMS B Finishes Processes and Fluids Committee
Arc Damage Assessment of Arc Plume and Physical DamageAIR6982 (Current)11/26/2025
Describes the relative measurement of assessing the damage zone of arc plasma to determine appropriate separation/segregation requirements between a wire harness and nearby components
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Standardized composite training programAIR6671 (Current)11/26/2025
SAE CACRC has produced several standards, each representing the best-practice, recommended minimum training syllabus for the aforementioned target groups. The purpose of this document is to promote the use of these SAE standards, particularly for developing training programs for employee training, qualification in airlines and maintenance organizations, and as reference in regulatory guidance material. It summarizes, as a quick reference, the content of each training document and its relation to and interaction with other training documents. Thereby it allows users to select the appropriate training documents and syllabi to establish a comprehensive, sequential training program build-up customized to the specific needs of the aforementioned functions (see figure). This document does not intend to introduce new training content/syllabus.
AMS CACRC Commercial Aircraft Composite Repair Committee
Guidelines for Specifying LVDTs and RVDTsARP5554 (Current)11/26/2025
As per Committee/Henry E. Harschburger recommendations
A-6B1 Hydraulic Servo Actuation Committee
Aluminum Alloy, Sheet and Plate, 6.3Cu - 0.30Mn - 0.06Ti - 0.10V - 0.18Zr, Solution Heat Treated, Cold Worked and Naturally Aged (2219 -T31/-T351)AMS4601B (Current)11/25/2025
This specification covers an aluminum alloy in the form of sheet and plate.
AMS D Nonferrous Alloys Committee
Cast Aluminum Alloy Composite 4.6Cu - 3.4Ti - 1.4B - 0.75Ag - 0.27Mg (205.0/TiB2/3p-T7P) Sand Cast, Solution, and Precipitation Heat TreatedAMS4482B (Current)11/25/2025
This specification covers a dilute aluminum/TiB2 metal matrix composite in the form of sand castings.
AMS D Nonferrous Alloys Committee
Cast Aluminum Alloy Composite, 4.6Cu - 3.4Ti - 1.4B - 0.75Ag - 0.27Mg (205.0/TiB2/3p-T7P), Investment Cast, Solution and Precipitation Heat TreatedAMS4471C (Current)11/25/2025
This specification covers a dilute aluminum/TiB2 metal matrix composite in the form of investment castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Plate (7255-T7751), 8.0Zn - 2.3Cu - 2.0Mg - 0.12Zr, Solution Heat Treated, Stress Relieved, and OveragedAMS4463B (Current)11/25/2025
This specification covers an aluminum alloy in the form of plate 0.750 to 1.500 inch, incl ( 19.05 to 38.10 mm, incl) in thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Verifying large alternate product code for an AMS document - AMS112425-1AMS112425XXXXXXXXXXXXXXXXXXXXXX-1 (Current)11/24/2025
Verifying large alternate product code for an AMS document - AMS112425-1
A-10 Aircraft Oxygen Equipment Committee
Magnesium Alloy, Sheet and Plate, 3.0Al - 1.0Zn - 0.20Mn (AZ31B-H24), Cold Rolled, Partially AnnealedAMS4377K (Current)11/21/2025
This specification covers a magnesium alloy in the form of sheet and plate.
AMS D Nonferrous Alloys Committee
Core, Honeycomb, Aluminum Alloy, Corrosion Inhibited For Sandwich Construction, 5052, 350 (177)AMS4348F (Current)11/21/2025
This specification covers bonded honeycomb core made of aluminum alloy and supplied in the form of blocks, slices, or other configurations as ordered.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Plate (2397-T87), 2.8Cu - 1.4Li - 0.30Mn - 0.12Zr - 0.10Zn, Solution Heat Treated, Cold Worked, and Artificially AgedAMS4328C (Current)11/21/2025
This specification covers an aluminum alloy in the form of plate 3.000 to 6.000 inch (76.20 to 152.40 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extruded Wide Panel Profiles (7150-T77511), 6.4Zn - 2.4Mg - 2.2Cu - 0.12Zr, Solution Heat Treated, Stress-Relieved, Straightened and OveragedAMS4325B (Current)11/21/2025
AMS4325A prohibits unauthorized exceptions (3.7), revises condition (3.2), properties (3.4.5), quality (3.5.1), reports (4.4.1), and identification (5.1.1), and results from a Five-Year Review and update of this specification.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Die Castings 8.5Si - 3.5Cu (A380.0-F) As Cast AMS4291K (Current)11/21/2025
This specification covers an aluminum alloy in the form of die castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Die Castings 9.5Si - 0.50Mg (360.0-F) As Cast AMS4290N (Current)11/21/2025
This specification covers an aluminum alloy in the form of die castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, Centrifugal 7.0Si - 0.30Mg (356.0-T6) Solution and Precipitation Heat Treated AMS4285G (Current)11/21/2025
This specification covers an aluminum alloy in the form of centrifugal castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, Permanent Mold 7.0Si - 0.30Mg (356.0-T6) Solution and Precipitation Heat Treated AMS4284L (Current)11/21/2025
This specification covers an aluminum alloy in the form of permanent mold castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Alclad Sheet, 4.4Cu - 1.5Mg - 0.60Mn (Alclad 2024-O), Annealed, Fine GrainAMS4274C (Current)11/21/2025
This specification covers an aluminum alloy in the form of sheet 0.009 to 0.126 inch (0.23 to 3.20 mm) inclusive, in nominal thickness, alclad.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extrusions, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-O), AnnealedAMS4160K (Current)11/13/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Plate, 5.7Zn - 2.2Mg - 1.6Cu - 0.22Cr (7475-T7351), Solution Heat Treated, Stress Relieved by Stretching, and Precipitation Heat TreatedAMS4202F (Current)11/13/2025
This specification covers an aluminum alloy in the form of plate 0.250 to 4.000 inch (6.35 to 101.60 mm) inclusive, in thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extrusions 4.5Cu - 0.85Si - 0.80Mn - 0.50Mg (2014-T6) Solution and Precipitation Heat TreatedAMS4153N (Current)11/13/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 32 square inches (206 cm2) in area (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate 4.4Cu - 1.5Mg - 0.60Mn (2024-O) Annealed; or when specified, “As Fabricated” (2024-F)AMS4035N (Current)11/13/2025
This specification covers an aluminum alloy in the form of sheet and plate 0.010 to 1.750 inch (0.25 to 44.45 mm) in thickness, supplied in the annealed (O temper) condition (see 8.4). When specified, product shall be supplied in the “as fabricated” (F) temper.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Castings, 5.0Si - 1.2Cu - 0.50Mg (C355.0-T6), Solution and Precipitation Heat TreatedAMS4215K (Current)11/13/2025
This specification covers an aluminum alloy in the form of sand, permanent mold, composite mold, and investment castings.
AMS D Nonferrous Alloys Committee
Electron-Beam Welding For Fatigue Critical ApplicationsAMS2680D (Current)9/30/2025
This specification defines the procedures and requirements for joining metals and alloys using the electron beam welding process.
AMS B Finishes Processes and Fluids Committee
Aluminum Alloy, Plate (7085-T7651) 7.5Zn - 1.6Cu - 1.5Mg - 0.12Zr Solution Heat Treated, Stress-Relieved, and OveragedAMS4329C (Current)9/30/2025
This specification covers an aluminum alloy in the form of plate 4.001 to 7.000 inch, incl. (101.62 to 177.80 mm, incl.) in thickness (see 8.4).
AMS D Nonferrous Alloys Committee
Aluminum Alloy Plate (2624-T351) 4.1Cu - 1.4Mg - 0.6Mn Solution Heat Treated, Cold Worked and Naturally AgedAMS4464B (Current)9/30/2025
This specification covers an aluminum alloy in the form of plate 0.500 to 1.500 inch, incl (12.70 to 38.10 mm, incl) in thickness (see 8.4).
AMS D Nonferrous Alloys Committee
Hard Anodic Coating on Aluminum and Aluminum AlloysAMS2469K (Historical)4/9/2024
This specification establishes the requirements for a hard anodic coating on aluminum and aluminum alloys.
AMS B Finishes Processes and Fluids Committee
Defect based fatigue life predictions for Aluminum Castings using Simulations2024-26-02891/16/2024
Aluminum casting parts generally have inherent internal defects such as porosity which lowers the fatigue strength of such castings. Accounting for such a fatigue strength reduction for Aluminum casted parts is the primary purpose of this paper. Authors have used Murakami et al [1] approach to calculate a ‘porosity correction factor’ for fatigue. The actual material S-N curve is modified using fatigue factors to account for the fatigue strength reduction due to presence of porosity. This approach was then validated on one of the fatigue failure cases on Aluminum casted housing. There was a close match between the test data and proposed approach for fatigue prediction. With this approach, engineers will be able to do fatigue predictions in presence of material defects like porosity with simple porosity correction factor, rather than using complex modeling of porosity in FEA or using detailed fracture mechanics methods. Engineers can also be able to provide acceptable levels of porosity
Kumar, Rohit, Gawture, Majnoo M
INVESTIGATION OF GASKET SEALING BEHAVIOUR OF AN ALL-ALUMINIUM HIGH PERFORMANCE, NEW GENERATION PASSENGER CAR ENGINE UNDER EXTREME ENGINE OPERATING CONDITIONS2024-26-00331/16/2024
The increasing demand for higher specific power, fuel economy, Operating Costs as well as meeting global emission norms have become the driving factors of today’s product development in the automotive market today. Substitution of high-density materials and more precise adjustment of material parameters help in significant weight decrease, but it is accompanied by undesirable cost increase and manufacturing complexity. This becomes a challenge for every automotive engineer to balance the above parameters to make a highly competitive design. This work is a part of the Design and Development of 2.2 L, 4 Cylinder TCIC Diesel Engine for a complete new monocoque vehicle platform, focused on automotive passenger car application. This paper explains the selection of a suitable cylinder head gasket technology for a lightweight engine that acts as a sealing interface between the cylinder block and cylinder head. The decision to select an aluminum alloy for both cylinder block and head still
DHADSE, ASHISH, Dharan R, Bharani, Vellandi, Vikraman, Sasikumar, M
Computational Fluid Dynamics Simulation for Additive Friction Stir Deposition of Aluminum AlloyF-0079-2023-181055/16/2023
ABSTRACT
Li, Xuxiao, Rajanna, Manoj, Lua, Jim, Timmons, Alan, Murray, Gabriel, Phan, Nam, Eberheim, Richard
test 03/01auto testauto testauto testauto testauto testauto testauto testauto testauto testauto testauto testSAE-PP-078071/3/2023
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Mutagaana, Festo
abc test 30/12auto testauto testauto testauto testauto testauto testauto testauto testauto testauto testauto testauto testauto testSAE-PP-0780612/30/2022
Mutagaana, F., "QE Testing 11/2-10 jms edit," SAE MobilityRxiv™ Preprint, submitted November 2, 2022, https://doi.org/10.47953/SAE-PP-07790.
Mutagaana, Festo
FE Modelling and Experimental evaluation for the surface integrity of thin walled aluminum alloy2022-26-12025/26/2022
The present study discusses the effect of installation torque on the surface and subsurface deformations for thin-walled 7075 aluminum alloy. A FE model was constructed to predict the effect of torque-induced stresses on thin-walled geometry followed by experimentation. Detailed surface analysis was performed on 7075 aluminum in terms of superficial discontinuities, residual stresses, and grain deformations. The localized strain hardening resulting from increased dislocation density and its effect on surface microhardness was further studied using EBSD and micro indentation. The predicted surface level plastic strain of 25% was further validated with grain deformations measured using optical and scanning electron microscopy.
Patil, Sandip Prakash, Yarolkar, Makrand
New Material for Battery Enclosures of Electric Vehicles2022-01-02673/29/2022
In recent years, aluminum alloys have become the dominant material for battery enclosures used in battery electric vehicles (“BEV”) due to their low density. Aluminum battery enclosures, or other platform parts, typically provide weight savings of ~40% compared to equivalent commercially-used steels. The best-suited materials for battery enclosures are 6000-series and 7000-series aluminum alloys. Despite its light weight and recyclability benefits, the aluminum alloys have a crucial disadvantage if the heat generated by the battery cells raises the temperature of battery enclosures above 600°F/315°C. At the exposure of more than 300 sec at 600°F/315°C or higher, the yield strength, especially for parts that are in direct contact with the battery cells drastically drops by more than 70%, and in the critical situation of fire (~2200°F/1205°C), the batteries enclosures fail within ~5 sec, creating a paramount safety concern for BEV passengers. New high strength steel for cold stamping
Vartanov, Gregory
Local Thermomechanical Processing for Improving Formability of High Strength Aluminum Sheets2022-01-02783/29/2022
Limited room temperature formability hinders the wide-spread use of high strength aluminum alloys in structural body-in-white parts. Stamping or extrusion at warm temperatures or from softer tempers are the current solutions. In this work, our approach is to start with age- and work-hardened sheets from 7xxx, 6xxx, and 5xxx family of alloys and improve their formability using local thermomechanical processing only in the regions demanding highest ductility in the forming processes. The processes used were friction stir processing (FSP) and roller bending-unbending. In both the methods sheets were locally deformed and heated simultaneously without any change in the final sheet geometry or chemistry. Initial results indicated significant deformation in the processed zones with minimal sheet distortion. FSP also resulted in dynamically recrystallized, fine grained (d <5 µm) microstructures in the processed regions with textures significantly different from the base material. This resulted
Nasim, Wahaz, Das, Hrishikesh, Kulkarni, Shank, Rohatgi, Aashish, HERLING, DARRELL, Grant, Glenn, Upadhyay, Piyush, Efe, Mert
Improving Keyhole Stability During Laser Welding of AA5xxx Alloys2022-01-02853/29/2022
Laser welding of the magnesium-bearing AA5xxx aluminum alloys is often beset by keyhole instability, especially in the lap through joint configuration. This phenomenon is characterized by periodic collapse of the keyhole leaving large voids in the weld zone. In addition, the top surface can exhibit undercut and roughness. In full penetration welds, keyhole instability can also produce a spikey root and severe top surface concavity. These discontinuities could prevent a weld from achieving engineering specification compliance, pose a craftsmanship concern, or reduce the strength and fatigue performance of the weld. In the case of a full penetration weld, the spikey root could compromise part fit-up and corrosion protection, or damage adjacent sheet metal, wiring, interior components, or trim. The objective of the present investigation was to evaluate the effect of travel speed on keyhole stability during laser welding of AA5xxx alloys without and with filler wire in lap through joint
Clarke, Jo Ann M., Hetrick, Elizabeth T.
Analysis of Gasoline Engine Piston for Carbon Fiber Material2022-01-04063/29/2022
In the present study, an automotive gasoline engine piston was designed and its various structural and thermal properties were analyzed for three different materials, namely, Gray Cast Iron, Aluminum Alloy, and Epoxy Carbon Woven (230 GPa) Prepreg. The design was done on SolidWorks 2019 and the analysis was carried out on ANSYS v18.1. The lightweight of the Epoxy Carbon Woven (230 GPa) Prepreg piston as compared to the other two pistons suggests that the inertial forces are reduced for the carbon fiber material. It is also observed that the structural strength of the Epoxy Carbon Woven (230 GPa) Prepreg material piston is more than that of Gray Cast Iron, and Aluminum Alloy piston. The temperature variation for the Epoxy Carbon Woven (230 GPa) Prepreg piston is less than that of the Gray Cast Iron and Aluminum Alloy piston, thus giving it a better thermal conductivity. The heat flux for the Gray Cast Iron and Aluminum Alloy pistons is greater than that of Epoxy Carbon Woven (230 GPa
Jain, Devanshu, Paul, Shourya, Brella, Rohan, Kumar, Naveen
Development of an electric vehicle battery module laser welding process using SYSWELD and validation by test data2022-01-03763/29/2022
With lightweight design in modern electric vehicles to achieve high energy efficiency, high strength and thin materials are widely adopted. For battery modules, 5000 and 6000 aluminum are typically utilized as a structural material with a thickness range between 1 to 5 mm. Laser welding is one of the most optimum welding tools for joining such a thin material due to its unique advantages, e.g., high welding speed, high accuracy, high energy yet the smallest heat affect zone, etc. This paper aims to develop an FE modeling procedure using SYSWELD to simulate the laser welding process used in electric vehicle battery module manufacturing. A sequentially-coupled thermo-mechanical analysis procedure is developed based on the welding processes for 6063 T6 aluminum alloys and the dissimilar joint between 6063 T6 and 5083 aluminum alloys. Different heat source models for laser welding are studies and compared. The effectiveness of the developed modeling procedure is confirmed by a large number
Song, Shaopin, JIANG, Weiran, Ding, Peiran
Aerospace Fluid System Standards, Metric, National and InternationalAIR2000F (Current)3/25/2022
The purpose of this aerospace information report is to provide a listing of national and international metric standards for use in aerospace fluid systems with their equivalent SAE inch, International ISO, and European AECMA standards.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Aerospace Fluid System Standards, Metric, National and InternationalAIR2000F-TEST-REC (Historical)3/25/2022
The purpose of this aerospace information report is to provide a listing of national and international metric standards for use in aerospace fluid systems with their equivalent SAE inch, International ISO, and European AECMA standards.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Silver surface treatment applicable to bolts for motorcycles2022-32-00411/9/2022
In motorcycles, the exposed mechanical parts play important roles in the styling design. The bolts that fasten these parts a good appearance in addition to the fastening function. Since many parts of a motorcycle are designed so as to appeal the mechanical and metallic beauty, needs are higher for silver-color bolts. Motorcycle bolts are exposed to the external environment, so they are required to have also cosmetic durability. Though there is a surface treatment having a higher cosmetic durability such as the chromium plating, due to its metallic gloss like a mirror, chrome-plated bolts are applicable only to specific models and parts. In this study, we developed a surface treatment that enhance the appearance and cosmetic durability required of bolts for motorcycles. The layer of developed surface treatment is dip coating with thin film polyorganosiloxane material on zinc plating. Clarified a zone where both the appearance and the cosmetic durability are attainable through the
Hirayama, Hiroshi, Inoue, Manabu, Koike, Takeshi
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