AGuidetoAluminumCastingAlloys-Rensselaerat.pdfVIP

A Guide to Aluminum Casting Alloys The specification of an aluminum alloy for a cast component is based upon the mechanical properties it can achieve. For the designer and purchaser, it is vital to understand that the properties obtained from one particular combination of casting alloy, foundry practice and thermal treatment may not be identical to those achieved with the same alloy in a different foundry or with a different thermal treating source. In all aluminum casting alloys, the percentages of alloying elements and impurities must be controlled carefully. If they are not, characteristics such as soundness, machinability, corrosion resistance and conductivity are affected adversely. For example, calcium and sodium, within a few thousandths of a percent, can have either a beneficial or detrimental effect upon both the soundness and machinability of alloys containing a high percentage of silicon (Si). Similarly, the use of phosphorus in controlled amounts has a beneficial effect on the hypereutectic aluminum-silicon alloys containing Si in excess of 12%. Special mechanical properties are obtained in many alloys through accurate control of chemistry, manufacturing and heat treating. Reliable ingot producers can supply foundries with ingot and heat treating specifications designed to obtain specific mechanical properties. However, while certain mechanical properties are improved, it is at the expense of others. For example, tensile and yield strengths can be increased, but this results in lower elongation and higher hardness. Higher elongation and lower hardness result in losses in tensile and yield strengths. Thermal Treatment Sand and permanent mold castings may be heat-treated to improve mechanical and physical properties. Die castings only can be stress relieved (and not solution heat-treated) because of their porous internal structure with gas inclusions, which may blister at high temperatures. Some alloys, such as 443.0 (w