01

NON-HEAT-TREATABLE ALLOYS

The non-heat-treatable alloys attain maximum strength beyond the annealed condition through cold work hardening. In the H tempers of sheet and plate, this is initially the result of cold rolling to final thickness, or may be the result of subsequent cold forming. They possess high corrosion resistance, good formability, pleasing appearance, and good weldability. They are widely used for manufactured products and general sheet and plate applications.

ALLOY 1100

Corrosion resistance is extremely high in rural, industrial and marine atmospheres. Neutral or fresh waters as well as sea waters and most food stuffs are compatible with this material as are gasoline, alcohol, ammonia and many neutral aqueous solutions of inorganic salts.

Finishing produces satisfactory results in terms of anodizing or chemical conversion. The material may be polished prior to anodizing for a high luster or etched prior to anodizing to produce a pleasing matte finish.

Welding, Brazing, and Soldering can be accomplished by all the processes used to join any aluminum alloy. '

Machining is generally more difficult than with any other aluminum alloy; however, machinability increases with an increase in hardness or temper. The material has a decided tendency to be gummy regardless of the machining process in question; consequently, all tools for cutting this material should possess a rather sharp cutting angle and a slicing action in their approach to the work.

Tensile Strength is about one-fifth that of mild steel.

Workability, because of its ductility, is unexcelled by any other commercial aluminum alloy, or most any other commercial metal. Spun or drawn parts which often require several successive operations are oftentimes produced from 1100 without resorting to an intermediate anneal.

Typical Thermal Treatment for annealing consists of bringing the metal up to 650 °F and then cooling in open air at room temperature. The time in the furnace need not be any longer than is necessary to bring all parts of the load up to temperature. The cooling rate is unimportant The resultant temper is 0.

End Uses for 1100 in the various tempers include such items as spun hollow ware, decorative parts of appliances and radio cabinets, heat exchanger fins, small motor covers, small ash trays and novelties, chemical equipment kitchen items such as measuring spoons, insulating panels, heat reflectors and general sheet metal work.

ALLOY 3003

Corrosion Resistance in rural atmospheres is excellent and in industrial and marine atmospheres the resistance to corrosive attack is high. Alloy 3003 possesses good resistance to most neutral or nearly fresh waters and sea water. Most food stuffs, organic acids, gasolines, oils and alcohols are compatible with this alloy as are some inorganic salt solutions.

Finishing produces excellent results when mechanical finishes are desired and the material will take chemical conversion coatings and organic coatings as well as any aluminum alloy. Anodizing will produce a good adherent coating with the possibility of slight discoloration (brownish cast) due to manganese. Since the anodic discoloration is a direct result of the alloying constituent it is impossible for the mill to completely eliminate this condition.

Welding may be done by all of the processes used to weld aluminum and brazing

may be accomplished with the torch, by using an automatic or manual controlled furnace system or by employing a salt bath system. Soldering of Alloy 3003 presents no problems.

Machining is hindered, to some extent, by the gummy characteristic of the alloy; however, like 1100, an increase in temper will be accompanied by a decrease in machining difficulty. All tools for machining this alloy should possess a rather sharp cutting angle. Machinery for such operations should be run at extremely high speeds with a light cut and fast feed or at moderate speeds with a relatively heavy cut and slow feeds. Generally the equipment available for machining this material will not run fast enough to produce the optimum machining conditions.

Strength, due to 1.2 manganese, is 20 higher than 1100. The increase in tensile strength, combined with excellent workability allows certain jobs to be done with 3003 which fail in fabrication using 1100 simply due to the latter's low strength.

Workability is excellent at either room or elevated temperatures. The hot working range extends from 500 to 950°F; however, most of the working of the metal is done at room temperature since cold working improves the mechanical properties while hot working leaves the metal at the annealed strength level. Like 1100, this alloy lends itself to spinning, drawing, impact extrusion and most other forms of metal working.

Thermal Operations (anneal cycle, 0 temper): Metal temperature 775°F. Time at temperature is unimportant The time in the furnace need not exceed that necessary to bring the entire load up to the annealing temperature. The cooling rate on this alloy is not critical.

Typical End Uses: Awnings, capacitor electrodes, fish boxes, food and chemical handling and storage equipment furniture (lawn chairs, carts, trays, etc.), gasoline and oil storage tanks, gas tanks for boats, heat exchangers, highway sign panels, insulation jacketing, kitchen equipment (refrigerator components, cooking pots, etc.), mobile home siding, name plates, outdoor display sign panels, piping, prefabricated portable shelters, pressure vessels, roofing, siding, ventilators, flashing, gutters and downspouts for farm and industrial buildings, spun parts, truck trailer roof sheeting, water and steam condensate storage tanks.

ALLOY 5005

Corrosion Resistance of 5005 is excellent It compares favorably with that of 3003 and in some environments, particularly marine, exceeds the resistance of 3003 due to its magnesium content.

Finishing produces superior results in that all standard finishes may be applied to this alloy and anodizing in particular produces a pleasing appearance. It exhibits much better anodizing characteristics than 3003. Further, the color match between anodized 5005 sheet and 6063 extrusions is good.

Welding may be done by any method used to weld other aluminum alloys. Brazing may be accomplished by any brazing method suitable to 1100 or 3003 but care should be taken to select the proper flux and filler since the melting point is somewhat below that of 3003. As with all aluminum joining techniques, regardless of alloy, cleanliness can determine the success or failure of the operation. Solderability of 5005 is good, but not as good as 1100 or 3003.

Machining creates the same problems and relies upon the same solutions as the machining of 3003. The strength is about equal to 3003.

Workability is generally comparable to 3003 except that caution should be exercised in attempting to utilize this alloy for severe draws without due consideration of the tooling requirements. As an example, a deep draw which might be accomplished in two draws with 3003 might well require three draws with 5005 since magnesium increases the work hardening rate.

Thermal Operations (anneal cycle, 0 temper): Metal temperature 650°F Time at temperature is unimportant The time in the furnace need not exceed that necessary to bring the entire load up to the annealing temperature. The cooling rate on the alloy is not critical.

Typical End Uses: Decorative and ornamental trim for appliances and architectural applications, insulation jacketing, kitchen utensils and equipment, mobile home siding, outdoor display sign frames and panels, patio covers, reflectors.

ALLOY 5052

Corrosion Resistance is excellent It is more resistant to attack from salt water than is Alloy 1100. It also resists attack by certain chemicals and most foodstuffs at room and elevated temperatures.

Finishing may be accomplished by all the standard finishes, both mechanical and chemical, which may be applied to any other aluminum alloy; however, anodizing for any length of time produces an anodic coating with a decidedly yellow cast attributable to the alloying constituents of the alloy.

Welding is accomplished by all the processes used to weld aluminum. The use of the inert-gas shielded arc method with either a tungsten or consumable electrode is the recommended procedure for welding this as well as other aluminum alloys. Brazing and soldering are difficult.

Machining, like 3003, will disclose a tendency toward gumminess. Good results, however, can be obtained through the use of tools having large top rake and side rake angles, smooth surfaces and keen edges. Light cutting may be done dry but most machining requires a copious supply of a good cutting lubricant Alloy 5052 was the highest strength non-heat-treatable aluminum alloy commercially available in the United States until the advent of alloys such as 5083 and 5086. It is a strong and tough alloy whose major constituents consist of 2.5 magnesium and 0.25 chromium. Further, this alloy has a higher endurance limit than most other wrought aluminum alloys making it an excellent selection for structures requiring high strength which will be subject to much vibration.

Workability is affected by the relatively high magnesium content of this alloy hence, the work hardening rate is fairly high. Nonetheless, this material is well suited for drawn shapes within its range of drawability. Maximum reduction between anneals is 50 or under, depending upon the product The material may also be spun but will require frequent anneals to achieve any major reduction. Coining and embossing of plate and sheet products in the "0" condition is also

practicable.

Thermal Operations (anneal cycle, 0 temper): Metal temperature 650°F. Time at temperature is unimportant. The time in the furnace need not exceed that necessary to bring the entire load up to the annealing temperature. The cooling rate on this alloy is not critical.

Typical End Uses: Aircraft fuel tanks, appliance components (trim, etc.), boats (hulls and components), bulk food processing equipment, chemical drums, decorative siding for buses, fertilizer tanks, fish boxes, heavy-duty cooking utensils, instrument and clock parts, prefabricated portable shelters, pressure vessels and storage tanks, tank trailer bodies, truck cabs, bumpers and fuel tanks, truck trailer components, sheet metal products.

ALLOY 5086

Corrosion Resistance is excellent with regard to general corrosion and pitting corrosion. In this connection the material behaves much like Alloy 5052. Further, 5086 demonstrates an excellent resistance to stress corrosion even at very high stress levels and in the presence of highly corrosive elements at temperatures 150°F and below. However, the material should not be subjected to both stress and corrosive elements at temperatures in excess of 150°F.

Finishing requires only the use of standard aluminum techniques. Weldments requiring painting would also require only standard treatment and preparation. Corrosion resistant anodized finishes may be applied to this alloy with no difficulty. Generally, 5086 is not recommended for decorative anodic finishes, since the coating would be quite cloudy or muddy in its appearance.

Weldability is excellent in the annealed condition, 5086 has a tensile strength 40 higher than 5052. The ductility of the welded material is high. This alloy is not considered brazeable or solderable.

Machinability is good. High speeds with fine to medium feeds and generous lubrication will produce generally good results. Alloy 5086 is a strong, tough alloy offering 40 more strength than 5052 in the annealed condition. Strength and ductility in the as-welded condition are better than possible with heat-treatable alloys.

Workability is less than that of 5052. It may be used for moderate draws and major bending and forming operations in the annealed state and moderate bending and forming applications in other tempers. The workability of 5086 may be extended by using an elevated temperature for forming and spinning operations. A hot working temperature of 400 °F is recommended for best results.

Typical End Uses: Aircraft fuel tanks, cryogenics (low temperature) applications, fish boxes, marine hulls and structural applications (ships and boats), materials handling equipment, oil field piping, ordnance applications, scaffolding, structurals (trusses, girders, towers, cranes, etc.), truck and tank trailer structural and welded assemblies (bulk haulers, dump bodies, fertilizer tanks, etc.), unfired pressure vessels.

ALLOY 5454

Corrosion Resistance is excellent to most corrosive influences, especially at prolonged or intermittent elevated temperatures in the 150-300 °F range, through which it also withstands stress corrosion better than most alloys in this group.

Finishing can be accomplished by any standard methods. Anodizing is sometimes used for maximum corrosion protection, but is generally not required because of naturally high corrosion resistance. Decorative anodic finishes are yellowish due to high manganese content.

Weldability is considered excellent for shielded arc and resistance methods, only fair for gas welding. Brazing and soldering are not usually recommended, but can be accomplished with proper procedures.

Machinability, though classed as poor because of gummy tendency, can be accomplished with high rake angles, clearances, speeds and feeds—with sharp and polished tools and ample lubricant, which also aids chip disposal.

Formability is especially good in 0 condition, drops slightly in H32, H34 and H112 tempers. The amount of cold work or height of working temperature is not as limited as with many high magnesium alloys because 5454 is so highly resistant to stress corrosion. Strength is among the highest for weldable alloys. It is selected in place of 5154 for greater resistance to stress corrosion cracking, especially in the 150-300°P range.

Thermal Operations (anneal cycle, 0 temper): Metal temperature 650°F. Time in the furnace need not be longer than necessary to bring all parts of load to annealing temperature. Rate of cooling is unimportant Typical End Uses include many applications where stress corrosion cracking might be a problem, especially at 150-300°F. This includes exhaust stacks, vessels handling chemicals at elevated temperatures, welded tank trailers transporting hot loads such as asphalt, etc. Welded marine construction also includes hull sides and bottoms, transoms, decking, framing, keels, chines, etc.