WORLDWIDE ENGINEERING STANDARDS

Material Specification Metals

GMW15657

Aluminum Forgings
3.1.3 Any chemical composition changes to the GMW alloy grades shall be shown on the engineering drawing. 3.2 Mechanical Requirements. 3.2.1 Tensile test specimens shall be excised from a part location specified on the engineering drawing. 3.2.2 The test specimen axis shall be oriented as parallel to major wrought direction of maximum metal flow. 3.2.3 Required tensile properties determined from heat treated forged parts are given in Table 2. 3.2.4 The engineering drawing may specify property requirements of alternate specimens that are not parallel to maximum metal flow. 3.2.5 The tension tests shall be made in accordance with test methods ISO 6892 and alternately ASTM B557. 3.2.6 Hardness testing shall be done in accordance with ISO 6506 and alternately ASTM E10. 3.2.7 A test plan shall be established upon mutual agreement between the seller and buyer. GMN7152 may be used as guidance in setting up the test plan system. 3.3 Physical Requirements. Typical physical properties associated with each alloy grade are shown in Appendix A. 3.4. Additional Requirements. 3.4.1 Microstructural Requirements. The stronger linear fibrous structure in the die forging process helps to improve the mechanical properties. The aim is to maintain the fibrous structure as much as possible and minimize recrystallized structure. 3.4.2 Forging Requirements. 3.4.2.1 Forgings furnished shall be of uniform quality and free from surface anomalies such as seams, laps, bursts, lubricants, dust and dirt, and quench cracks, all to an extent that would be detrimental to safe handling, machinability, appearance or performance. 3.4.2.2 Cracks and crack-like anomalies are not permitted.

1 Scope
This material standard covers forgings made of Aluminum alloys used in automotive and allied industries. This specification specifies chemical composition and material properties based on test coupons excised from forged components. 1.1 Material Description. The materials are aluminum alloys of Aluminum Association (AA) 6000 and 7000 series and some vendor specific alloys similar to 6000 series. 1.2 Symbols. Not applicable. 1.3 Typical Applications. Aluminum alloy forging applications are many in most vehicle systems. Major applications are chassis components such as control arms, knuckles, brackets, prop-shafts, yokes, etc.

2 References
Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM B557 ASTM B918/B807 ASTM E10 ASTM G47 GMN7152 GMW3001 ISO 209 ISO 6506 ISO 6892 ISO 16455 GMW3059

2.2 GM Standards/Specifications.

2.3 Additional References. Aluminum Association (AA)

3 Requirements
3.1 Chemical Requirements. 3.1.1 Forgings furnished to this specification shall confirm to the composition limits shown in Table 1. 3.1.2 Alloy designations and composition limits were obtained from AA and ISO 209 reference standards when available. Some are vendor specifications.

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Originating Department: North American Engineering Standards

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GMW15657

GM WORLDWIDE ENGINEERING STANDARDS

stoichiometric Mg2Si are relatively more prone to SCC. Short transverse direction in forging is more prone to SCC than others. Fine grains minimize SCC. Microstructural differences among various heat treatments in the form of size and type of precipitates at the grain boundaries could also be a factor. Hence, alloy percentages in materials, fabricating methodologies, heat treatment methods, loading paths, etc., shall be carefully selected to minimize SCC so as to meet the durability requirements of components. Stress-corrosion testing may be performed per test method ISO 16455 or ASTM G47.

3.4.2.3 Any anomalies, plus surface roughness and forging cleanliness may have maximum allowable limits specified. 3.4.2.4 For any of the above forging requirements, a measurement system shall be agreed upon between purchaser and supplier. 3.4.3 Stress-Corrosion Resistance. Stress Corrosion Cracking (SCC) is caused by sustained tensile stress under some service environments (Example: corrosive environment) which could result in premature failure of parts along grain boundaries. Varying amounts of copper in the alloy influence SCC differently. Alloys containing higher percentage of copper and silicon in excess of

Table 1: Chemical Composition Limits in % by Mass for Aluminum Forging Alloys (Remainder of Alloy is Aluminum)
GMW Grades GMW15657M-AL-FMg1SiCu(AA6061) Si1MgMn(AA6082) Si1MgCuMn Si1Mg1MnCu Zn5Mg2Cu1(AA7033)
Note 1

Elements % by mass Silicon 0.40 to 0.80 0.70 to 1.30 0.85 to 0.95 0.95 to 1.15 0.15 max Iron 0.70 max 0.50 max 0.20 max 0.30 max 0.30 max Copper 0.15 to 0.40 0.10 max 0.45 to 0.55 0.40 to 0.50 0.70 to 1.30 Manganese 0.15 max 0.40 to 1.00 0.45 to 0.50 0.40 to 0.55 0.10 max Magnesium 0.80 to 1.20 0.60 to 1.20 0.75 to 0.85 0.85 to 1.10 1.30 to 2.20

GMW Grades GMW15657M-AL-FMg1SiCu(AA6061) Si1MgMn(AA6082) Si1MgCuMn Si1Mg1MnCu Zn5Mg2Cu1(AA7033)

Note 1

Elements % by mass Other Chromium 0.04 to 0.35 0.25 max 0.17 to 0.24 0.10 to 0.20 0.20 max Zinc 0.25 max 0.20 max 0.05 max 0.25 max 4.6 to 5.6 Titanium 0.15 max 0.10 max 0.02 to 0.04 0.10 max 0.10 max Zirconium N/A
Note 3 Note 3 Note 2

Each 0.05 0.05 0.05 0.05 0.05

Total 0.15 0.15 0.15 0.15 0.15

N/A

0.04 max 0.05 max 0.08 to 0.15

Note 1: First part of alloy call out follows ISO format. The second part is AA alloy designation when available. Note 2: Residuals are similar to AA specification guidelines. Note 3: N/A Not Applicable.

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GMW15657

Table 2: Minimum Mechanical Properties at +23 5 in Test Coupons Excised in the Direction of Grain Flow From Forged Parts After T6 Heat Treatment
GMW15657M-AL-FMg1SiCu(A 6061) -T6 Si1MgMn(AA6082)-T6 Si1MgCuMn-T6 Si1Mg1MnCu-T6 Zn5Mg2Cu1(AA7033)-T6 Tensile Strength MPa 310 340 360 370 460 Yield Strength MPa 270 310 330 345 400 Hardness HBW 95 95 105 104 120 Young's Modulus Note 1 GPa 69 70 70 70 70 Poisson's Note 1 Ratio 0.33 0.33 0.33 0.33 0.33

Elongation % 10 10 10 10 10

Note 1: Youngs modulus and Poissons ratio given in this table are for information only; these properties are not subject to minimum requirements.

4 Manufacturing Process
4.1 Forging. Forgings shall be done with closed dies, conventional (flash) die forging or flash-free die forging. Aluminum does not flow readily, even at high pressure, under forging temperatures. As a result, forgings used in automotive applications may require multiple hits/dies. A bending or roll forming operation may also be needed. The dies are usually heated and appropriate lubricants are used for ease of material flow in the die and release of the part from the die. 4.1.1 Starting stock for automotive parts is generally extruded round bar. Other extruded shapes can also be utilized depending upon the part configuration and the number of parts to be produced. The extruded bar is already fully wrought ensuring that the final forging will have maximum grain refinement and free of any porosity or residual cast structure. This contributes for improved mechanical properties. 4.1.2 Cast stock of continuously cast chilled bars may also be used upon approval by GM materials engineering. Care must be taken to select the appropriate forge press tonnage since the advantage of oriented grain flow and dense grain structure with extruded bar is absent with cast stock. Sufficient metal movement during forging operations is necessary to rearrange cast grain structure for optimum mechanical properties. 4.1.3 The billet castings used for extrusion shall be free of anomalies detrimental to forging. The continuously cast bars forged as cast shall be peeled to remove surface anomalies. All billet castings used for extrusion or cast bars directly used in forgings shall be ultrasonically tested to verify absence of internal cracks. Further they are homogenized by heating to appropriate April 2008

temperature and time to eliminate any segregation of alloying elements during the casting process that may impede enhanced mechanical properties. Any deviation from the above requirements shall be approved by GM materials engineering. 4.1.4 Parts may require handwork, such as grinding in between forging steps to eliminate surface imperfections which could be forged into the part during subsequent forging steps. 4.2. Heat Treatment. Forged parts are usually supplied with T6 heat treatment. T6 involves solution heat-treatment, quenching in appropriate media to minimize distortion and precipitation hardening (artificial aging). Some forgings may distort during quench. It may be necessary to straighten these parts before the aging cycle. The heat treatment shall be in accordance with practice ASTM B918/B807. Note: Upon approval from GM materials engineering, a separate solution heat-treatment may not be carried out. Instead, when the part is heated to solution heat-treatment temperature (analogous to Extrusion Press Solution Heat Treatment for Aluminum Alloys ASTM B807) in the final die forging and quenched without any delay, it may be accepted. The process must be highly automated and capability shall be proven. Controls are needed to reject any part automatically when the process control settings are out of range. 4.3. Cleaning and Inspection. 4.3.1 Forgings shall be crack free. 4.3.2 To comply with this requirement, 100% fluorescent dye penetrant inspection may be specified. 4.3.3 The parts must be etched to perform this inspection. Page 3 of 5

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7.2 Acronyms, Abbreviations, and Symbols. AA Aluminum Association SCC Stress Corrosion Cracking

4.3.4 For parts that are not etched for subsequent penetrant inspection, if the cosmetic appearance is an issue on certain applications, appropriate methods shall be used to clean the die lubricant. 4.3.5 Parts shall not be ground with a grinding wheel after the final forging step which may smear the surface anomalies before this inspection.

8 Coding System
This standard shall be referenced in other documents, drawings, etc., as follows: Material per GMW15657 Example: GMW15657M-AL-F-Mg1SiCu(xxxx)-T6
Where:

5 Rules and Regulations

5.1 All materials supplied to this standard must comply with the requirements of GMW3001, Rules and Regulations for Material Specifications. 5.2 All materials supplied to this standard must comply with the requirements of GMW3059, Restricted and Reportable Substances for Parts.

GMW 15657 M AL F Mg1SiCu (xxxx) T6

6 Approved Sources
Engineering qualifications of an approved source are required for this standard. Only sources listed in the GM Materials File (i.e., GM Supply Power) under this standard number have been qualified by engineering as meeting the requirements of this standard. For other GM locations, the responsible engineering group should be contacted to obtain the approved source in that individual country.

= GM Worldwide = Sequential Number = Material Type - Metal = Category = Subcategory - Primary forming method - Forging = Alloy callout per ISO format (See Table 1) = AA Alloy origination cross reference when available (see Table 1) = Heat Treatment

9 Release and Revisions

9.1 Release. This standard originated in August 2007. It was first approved by the Global Nonferrous Materials Team in February 2008. It was first published in April 2008. .

7 Notes
7.1 Glossary. Not applicable.

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GMW15657

Appendix A
Table A1: Typical Physical properties for GMW Preferred Forging Alloys
Average Coefficient of thermal expansion at +20 to +100C 1/K x 10 23.6 23.4 23.4 23.4 23.4
-6

Theoretical Density GMW15657M-AL-Fgm/cm 2.70 2.71 2.71 2.71 2.76

3

Melting Range. C 582 to 652 585 to 650 585 to 650 574 to 650 582 to 632

Electrical conductivity at Note 1 +20C m/mm 25 27 27 27 25

2

Thermal Conductivity at Note 1 +100C W/mK 167 170 170 170 150

Average Coefficient of thermal expansion at +20 to +300C 1/K x 10 25.2 25.2 25.2 25.2 25.2
-6

Mg1SiCu(AA6061) Si1MgMn(AA6082) Si1MgCuMn Si1Mg1MnCu Zn5Mg2Cu1(AA7033)

Note 1: Electrical and Thermal conductivities are for T6 Temper.

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