ALUMINIUM ALLOYS AND

IT’S APPLICATION IN
AEROSPACE

Presentation by
1.Triyambkeshwar saxena BT16mec085
2.Rahul umare BT16mec086
3.Vaibhav harle BT16mec087
 AIRCRAFT MATERIALS

1. Basic requirements
• High strength and stiffness
• Low density
=> high specific properties e.g. strength/density, yield strength/density,
E/density
• High corrossion resistance
• Fatigue resistance and damage tolerance
• Good technology properties (formability, machinability, weldability)
• Special aerospace standards and specifications

2. Basic aircraft materials for airframe structures

• Aluminium alloys
• Magnesium alloys
• Titanium alloys
• Composite materials
 DEVELOPMENT OF AIRCRAFT MATERIALS FOR
AIRFRAME STRUCTURES

other materials

Relative share composites

of structural
materials Ti alloys
Mg alloys
other Al alloys

pure AlZnMgCu
alloys
wood
AlCuMg alloys
pure AlCuMg
alloys

new Al
alloys
steel
Year
COMPOSITE SHARE IN MILITARY AIRCRAFT
STRUCTURES IN USA AND EUROPE

Structural materials on Eurofighter

Aluminium – Al
• plane centered cubic lattice
• melting point 660 °C
• density 2.7 g/cm³
• very good electrical and heat conductivity
• very good corrosion resistance
• low mechanical properties
• solid solutions with alloying elements
• maximum solubility is temperature dependent
– Cu: 6 % at 548 °C; 0.1 % at RT
– Mg: 17 % at 449 °C; 1.9 % at RT
– Zn: 37 % at 300 °C; 2 % at RT
– Si: 1.95 % at 577 °C; 0 % at RT

Substitution solid solution

a)alloying atom > aluminium atom
b)pure aluminium
c)alloying atom < aluminium atom
 CHARACTERISTICS OF ALUMINIUM
ALLOYS
Advantages
 Low density 2.47- 2.89 g/cm³
 Good specific properties – Rm/ρ, E/ ρ
 Generally very good corrosion resistance (exception alloys
with Cu)
 Mostly good weldability – mainly using pressure methods
 Good machinability
 Good formability
 Great range of semifinished products
(sheet, rods, tubes etc.)
 Long-lasting experience
 Acceptable price
 SHORTCOMINGS

LOW HARDNESS, SUSCEPTIBILITY TO SURFACE DAMAGE

HIGH STRENGTH ALLOYS (CONTAINING CU) NEED
ADDITIONAL ANTI-CORROSION PROTECTION:
Cladding – surface protection using a thin layer of pure
aluminium or alloy with the good corrosion resistance
Anodizing – forming of surface oxide layer (Al2O3)
IT IS DIFFICULT TO WELD HIGH STRENGTH ALLOYS BY FUSION
WELDING
DANGER OF ELECTROCHEMICAL CORROSION DUE TO
CONTACT WITH METALS:
Al-Cu, Al-Ni alloys, Al-Mg alloys, Al-steel
 REFERENCE ALUMINIUM ALLOYS IN AIRFRAME
STRUCTURE

Structure Part Control parametr Reference alloys

Wing Upper panels compression 7150-T6/T77

Upper stringers compression 7050-T74
Lower panels damage tolerance (DT) 2024-T3, 2324-T39
Lower stringers tension + DT 2024-T3
Beams, ribs static properties 7050-T74, 7010-T76

Fuselage Upper panels compression, DT, formability 2024 clad-T3

Lower panels tension + DT 2024 clad-T3
Stiffeners tension/compression 7175-T73
Main frame complex 7010+7050-T74

Other All types 7010/7050/7075

parts
TYPICAL MECHANICAL PROPERTIES OF ALUMINIUM-
LITHIUM ALLOYS

Temper Direction Tensile strength Yield strength Elongation

MPa MPa %
Alloy 2090: 2.7Cu-2.2Li-0.12Zr; E = 76 GPa, ρ = 2.59 g/ccm

L 530 527 3
T 83
(near peak aged) LT 505 503 6

45° 440 440

Alloy 8090: 2.45Li-1.3Cu-0.95Mg-0.12Zr; E = 77 GPa; ρ = 2.55 g/ccm

L 480 400 4.5

T8X
(near peak aged) LT 465 395 5.5

45° 400 325 7.5

CASTING ALUMINUM ALLOYS
 Designation (in addition to EN)
 Often used system (Aluminum Association - USA): three digit designation -
the first digit indicates a main alloying element
 1XX  99,0 % Al
 2XX Al - Cu
 3XX Al - Si - Mg
Al - Si - Cu
Al - Si - Cu - Mg
 4XX Al - Si
 5XX Al – Mg
 7XX Al - Zn
 8XX Al – Sn

A letter ahead of designation marks alloys with the same content of main alloying
elements but with different content of impurities or micro alloying
elements.(e.g. 201 - A201, 356 - A356, 357 - A357)
Additional digit .0 means shape casting, digit .1 or .2 ingots
 Typical castings in aircraft structures

Al – front body of engine Al- steering part - 1,1 kg

32 kg - D=700 mm 390 x 180 x 100 mm

Al – casing - 1,3 kg Al – pedal - 0,4 kg

470 x 190 x 170 mm 180 x 150 x 100 mm
 General characteristics

 Micro and macro structures of metal are influenced by conditions of metal

solidification – quantity of nuclei, temperature interval of solidification, cooling
rate …
A fine, equiaxed grain structure is normally desired in aluminum
casting (Al-Ti or Al-Ti-B alloys are most widely used grain refiners)

 Mechanical properties are influenced by existence of casting defects – porosity,

inclusions (mainly oxides), shrinkage voids ….

 Alloys – heat treatable , non heat treatable

 Mechanical properties are mostly lower comparing wrought alloys of the similar
chemical composition

 High quality aircraft casting need careful metallurgical processing of liquid metal

 Degassing – hydrogen elimination (hydrogen causes porosity)

 Grain refinement and modification for better mechanical properties
 Filtration for inclusions removing
 Dendritic microstructure of hypoeutectic alloy
AlSi10Mg – sand casting

wall thickness 2 mm wall thickness 10 mm

There is direct relation between mechanical properties and dendrite

arm spacing (DAS) → different properties in different portions of
casting
• Alloys of Al–Cu system
- Composition 4 – 6 % Cu
- Copper substantially improves strength and hardness in the as-cast and
heat- treated conditions
- Copper generally reduces corrosion resistance and, in specific compositions
stress corrosion susceptibility
- Copper also reduces hot tear resistance and decreases castability
- Main advantage: high strength up to 300 °C
- Basic alloys
• ČSN 424351, 201, A 201, AL 7
• 242, A242
• B295
- Application:
Smaller , simple, high-strength castings for service at higher
temperatures (cylinder heads, pistons, pumps, aerospace housings, aircraft
fittings)
 Alloys of Al–Si + (Mg, Cu, Ni) system
 The most important alloys for aircraft castings
 Silicon improves casting characteristics (fluidity, hot tear resistance, feeding),
Si content depends on casting methods
 Sand and plaster molds, investment casting 5-7% Si
 Permanent molds 7-9% Si
 Die casting 8-12% Si
 Alloys containing Mg are heat treatable, hardening phase is Mg2Si
 Alloys Al-Si with alloying elements Mg and Cu have after heat treatment high
mechanical properties but lower plasticity and corrosion resistance
 Ni is alloying element in hypereutectic alloys for service at higher temperatures (e.g.
engine pistons)
 Strength and ductility can be improved using modification for refinement of eutectic
phases
 Principal – addition small quantities of Na or Sr into liquid metal before casting
 Results – increased tensile strength (40 %), impact strength (up to 400 %), ductility (2x)
 Mechanical properties can be improved also due to grain refinement buy rapid cooling
in permanent metal molds
THANK YOU