PROPERTIES OF ALUMINUM ALLOYS

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1 PROPERTIES OF ALUMINUM ALLOYS Fatigue Data and the Effects of Temperature, Product Form, and Processing J. GILBERT KAUFMAN ASM International Materials Park, Ohio

2 Copyright 2008 by ASM International All rights reserved No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of the copyright owner. First printing, July 2008 Great care is taken in the compilation and production of this book, but it should be made clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FIT- NESS FOR A PARTICULAR PURPOSE, ARE GIVEN IN CONNECTION WITH THIS PUBLICATION. Although this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the use of this publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions of product or material use are outside of ASM s control, ASM assumes no liability or obligation in connection with any use of this information. No claim of any kind, whether as to products or information in this publication, and whether or not based on negligence, shall be greater in amount than the purchase price of this product or publication in respect of which damages are claimed. THE REMEDY HEREBY PROVIDED SHALL BE THE EXCLUSIVE AND SOLE REM- EDY OF BUYER, AND IN NO EVENT SHALL EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR CONSE- QUENTIAL DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF SUCH PARTY. As with any material, evaluation of the material under end-use conditions prior to specification is essential. Therefore, specific testing under actual conditions is recommended. Nothing contained in this book shall be construed as a grant of any right of manufacture, sale, use, or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in this book shall be construed as a defense against any alleged infringement of letters patent, copyright, or trademark, or as a defense against liability for such infringement. Comments, criticisms, and suggestions are invited, and should be forwarded to ASM International. Prepared under the direction of the ASM International Technical Book Committee ( ), Lichun L. Chen, Chair. ASM International staff who worked on this project include Scott Henry, Senior Manager of Product and Service Development; Charles Moosbrugger, Technical Editor; Ann Britton, Editorial Assistant; Bonnie Sanders, Manager of Production; Madrid Tramble, Senior Production Coordinator; Patricia Conti, Production Coordinator; Diane Grubbs, Production Coordinator; Rachel Frayser, Production Coordinator; and Kathryn Muldoon, Production Assistant Library of Congress Control Number: ISBN-13: ISBN-10: SAN: ASM International Materials Park, OH Printed in the United States of America

3 Contents Foreword and Acknowledgments...v About the Author...vii Chapter 1: Introduction and Background Source of Fatigue Data Style of Presentation of Fatigue Data Aluminum Association Alloy and Temper Designation Systems Units Systems Applicability and Cautions in Use of the Data Applicability of Small-Specimen Fatigue Data Residual-Stress Effects May Be Present Current versus Inactive Alloys Chapter 2: Descriptions of Specimens and Test Procedures Rotating-Beam Reversed-Bending Fatigue Tests at Room Temperature Rotating-Beam Reversed-Bending Fatigue Tests at Elevated Temperatures, with and without Prior Holding at Various Temperatures Flexural Fatigue Tests at Room Temperature Axial-Stress Fatigue Tests at Room, Subzero, and Elevated Temperatures Torsional Fatigue Tests Testing Laboratory Environment S-N Plots of Stress versus Fatigue Life Modified Goodman Fatigue Diagrams Effects of Testing Machine Variables Sheet-Flexural Testing Machines Rotating Simple versus Rotating Cantilever Beam Specimen Preparation Variables Preparation for Cast Specimens and Relation to Residual Stresses Chapter 3: Presentation of Fatigue Data Alloy Presentation Sequence Temper Presentation Sequence S-N Curve and Goodman Diagram Numbering System Tabular Summaries of Fatigue Strengths Inactive Alloys General Notes Data Set Sequence of Curves by Alloy Chapter 4: General Observations and Comparisons Total Data Spread among Alloys Data Band Width Questions about the Existence of an Endurance Limit Specimen Directional Effects Correlations with Static Strength Chapter 5: Comparisons of Fatigue Properties of Various Alloys, Tempers, and Products Wrought Alloys xxx Pure Aluminum xxx Alloys xxx Alloys xxx Alloys xxx Alloys xxx Alloys xxx Alloys Comparison of Different Wrought Products Extruded Shapes Thick Plate, Forgings, and Extruded Shapes Wrought Product Temper Annealed (O) Temper Strain-Hardening Tempers, H-Type Heat Treat Tempers, T-Type Comparison of Wrought versus Cast Alloys Comparisons of Some Cast Aluminum Alloys Premium-Strength Casting Alloys Effect of Surface Cladding Chapter 6: Influence of Production Process Variables on Fatigue Properties Wrought Alloy Processing Practices Effect of Type of Starting Stock for Forgings Effect of Strain Hardening on Fatigue Strength Effect of Solution Heat Treatment on Fatigue Strength Coiled Sheet versus Flat Sheet Effect of Continuous versus Batch Heat Treating of Sheet Effect of Type of Quench Following Heat Treatment Effect of Precipitation Age Hardening Effect of Stress Relief Effect of Additional Cold Work Following Solution Heat Treatment Variation in Fatigue Properties in Thick versus Thin Plate and Forgings Variation in Fatigue Properties in Large Cross-Sectional and Long-Length Extruded Products Effect of Pressure Welds in Hollow Extrusions iii

4 6.2 Casting Alloy Process Practices Comparison of Casting Processes Improvements with Time Sand, Permanent Mold, and Die Casting Differences Effects of Porosity Premium Casting Practices Squeeze Casting Chapter 7: Effects of Microstructure and Microporosity Effect of Degree of Recrystallization Grain Size Ultrasonic Quality Microporosity Chapter 8: Influence of Fabrication Finishing Variables on Fatigue Properties Surface Treatments and Conditions Anodizing and Related Oxide-Based Coatings Automotive Body Sheet Finishing Porcelain Enameling Nitric Acid and Other Etchants Chemical Milling Extrusion Die Lines on the Surface Surface Rolling and Peening Flash Coating with Copper Ni-SiC Electrochemical Plating Joining Techniques Fusion Welding Flash Welding Brazing Alforging Riveting Chapter 9: Effect of Temperature and Environment High Temperatures Influence of High Temperature on Fatigue Strength of Wrought Alloys Effect of Long Holding Times at Elevated Temperatures for Wrought Alloys Influence of High Temperature on Fatigue Strength of Cast Alloys Subzero Temperatures Effect of Environment Chapter 10: Effect of Stress Concentrations, Primarily Sharp Notches Notch Severity Notches and Strain-Hardening Wrought Alloys Notches and Solution Heat Treating and Precipitation Aging Wrought Alloys Notches in the Surface of Clad Sheet Notches in Casting Alloys Appendix 1: The Aluminum Association Alloy and Temper Designation Systems Appendix 2: Metrication of Aluminum Properties Appendix 3: Glossary Appendix 4: Abbreviations and Symbols Appendix 5: Tabular Summaries of Fatigue Strengths Appendix 6: Fatigue Test Specimen Drawings Alloy Index Fatigue Diagrams Index Subject Index iv

5 Foreword and Acknowledgments It is the objective of this book to address the potential usefulness of a broad summary of consistent data on the fatigue properties of aluminum alloy from a single source generated using consistent testing procedures and practices. In addition, the data illustrate the effects of many testing, product, and processing variables in a manner making many such comparisons useful. The author gratefully acknowledges the support of Alcoa, Inc. and in particular the efforts of Dr. Robert J. Bucci and his management in arranging and approving the release of the information contained herein. Alcoa, Inc. once again enabled the author to include many previously unpublished data and related information from Alcoa s archives that add immeasurably to the depth and breadth of coverage. In that regard, the author would also like to acknowledge the helpful search and retrieval support from Nick Kotow and others at the Alcoa Laboratories Research Library. J.G. (Gil) Kaufman, FASM v

About the Author J. (Gil) Kaufman has a background of over 50 years in the aluminum and materials information industries and remains an active consultant in both areas.

6 About the Author J. (Gil) Kaufman has a background of over 50 years in the aluminum and materials information industries and remains an active consultant in both areas. In 1997, he retired as Vice President, Technology for the Aluminum Association, Inc., headquartered in Washington, D.C., and is currently president of his consulting company, Kaufman Associates. Earlier in his career, he spent 26 years with the Aluminum Company of America, where he managed engineering properties and fabricating metallurgical research, and 5 with ARCO Metals, where he was Vice President, Research and Engineering. Many of the data presented in this volume were generated over the period when the author was active in or managing the Alcod testing laboratory activities. Kaufman also served for nine years as President and CEO of the National Materials Property Data Network, where, working with STN International and Chemical Abstracts Service, he established a worldwide online network of more than 25 materials databases. Gil is a Fellow and Honorary Member of ASTM International and a Fellow and Life Member of ASM International. He has published more than 130 articles, including five books, on aluminum alloys and materials data systems. vii

7 ASM International is the society for materials engineers and scientists, a worldwide network dedicated to advancing industry, technology, and applications of metals and materials. ASM International, Materials Park, Ohio, USA This publication is copyright ASM International. All rights reserved. Publication title Properties of Aluminum Alloys: Fatigue Data and the Effects of Temperature, Product Form, and Processing Product code 05156G To order products from ASM International: Online Visit /bookstore Telephone (US) or (Outside US) Fax Mail Customer Service, ASM International 9639 Kinsman Rd, Materials Park, Ohio , USA CustomerService@asminternational.org In Europe In Japan American Technical Publishers Ltd Knowl Piece, Wilbury Way, Hitchin Hertfordshire SG4 0SX, United Kingdom Telephone: (account holders), (credit card) Neutrino Inc. Takahashi Bldg., 44-3 Fuda 1-chome, Chofu-Shi, Tokyo 182 Japan Telephone: 81 (0) Terms of Use. This publication is being made available in PDF format as a benefit to members and customers of ASM International. You may download and print a copy of this publication for your personal use only. Other use and distribution is prohibited without the express written permission of ASM International. No warranties, express or implied, including, without limitation, warranties of merchantability or fitness for a particular purpose, are given in connection with this publication. Although this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the use of this publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions of product or material use are outside of ASM's control, ASM assumes no liability or obligation in connection with any use of this information. As with any material, evaluation of the material under end-use conditions prior to specification is essential. Therefore, specific testing under actual conditions is recommended. Nothing contained in this publication shall be construed as a grant of any right of manufacture, sale, use, or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in this publication shall be construed as a defense against any alleged infringement of letters patent, copyright, or trademark, or as a defense against liability for such infringement.

Relational Analysis. Guidelines for Estimating the High- and Low-Temperature Properties of Metals J. GILBERT KAUFMAN

Relational Analysis. Guidelines for Estimating the High- and Low-Temperature Properties of Metals J. GILBERT KAUFMAN Relational Analysis Guidelines for Estimating the High- and Low-Temperature Properties of Metals J. GILBERT KAUFMAN ASM International Materials Park, Ohio 44073-0002 Copyright 2011 by ASM International