ALUMINUM AND ITS ALLOYS
1. INTRODUCTION
Aluminum (Al) is a lightweight, silvery-white metal, atomic number 13, known for:
Low density (~2.7 g/cm³)
High corrosion resistance (forms natural oxide layer)
Good electrical and thermal conductivity
High ductility and malleability
But pure Aluminum is relatively soft and low in strength. Therefore, Aluminum is alloyed with
other elements to improve its mechanical properties in engineering applications.
Aluminum alloys are materials made by adding other elements (like Cu, Mg, Si, Zn, Mn) to pure
Aluminum to enhance properties like:
Strength
Hardness
Wear resistance
Fatigue life
Thermal stability
Depending on processing and composition, Aluminum alloys are classified into:
Wrought Alloys (like 6061, 7075) → Can be heat-treated for very high strength and
Mechanically worked (rolling, extrusion, forging).
Casting Alloys (like A356, 319) → Formed by melting and pouring into moulds designed
for complex shapes and good thermal properties.
A) Mechanical Behavior of Aluminum and its Alloys
B) Typical Engineering Applications
Reason to use Aluminum Alloys in Mechanical Engineering Applications
Weight Saving: ~⅓ the weight of steel- crucial for aerospace, automotive sectors
Strength-to-Weight Ratio: High-performance structures
Corrosion Resistance: Long service life with low maintenance
Formability: Easy to roll, extrude, weld, machine
Thermal Properties: Excellent heat dissipation (good for heat exchangers, radiators)
2. CLASSIFICATION OF ALUMINUM ALLOYS
Aluminum alloys are named using standardized systems developed by organizations like AA
(Aluminum Association) and ISO. The naming conventions help identify their chemical
composition, processing method, and heat treatment state. Here is a breakdown:
A) WROUGHT ALUMINUM ALLOYS
Named with a 4-digit number system
i) Series Overview
Major Alloying
Series Examples
Element
1xxx 99%+ Pure Aluminum 1050, 1100
2xxx Copper (Cu) 2024, 2618
3xxx Manganese (Mn) 3003, 3105
4xxx Silicon (Si) 4045, 4032
5xxx Magnesium (Mg) 5052, 5083
6xxx Mg + Si 6061, 6082
7xxx Zinc (Zn) 7075, 7475
8xxx Misc (Fe, Li) 8011, 8090
ii) Properties and Applications
Heat
Corrosion
Alloy Strength Weldability Treatabl Main Applications
Resistance
e
Electrical wires,
1050 / 1100 Low Very High Good No packaging foil, kitchen
utensils
Aircraft structures,
2024 Very High Low Poor Yes
aerospace fittings
Marine vessels, pressure
5052 Medium Very High Excellent No
tanks, fuel tanks
Automotive parts,
6061 High High Excellent Yes
pipelines, bicycle frames
Aerospace frames,
Moderate-
7075 Very High Fair Yes defence parts, sporting
Low
equipment
Food & Pharma
8011 Low High Good No
packagings
Notes:
Higher Series (2xxx, 7xxx): High strength → Aerospace.
5xxx Series: Excellent corrosion resistance → Marine.
6xxx Series: General-purpose → Automotive, structural.
1xxx Series: Pure, soft → Electrical and chemical industries.
Temper Designation suffixes like -T6, -O, -F, where “-T6” or “-O” indicates heat treatment or
temper (e.g., 6061-T6 = solution heat treated and artificially aged).
B) CASTING ALUMINUM ALLOYS
Named with a 4-digit number + decimal + letter
Example:
A356.0
First digit (A3): Major alloying group (A = modification, 3 = Si)
Second and third digits (56): Specific alloy designation
Decimal (.0): Casting (.1 = ingot)
i) Series Overview
Series Main Elements Examples
1xx.x Pure Al 135.0
2xx.x Cu 206.0
3xx.x Si + Cu/Mg 319.0, A356.0
4xx.x Si 443.0
5xx.x Mg 535.0
7xx.x Zn 713.0
8xx.x Sn 850.0
9xx.x Misc 953.0
ii) Properties and Applications
Main Alloying
Alloy Key Properties Common Applications
Elements
Excellent castability, good Automotive parts
weldability, moderate-high (wheels, frames),
A356.0 Si + Mg
strength after T6 heat aerospace castings, pump
treatment housings
Good wear resistance, good
Engine blocks, cylinder
319.0 Si + Cu machinability, moderate
heads, transmission cases
strength
Additive manufacturing
High strength after heat
(3D printing), aerospace
AlSi10Mg Si + Mg treatment, lightweight, good
parts, motorsport
corrosion resistance
components
Good corrosion resistance, Engine components,
A319.0 Si + Cu + Fe
better thermal conductivity compressor parts
A356-T6 Si + Mg (heat treated) Very high strength and Aircraft components,
excellent fatigue resistance high-performance
automotive parts
Intricate die-cast parts,
Excellent fluidity, pressure
A413.0 Si housings, compressor
tightness, low shrinkage
bodies
Good pressure tightness,
Automotive and
corrosion resistance, better
A360.0 Si + Mg aerospace structural
mechanical properties than
components
A380
Excellent castability, good Automotive parts
A380.0 Si + Cu + Fe mechanical strength, (gearboxes, engine
moderate corrosion resistance blocks), housings
iii) Casting Process Types
Process Notes Typical Alloys
Sand Casting Good for large parts, lower precision A356, 319
Die Casting High precision, mass production A380, A360, A413
Investment Casting Complex, fine details A356, AlSi10Mg
Good surface finish, stronger than
Permanent Mold Casting A356, 319
sand casting
RESEARCH TOPICS IN ALUMINUM ALLOYS
1. Development of High-Strength, High-Ductility Aluminum Alloys
Tailoring microstructure using nano-precipitation and grain refinement.
Strength-ductility trade-off using severe plastic deformation (SPD) techniques.
2. Corrosion Behavior and Surface Engineering of Aluminum Alloys
Advanced surface coatings (e.g., nano-ceramic, graphene coatings).
Electrochemical analysis of corrosion mechanisms in marine/industrial environments.
3. Aluminum Alloys for Additive Manufacturing (3D Printing)
Development of printable Al-Si-Mg alloys.
Study of solidification microstructures during laser powder bed fusion.
Reducing porosity and improving mechanical properties of printed parts.
4. Aluminum-Based Metal Matrix Composites (Al-MMCs)
Reinforcement of Al alloys with SiC, graphene, or nano-ceramics.
Wear resistance, thermal conductivity, and lightweight armor applications.
5. Joining and Welding of Aluminum Alloys
Friction stir welding (FSW) and laser welding of dissimilar Al alloys.
Study of interfacial microstructure and defect control.
6. High-Temperature Aluminum Alloys
Design of Al-Cu-Li, Al-Sc, and Al-Fe systems for aerospace engines.
Creep resistance and thermal stability for structures above 300°C.
7. Aluminum Alloys for Battery and Hydrogen Applications
Study of Al alloys for battery casings (lithium-ion) and hydrogen storage tanks.
Hydrogen embrittlement resistance in Al alloys.
8. Life-Cycle Assessment and Recycling of Aluminum Alloys
Sustainable alloy development using 100% recycled aluminum.
Mechanical performance degradation after recycling.
EMERGING RESEARCH TECHNIQUES
Electron microscopy (TEM, SEM) for nano-characterization
Atom probe tomography (APT) for 3D atom-level imaging
Thermo-mechanical simulation (Phase field modelling, CALPHAD methods)
Machine learning to predict alloy design and performance.
Summary
Field Focus
Alloy Design Stronger, lighter, corrosion-resistant Aluminum
Manufacturing Additive manufacturing, friction stir welding
Surface Engineering Coatings, treatments for extreme environments
Sustainability Recycling, eco-friendly alloys
