Aluminum Alloys

An aluminum alloy is an alloy in which aluminum (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon, tin, nickel and zinc. There are two principal classifications, namely casting alloys and wrought alloys, both of which are further subdivided into the categories heat-treatable and non-heat-treatable. About 85% of aluminum is used for wrought products, for example rolled plate, foils and extrusions. Cast aluminum alloys yield cost-effective products due to the low melting point, although they generally have lower tensile strengths than wrought alloys. The most important cast aluminum alloy system is Al–Si, where the high levels of silicon (4–13%) contribute to give good casting characteristics. Aluminum alloys are widely used in engineering structures and components where light weight or corrosion resistance is required.

Aluminum alloy surfaces will develop a white, protective layer of aluminum oxide if left unprotected by anodizing and/or correct painting procedures. In a wet environment, galvanic corrosion can occur when an aluminum alloy is placed in electrical contact with other metals with more positive corrosion potentials than aluminum, and an electrolyte is present that allows ion exchange. Also referred to as dissimilar-metal corrosion, this process can occur as exfoliation or as intergranular corrosion. Aluminum alloys can be improperly heat treated, causing internal element separation which corrodes the metal from the inside out.

Aluminum alloy compositions are registered with The Aluminum Association. Many organizations publish more specific standards for the manufacture of aluminum alloy, including the Society of Automotive Engineers standards organization, specifically its aerospace standards subgroups, and ASTM International.