The Heat Treat Doctor

Daniel H. Herring | 630-834-3017 | [email protected]

Heat Treating of Aluminum Castings

T h heat treatment of cast aluminium alloys (Ta-

he
bble 1) is carried out to increase their strength and
hardness and to change their physical, mechani-
h
ccal and metallurgical properties. Let’s learn more.
Different types of castings require different thermal treat-
ments (Fig. 1). For example, improved mechanical and physical
Precipitation (Aging) – TE Condition (T5 or T51)
Artifical aging treatment is carried out at temperatures above am-
bient, typically in the range of 150-200˚C (300-400˚F). This type
of heat treatment is done at these relatively low temperatures to
eliminate growth. They are also used to stabilize the castings di-
mensionally (improving mechanical properties somewhat) and to
properties can be produced in sand and permanent-mold cast- improve machinability. Soak (hold) times can vary between two
ings by heat treatment. By contrast, some alloys – such as 443.0 and 24 hours depending upon the alloy and the cross-sectional
that contain little or no copper, zinc or thickness of the part. Lower temperatures and longer times pro-
magnesium – do not respond to heat treat- mote precipitation and often enhanced mechanical properties.
ment and do not exhibit improvements in
mechanical properties. Others, such as die Solution Treated and Stabilized – TB7 Condition
castings, can only be given a stress relief After solution treatment, castings can be heated into the range
(and not solution heat treated) because of of 200-250˚C (400-480˚F) for stabilization and homogenization of
their porous internal structure due to fears the alloying elements. Times and temperature vary with the type
of surface blistering and internal porosity. of alloy and mass of the component.
Each type of heat treatment is worth un-
derstanding in more detail. Solution Treatment and Precipitation Hardening –
TF Condition (T6 or T61)
Heat Treatment Solution treatment followed by precipitation (age) hardening pro-
Solution Treatment – TB Condition (T4) duces the highest strength and mechanical properties (tensile and
Castings are heated to a temperature just below the alloy melt- yield strength) while retaining ductility (elongation). Precipita-
ing point (dependent on chemical composition) and held at this tion (age) hardening stabilizes the properties.
temperature (dependent on alloy and cross-sectional thickness) a
sufficient amount of time to allow the alloying elements to enter Solution Treated and Stabilized –
into solid solution. Upon quenching, these elements are in a super- TF7 Condition (T7 or T71)
saturated metastable state. Quench media include water, boiling Castings used for elevated-temperature service may benefit from
water or polymer. Choice of the quenchant is often a balance a solution treatment and stabilization between 200-250˚C (400-
between achieving mechanical properties and managing distor- 480˚F) in order to stabilize mechanical properties when the com-
tion while avoiding the buildup of internal stresses in the part. ponent is exposed to temperatures close to or in this range. This
Although mechanical properties increase somewhat by natural heat treatment improves mechanical properties to a large degree,
aging, precipitation hardening (artificially aging) is typically em- stabilizes the castings and usually results in a slightly lower tensile
ployed to achieve maximum benefit to the mechanical properties. and yield strength but an increased elongation value compared to
the T6 series of heat treatments.
Table 1. Classification of thermal treatments of cast
aluminum alloys Stress Relief and Annealing – TS Condition
Suffix Designation Heat Treatment Stress relief and annealing
anneal can be used to remove stresses
M None – As cast or as manufactured in a casting
cast or to soften the component
for subsequent
s shaping or mechani-
TB (T4) Solution treated and naturally aged
cal-working operations. Stress relief is
cal-w
TE (T5) Artificially aged
typically performed between 200-250˚C
typica
TB7 Solution treated and stabilized (400-480˚F) while annealing is done
(400-48
TF (T6) Solution heat treated and fully artificially
ly aged around 300-400˚C (575-750˚F).
TF7 Solution treated and artificially aged and
nd stabilized Fig. 1. Cast aluminum engine block
TS Stress relieved and annealed (Photograph Courtesy of Wisconsin Oven
Corporation; East Troy, Wis.)

22 February 2010 - IndustrialHeating.com

 rial H

•
•
TH
Alloy Selection Sometimes one mechanical property (e.g., ribs or pockets and for parts unsuitable
Aluminum casting alloys (Table 2) are yield strength) dictates alloy choice and/or for casting in metal molds. Sand cast-
numbered in accordance with a three- casting method. ing usually requires minimum tooling
digit-plus-decimal designation in order In most cases, aluminum castings are charge, but the unit price of the castings
to identify major alloying elements (and chosen as the most cost-effective solu- and the fi nished part can be high. Per-
some alloy combinations). tion based on raw material and produc- manent mold casting requires a higher
The digit following the decimal in tion cost. However, knowledge of end-use tooling charge, but the unit price is
each alloy number indicates the form of service requirements and how to optimize lower, particularly for longer runs. Die
product. design efficiency and/or lower production casting usually requires the
costs in manufacturing (e.g., reproducibil- highest tooling charge but
• “0” indicates the chemistry limits ap- ity) may change the design. For instance, also the lowest piece price
plied to an alloy casting. a casting with sound design may have a on large quantities. IH
• “1” indicates the chemistry limits for in- size or shape that will promote distortion
Table 2. Cast aluminum alloy designations
got used to make the alloy casting. in heat treating. A wide variety of appli-
Series Alloy Type
• “2” indicates the chemistry limits for cations (Table 4, Fig. 2) are possible.
1XX.X 99.0% Al (minimum)
ingot are different (typically tighter). Casting method is also an important
2XX.X Al + Cu
consideration. For example, castings re-
3XX.X Al + Si-Mg or Si-Cu or Si-Mg-Cu
Generally, the XXX.1 designation indi- quired in large quantities favor perma-
4XX.X Al + Si
cates the ingot is supplied as a secondary nent molds, die casting or automated
5XX.X Al + Mg
product (e.g., remelted from scrap), where- sand casting (provided the size and de-
as the XXX.2 designation suggests the in- sign features of the casting and available 6XX.X Reserved

got is produced from primary aluminum. alloys are suitable). Sand casting often 7XX.X Al + Zn

Some alloy names are preceded by a letter is used to produce parts with hollow 8XX.X Al + Sn
so as to distinguish between alloys that cavities and a complex arrangement of 9XX.X Reserved
differ only slightly in percentages of im-
purities or minor alloying elements (e.g., Table 4. Typical applications
356.0, A356.0, B356.0 or F356.0). Alloy Typical Applications Remarks
In order to choose the alloy, casting 242.0 / Cylinder heads, generator housings (aircraft), Applications where strength and hardness at
process and heat treatment, the engineer A242.0 pistons (aircraft, diesel, motorcycle) high temperatures are desirable.
begins by understanding the service con- Sand castings: crankcases (internal combus-
ditions under which the component part 319.0 / tion and diesel Engines), pans (oil), tanks Applications where moderate strength is
A319.0 / (gasoline and oil) required. Mechanical properties are not ad-
will operate. In order to achieve the de- B319.0 / Permanent mold castings: engine compo- versely affected by slight changes in impurity
sired strength, hardness, corrosion resis- 320 nents (various), heads (water-cooled cylin- content.
tance, impact strength or machinability, der), housings (rear axle)
designers have over 60 casting alloys in use Sand castings: brackets, blocks (water-cooled
cylinder), cases (automotive transmission),
today and up to five different heat treat- fittings, housings (rear axle), pump bodies Applications where excellent casting charac-
ments they can select (Table 3 – online). Permanent mold castings: bodies (valve), teristics are required. In the –T6 condition for
356.0
blocks (engine), brackets (springs), elbows marine applications where pressure tightness
(fuel tanks), fittings (fuselage, tank car), and/or corrosion resistance are required.
hardware (marine), machine tool parts, pump
parts, rudder-control supports
Airframes, chassis parts (trucks), machine Applications where higher strength and higher
A356.0
parts, missile components, structural parts ductility (especially elongation) are desirable.
A380.0 / Housings (lawn mowers), heads (air-cooled Applications for general-purpose die castings
B380.0 cylinders), gear cases, radio transmitters with good mechanical properties.
Blocks (internal-combustion engines), brakes, Applications where high hardness, good wear
A390.0 /
cylinder bodies (compressors), pistons resistance and low coefficient of thermal
B390.0
(internal-combustion engines), pumps expansion are required.
Brackets, c-clamps, computing devices, in- Applications requiring strength, shock resis-
535.0
Fig. 2. Load of aluminum castings for heat struments, machined parts tance, ductility and dimensional stability.
treatment at a commercial shop Applications requiring good strength, shock
Castings (marine), farm machinery, machine-
(Photograph courtesy of Wisconsin Oven 712.0 and corrosion resistance, machinability and
tool parts
Corporation; East Troy, Wis.) dimensional stability.

24 February 2010 - IndustrialHeating.com