This datasheet provides information on composition limits, fabrication characteristics, processing effects on physical and mechanical properties, and applications of bright-finishing alloys 5457, 5557, and 5657. A table lists approximate bend radii for 90 deg cold bending of alloy 5557.

Anodizing refers to conversion coating of the surface of aluminum and its alloys to porous aluminum oxide. This article provides the reasons for performing anodizing and discusses the three principal types of anodizing processes, namely, chromic acid process, sulfuric acid process, and hard anodic process. It describes the limitations imposed by variables, such as alloy composition, surface finish, prior processing, temper or heat treatment, and the use of inserts, on the anodizing processes. The article explains the causes and means adopted for correcting several specific problems in anodizing aluminum. It also discusses the process control techniques and equipment used for anodizing. The article reviews the sealing processes for anodic coatings and the method for coloring the coatings. It concludes with a discussion on the effects of anodic coatings on the surface and mechanical properties of aluminum and its alloys.

This article begins with a discussion on the classification of aluminum alloys and the selection of alloy and temper based on machinability. It provides an overview of cutting force and power, tool design and material, and general machining conditions. In addition, the article discusses distortion and dimensional variation and machining problems during the machining of high-silicon aluminum alloy. It also provides information on tool design and material, speed and feed, and the cutting fluid used for various machining processes, namely, turning, boring, planing and shaping, broaching, reaming, tapping, milling, sawing, grinding, honing, and lapping. The article concludes with a discussion on drilling operations in automatic bar and chucking machines and drill presses.

The most widely accepted alloy and temper designation system for aluminum and its alloys is maintained by the Aluminum Association and recognized by the American National Standards Institute (ANSI) as the American National Standard Alloy and Temper Designation Systems for Aluminum (ANSI H35.1). This article provides a detailed discussion on the alloy and temper designation system for aluminum and its alloys. The Aluminum Association alloy designations are grouped as wrought and cast alloys. Lengthy tables provide information on alloying elements in wrought aluminum and aluminum alloys; nominal composition of aluminum alloy castings; typical mechanical properties of wrought and cast aluminum alloys in various temper conditions; and cross references to former and current cast aluminum alloy designations.

Commercial aluminum alloys are classified based on how they are made and what they contain. This article describes the ANSI H35.1 designation system, which is widely used to classify wrought and cast aluminum alloys. The ANSI standard uses a four-digit numbering system to identify alloying elements, compositional modifications, purity levels, and product types. It also uses a multicharacter code to convey process-related details on heat treating, hardening, cooling, cold working, and other stabilization treatments. The article includes several large tables that provide extensive information on aluminum alloy and temper designations and how they correspond to critical mechanical properties as well as other designation systems.

This article provides a detailed account on forming operations (blanking, piercing, press-brake forming, contour rolling, deep drawing, cold forming, and hot forming) of various nonferrous metals, including aluminum alloys, beryllium, copper and its alloys, magnesium alloys, nickel alloys, titanium alloys, and platinum metals. It discusses the formability, equipment and tooling, and lubricants used in the forming operations of these nonferrous metals.

This article focuses on the three basic groups of flexible-die forming methods: rubber pad, fluid cell, and fluid forming. It provides information on the Guerin process, the Verson-Wheelon process, the trapped-rubber process, the Marform process, the Hydroform process, the SAAB process, and the Demarest process. The article provides a discussion on the procedures of these processes, as well as the presses and tools used. It describes the methods of hydraulic forming of thin metal parts, namely, hydraulic forming with diaphragm, hydraulic forming with gasket and pressure control, and hydrobuckling.

Aluminum mill products are those that have been subjected to plastic deformation by hot- and cold-working mill processes such as rolling, extruding, and drawing, either singly or in combination. Microstructural changes associated with the working and with any accompanying thermal treatments are used to control certain properties and characteristics of the worked, or wrought, product or alloy. This article discusses the designation system, classification, product forms, corrosion and fabrication characteristics, and applications of wrought aluminum alloys. Commercial wrought aluminum products are divided into flat-rolled products (sheet, plate, and foil); rod, bar, and wire; tubular products; shapes; and forgings. The article discusses factors affecting the strengthening mechanisms, fracture toughness, and physical properties of aluminum alloys, in addition to the effects of alloying on the physical and mechanical properties. Important alloying elements and impurities are listed alphabetically as a concise review of major effects.

Non-heat-treatable aluminum alloys constitute a group of alloys that rely solely upon cold work and solid solution strengthening for their strength properties. This article focuses on the weldability and weld properties of different classes on non-heat-treatable aluminum alloys.

Chemical brightening (bright dipping) and electrolytic brightening (electropolishing) are essentially selective-dissolution processes, in which the high points of a rough surface of aluminum are attacked more rapidly than the depressions, and the peaks and valleys are smoothed to produce a bright and beautiful finish. This article discusses the metallurgical factors, optical factors, and applications of the chemical and electrolytic brightening. It compares the chemical brightening and electrolytic brightening, and presents the advantages of the chemical and electrolytic brightening processes in terms of performance and economy. The article describes the phosphoric-nitric acid baths and phosphoric-sulfuric acid baths used for chemical brightening. Solution compositions and operating conditions for three commercial electropolishing processes, as well as for suitable post-treatments, are presented in a table.

Etching aluminum can be a pretreatment step for anodizing, chemical conversion coating, metal-to-rubber bonding, and a host of other processes. Chemical etching, using either alkaline or acid solutions, produces a matte finish on aluminum products. This article describes the alkaline etching and acid etching of aluminum. Alkaline etching reduces or eliminates surface scratches, nicks, extrusion die lines, and other imperfections. Acid etching can be done without heavy smut problems, particularly on aluminum die castings. Hydrochloric, hydrofluoric, nitric, phosphoric, chromic, and sulfuric acids are used in acid etching. The article presents a flow chart of the operations used in acid etching.

This article is a comprehensive collection of property data for wrought aluminum and aluminum alloys. Data are provided for the physical properties and mechanical properties of wrought aluminum and aluminum alloys. The listing also includes values that indicate the effect of temperatures on tensile strength, yield strength, and elongation, and the mechanical properly limits for aluminum alloy die forgings, non-heat-treatable and heat-treatable aluminum alloy sheets and plates, and non-heat-treatable aluminum alloy extruded wires, rods, bars, and shapes.

This article describes the effects of cyclic fatigue properties on aluminum alloys. It provides a discussion on strain-control fatigue and the effects of two microstructural features on the strain life of aluminum alloys: shearable precipitates and precipitate-free zones. The article discusses various models of fatigue crack growth (FCG) and the effects of alloy microstructure and composition on FCG.

Heat treatment of aluminum alloys is assessed by various quality-assurance methods that include metallographic examination, hardness measurements, mechanical property tests, corrosion-resistance tests, and electrical conductivity testing. The use of hardness measurements in the quality assurance of heat treated aluminum products is effectively used in conjunction with the measurement of surface electrical conductivity. This article provides a detailed discussion of the error sources in eddy-current conductivity measurements. It also presents useful information on the variation of electrical conductivity of alloy 2024 samples as a function of aging time at different isothermal holding temperatures.

More than 450 alloy designations/compositions have been registered by the Aluminum Association (AA) Inc. for aluminum and aluminum alloys. This article contains tables that list the designations and composition limits of wrought unalloyed aluminum and wrought aluminum alloys, and designations and composition limits for aluminum alloys in the form of castings and ingot. It provides helpful information on the Unified Numbering System (UNS) numbers and its corresponding AA numbers for aluminum and aluminum alloys, and the international alloy designations cross-referenced to its equivalent compositions of wrought AA alloys.

This article discusses the classification, characteristics and temper designations of wrought aluminum alloys. Wrought aluminum products are available as flat-rolled products such as sheets, plates, and foils; rods, bars, and wires; tubular products such as tubes and pipes; extruded shapes; forgings; and impacts. The article provides information on product economics, design and selection, including product dimension and dimension tolerances, and design and use of wrought product capabilities. Finally, it tabulates the specifications and standards for aluminum mill products.

Bend tests are conducted to determine the ductility or strength of a material. This article discusses the different bend tests with emphasis on test methods, apparatuses, procedures, specimen preparation, and interpretation and reporting of results. The types of bend tests discussed are bending ductility tests, bending strength tests (ASTM E 855), bend tests as per EN 12384 and JIS 3130, and computer-aided bending tests. The three standard bending strength tests are the cantilever beam bend test, the three-point bend test, and the four-point bend test. European Standard EN 12384 specifies a bend test to determine the modulus of elasticity in bending. Japanese Industrial Standard JIS 3130 specifies two tests to determine the elastic limit of spring plate or strip: the repeated deflection spring test and the moment type spring test.

This article contains a table that lists the values of nominal compositions and composition limits of wrought aluminum alloys.

This article discusses the corrosion resistance of aluminum and aluminum alloys in various environments, such as in natural atmospheres, fresh waters, seawater, and soils, and when exposed to chemicals and their solutions and foods. It describes the forms of corrosion of aluminum and aluminum alloys, including pitting corrosion, intergranular corrosion, exfoliation corrosion, galvanic corrosion, stray-current corrosion, deposition corrosion, crevice corrosion, filiform corrosion, stress-corrosion cracking, corrosion fatigue, and hydrogen embrittlement. The article also presents a short note on aluminum clad products and corrosion at joints.

Aluminum and its alloys are used in a broad range of applications. This article discusses the primary and secondary production of aluminum and the classification system for cast and wrought products. It describes some of the more common manufactured forms, including commercial wrought aluminum products, aluminum alloy engineered castings, powder metallurgy parts, and metal-matrix composites. The article also reviews fabrication characteristics such as machining, forming, forging, and joining. It concludes with a description of the major industrial applications of wrought and cast aluminum alloys.