Aluminum casting alloys are among the most versatile of all common foundry alloys and generally have high castability ratings. This article provides an overview of the common methods of aluminum shape casting. It discusses the designations of aluminum casting alloys categorized by the Aluminum Association designation system. The article summarizes the basic composition groupings of aluminum casting alloy and discusses the effects of specific alloying elements and impurities. The characteristics of the important casting processes are summarized and compared in a table. The article presents the advantages and disadvantages of green sand casting, permanent mold casting, semipermanent mold casting, and high-pressure die casting. A discussion on other casting processes, such as investment casting, lost foam, plaster mold casting, pressure casting, centrifugal casting, and semisolid casting, is also included.

Grain refinement in aluminum casting alloys tends to reduce the amount of porosity and the size of the pores and to improve mechanical properties, especially fatigue strength. This article provides information on measurement of grain size in alloys and describes the mechanisms of grain refinement in aluminum casting alloys. It reviews the use of boron and titanium as a grain refiner for aluminum casting alloys. The article discusses the best practices for grain refinement in various aluminum casting alloys. These include aluminum-silicon casting alloys, aluminum-silicon-copper casting alloys, aluminum-silicon-copper casting alloys, aluminum-zinc-magnesium casting alloys, and aluminum-magnesium casting alloys. The article also examines the benefits of grain refinement in aluminum casting alloys.

Alloys 355.0 and C355.0 are high-strength alloys used in various applications where castings are usually heat treated for maximum strength. This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, fabrication characteristics, and application characteristics of these 3xxx series alloys.

This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, and applications characteristics of Al-Si-Mg high-strength casting alloys 356.0 and A356.0. Figures illustrate the variation of Charpy impact energy in A356-T6 castings as a function of solution time; and room-temperature aging characteristics for aluminum alloy 356.0-T4. Growth and hardness curves for aluminum alloy 356.0-T4 are also presented.

The family of type 357 alloys contain the highest magnesium levels and are used where high strength is required. This datasheet provides information on key alloy metallurgy, fabrication characteristics, processing effects on physical and mechanical properties, and applications characteristics of Al-Si-Mg high-strength casting alloys.

Understanding the mechanical properties of aluminum alloys is useful for the designer for choosing the best alloy and establishing appropriate allowable stress values, and for the aluminum producer to control the fabrication processes. This article discusses the nature and significance of mechanical property data and of stress-strain curves detailing the effects of mechanical properties on the design and selection of aluminum alloys. The properties include tensile, compressive, shear, bearing, creep and creep-rupture, fatigue, and fracture resistance properties.

The 206.0, A206.0, and B206.0 alloys (aluminum alloys 2xxx) are structural castings in the heat-treated temper for automotive and aerospace applications where high tensile and yield strengths with moderate elongations are needed. This datasheet provides information on key alloy metallurgy and fabrication characteristics of these 2xxx series alloys, as well as the effects of processing on their typical physical and mechanical properties.

Alloys 242.0 and A242.0 are age-hardenable casting alloys with excellent strength at elevated temperatures. This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, fabrication characteristics, and application characteristics of these 2xxx series alloys.

Alloy 365.0 and A365.0 are developed near eutectic Al-Si die-casting alloys with additions of manganese to reduce die soldering. This datasheet provides information on key alloy metallurgy, processing effects on tensile properties, and fabrication characteristics of these 3xxx series alloys.

This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, and applications of natural aging casting alloys 711.0 and 712.0. The fatigue strength of smooth and notched permanent mold aluminum casting of C712.0-F is illustrated.

The aluminum alloys 367.0 and 368.0 are high-performance, low-iron, die-casting alloys that rely on strontium for die soldering resistance. In these alloys, the lower iron content minimizes the formation of needle-like, Al-Fe-Si phases that can deteriorate strength, elongation and fatigue behavior. This datasheet provides information on key alloy metallurgy, processing effects on tensile properties, and fabrication characteristics of these 3xxx series alloys.

The aluminum alloys 380.0, A380.0, and B380.0 are widely used for making general-purpose die castings. This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, fabrication characteristics, and application characteristics of these 3xxx series alloys.

Alloys 771.0 and 772.0 are high-strength, shock-resistant, aluminum sand-casting alloys that develop a high combination of physical and mechanical properties in the as-cast and room-temperature-aged conditions. This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, and fabrication characteristics of these 7xxx series alloys.

The aluminum alloys 383.0, 384.0, and A384.0 are Al-Si-Cu high-strength die-casting alloys suitable for castings with thin walls and large areas. This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, and fabrication characteristics of these 3xxx series alloys.

This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, and application characteristics of Al-Si-Cu-Mg hypereutectic casting alloys 390.0, A390.0, and B390.0. Tool lives for the machining of alloys 380 and 390 are illustrated.

The 391-type hypereutectic aluminum-silicon alloys are hypereutectic alloys designed for applications where excellent wear resistance is needed. They are similar to the 390 family of alloys, except for a low copper content to improve castability and corrosion resistance. This datasheet provides information on key alloy metallurgy and processing effects on mechanical properties of separately cast test bars of these alloys.

This datasheet provides information on key alloy metallurgy, fabrication characteristics, processing effects on physical and mechanical properties, and application characteristics of Al-Si die casting alloys 413.0 and A413.0.

The Al-Mg moderate-strength casting alloys 511.0, 512.0 and 513.0 are variations of alloy 514.0. Their most important characteristic is corrosion resistance, including exposure to seawater and marine atmospheres. This datasheet provides information on key alloy metallurgy, fabrication characteristics, processing effects on physical and mechanical properties, and applications of these alloys.

This datasheet provides information on key alloy metallurgy, processing effects on physical and mechanical properties, and application characteristics of Al-Si-Mg general-purpose die-casting alloys 360.0 and A360.0.