ASM HandbookW Volume 2A Aluminum Science and Technology Prepared under the direction of the ASM International Handbook Committee Volume Editors Kevin Anderson, FASM, Mercury Marine John Weritz, Aluminum Association J. Gilbert Kaufman, FASM, Kaufman Associates Division Editors Anthony Anderson, ITW Welding North America Michael E. Finn, Finn Metalworking and Cutting Solutions D.S. MacKenzie, Houghton International David Neff, Pyrotek (Retired), Jude Mary Runge, CompCote International, Inc Geoffrey Sigworth, Consultant ASM International Staff Steve Lampman, Senior Content Developer Victoria Burt, Content Developer Amy Nolan, Content Developer Susan Sellers, Content Development and Business Coordinator Madrid Tramble, Manager of Production Jennifer Kelly, Production Coordinator Karen Marken, Senior Managing Editor Scott D. Henry, Senior Manager, Content Development Editorial Assistance Ed Kubel Jo Hannah Leyda Elizabeth Marquard Beverly Musgrove Lilla Ryan W ASM International Materials Park, Ohio 44073-0002 www.asminternational.org Copyright # 2018 by ASM InternationalW All rights reserved No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of the copyright owner. First printing, November 2018 This Volume is a collective effort involving hundreds of technical specialists. It brings together a wealth of information from worldwide sources to help scientists, engineers, and technicians solve current and long-range problems. Great care is taken in the compilation and production of this Volume, but it should be made clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE GIVEN IN CONNECTION WITH THIS PUBLICATION. Although this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the use of this publication alone. This pub- lication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions of product or material use are outside of ASM’s control, ASM assumes no liability or obligation in connection with any use of this information. No claim of any kind, whether as to products or information in this publication, and whether or not based on negligence, shall be greater in amount than the purchase price of this product or publication in respect of which damages are claimed. THE REMEDY HEREBY PROVIDED SHALL BE THE EXCLUSIVE AND SOLE REMEDY OF BUYER, AND IN NO EVENT SHALL EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEG- LIGENCE OF SUCH PARTY. As with any material, evaluation of the material under end-use conditions prior to specification is essen- tial. Therefore, specific testing under actual conditions is recommended. Nothing contained in this Volume shall be construed as a grant of any right of manufacture, sale, use, or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in this Volume shall be construed as a defense against any alleged infringement of letters patent, copyright, or trademark, or as a defense against liability for such infringement. Comments, criticisms, and suggestions are invited, and should be forwarded to ASM International. Library of Congress Cataloging-in-Publication Data ASM International ASM Handbook Includes bibliographical references and indexes Contents: v.1. Properties and selection—irons, steels, and high-performance alloys—v.2. Properties and selection—nonferrous alloys and special-purpose materials—[etc.]—v.23. Materials for medical devices 1. Metals—Handbooks, manuals, etc. 2. Metal-work—Handbooks, manuals, etc. I. ASM International. Handbook Committee. II. Metals Handbook. TA459.M43 1990 620.1’6 90-115 SAN: 204-7586 ISBN-13: 978-1-62708-158-0 (print) ISBN-13: 978-1-62708-159-7 (pdf) ISBN-13: 978-1-62708-207-5 (electronic) ASM InternationalW Materials Park, OH 44073-0002 www.asminternational.org Printed in the United States of America Foreword Aluminum Science and Technology is a new addition, as Volume 2A, to the ASM Handbook series and is part of an effort to produce volumes dedicated to important classes of engineering materials. The first volume dedicated to an important material class is ASM Handbook, Volume 1A, Cast Iron Science and Technology (2017). Volume 2A continues in this effort, building not only from the ASM Specialty Handbook: Aluminum and Its Alloys (1993) but also the classic three-volume set Aluminum edited by Kent R. Van Horn (American Society for Metals, 1967). The extent of coverage also neces- sitates ASM Handbook, Volume 2B, Properties and Selection of Aluminum Alloys for publication in 2019. ASM International and the Board of Trustees are grateful for the work and dedication of volunteer editors, authors, and reviewers who devoted their time and expertise to develop a reference publication of the highest technical and editorial quality. A special note of thanks is offered to the volume and divi- sion editors and their commitment to present a publication of the highest technical and editorial quality. The result is a comprehensive reference work that will help readers solve problems and gain insights. Dr. Frederick E. Schmidt President ASM International William T. Mahoney Chief Executive Officer ASM International v Preface Kevin Anderson, FASM John Weritz J. Gilbert Kaufman, FASM Mercury Marine Aluminum Association Kaufman Associates The breadth and importance of aluminum in modern society con- and practitioners in aluminum technology. The extent of coverage also tinues to grow, even with over 130 years of development since the inde- necessitated an additional publication, ASM Handbook, Volume 2B, pendent discovery of electrochemical reduction of alumina in 1886 by Properties and Selection of Aluminum Alloys for release in 2019. Paul Louis Toussaint He´roult (1863–1914) in France and Charles Martin Hall (1863–1914) in the United States. The extent of aluminum This Volume represents the collected efforts of scores of authors technology and applications is too vast for any single volume, but the and reviewers. The editors wish to extend their heartfelt thanks to all intent of this volume is to give readers a foundation on aluminum who participated in this volume development and for the insightful technology and practical details and insights on the processes, capabil- and extensive contributions provided for the wider engineering ities, and variables in producing and fabricating aluminum products. community. Partially patterned from the three-volume set Aluminum edited by Kent R. Van Horn (American Society for Metals, 1967), this volume Kevin Anderson, Mercury Marine is intended to replace the ASM Specialty Handbook: Aluminum and Its John Weritz, Aluminum Association Alloys (1993) with major updates and additions by leading innovators J. Gilbert Kaufman, Kaufman Associates vi List of Contributors and Reviewers Diran Apelian W.C. Harrigan, Jr Erik Miller Worcester Polytechnic Institute MMC Engineering, Inc. Miller Electric Mfg. Co. Anthony Anderson Martin Hartlieb David Neff ITW Welding North America Viami International Pyrotek (Retired) Kevin Anderson Sameehan S. Joshi Linda Newman Mercury Marine University of North Texas Houghton International J. Baumeister Mark Jozefowicz Mary Oakley Fraunhofer Institute for Manufacturing Reliant Aluminum Products, LLC Consultant Technology and Advanced Materials J. Gilbert Kaufman George Olive Patrick Berube Kaufman Associates Enclos Hobart Brothers Co. Serhat Kaya Elsa A. Olivetti Victoria Burt Superform Massachusetts Institute of Technology ASM International Sean Kelly Toby Padfield Wayne Chandler Worcester Polytechnic Institute American Axle & Manufacturing SIC Technologies, Inc. James LaBelle Mangesh V. Pantawane Lichun (Leigh) Chen CSD Structural Engineers University of North Texas Superior Essex Chaman Lall Pinakin Patel Larry Chesterfield Metal Powder Products Company Techevon LLC Anodizing Technologies, Inc. S. Lampman Tej Patel Kevin Colligan ASM International Techevon LLC Nova-Tech Engineering, LP Peter Lee Cheryl Roberts Narendra B. Dahotre Manchester University KTA-Tator, Inc. University of North Texas Robert Leggat Jude Mary Runge Devan DePauw KTA-Tator, Inc. CompCote International, Inc. Northwestern Michigan College M. (Kumar) Sadayappan D. Lehmhus Ralph Dorward Natural Resources Canada Kaiser Aluminum (Retired) Fraunhofer Institute for Manufacturing Technology and Advanced Materials Pradip Saha Tiffany A. Dux The Boeing Company Shuang Liu Arconic Forgings & Extrusions Miller Electric Mfg. Co. Satyam Sahay Abdallah Elsayed John Deere Technology Center India D.S. MacKenzie University of Guelph Robert Sanders Houghton International Thomas Fiedler Novellis Richard Mahn Newcastle University Wojtek Szczypiorski Consultant Michael E. Finn Hazelett Corporation Finn Metalworking and Cutting Solutions William Mankins Mark E. Schlesinger Rafael Gallo Metallurgical Services Incorporated Missouri University of Science and Pyrotek Richard Martukanitz Technology Jennifer L. Giocondi Pennsylvania State University Dusan P. Sekulic Arconic University of Kentucky Stephen P. Midson Cullen L. Hackler The Midson Group, Inc. and Jason Sheuring Porcelain Enamel Institute, Inc. Colorado School of