Standards For Aluminium Sand and Permanent Die Casting [PDF]

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Standards for Aluminum 18 Sand and Permanent Mold Castings

Standards for Aluminum Sand and Permanent Mold Castings 15th Edition 2008

Standards For Aluminum Sand and Permanent Mold Castings

PREFACE

THE ALUMINUM ASSOCIATION CASTING STANDARDS PROGRAM

Aluminum permanent mold and sand castings are widely used in all types of applications due to aluminum’s exceptional characteristics and the great design flexibility inherent in these two casting processes. Historically, foundries each used their own individual standards covering the various aspects of permanent mold and sand castings. As new techniques and molding materials became available, they also contributed to further variations. The variations in that information, along with the lack of data in many areas, indicated the need for reliable and realistic criteria to which castings could be consistently produced. These criteria would provide all persons involved in the procurement of castings with an instrument by which they could expect foundries to base proposals and produce castings to a specific quality level. Therefore, The Aluminum Association, as a service to the customers of the industry, prepared this guide for designers, engineers, buyers and production personnel as to the most economical use of the permanent mold and sand casting processes. This guide has two chapters each of which contains a series of product standards: E Series, Engineering Standards and M Series, Metallurgical Standards and Data. Dimensions, tolerances and other quantities expressed in both U.S. customary and Metric units in these standards are not necessarily identical due to rounding practices used by the committee. These Product Standards are not intended to be limiting in any way but rather they are expected to provide a measure of optimum conditions for the most economical use of the processes included and to provide consistency in terminology and definition, thereby resulting in a better understanding between supplier and user. The use of these standards by any member or nonmember of The Aluminum Association is voluntary and issuance or existence of these standards does not in any respect prevent or restrict any member or nonmember from manufacturing or supplying products not in conformance with these standards. As all published material is subject to change as new experience is gained, it is suggested that the data contained herein be verified with The Aluminum Association if there is any doubt as to their current validity.

FIFTEENTH EDITION JULY 2008 This issue supersedes all prior issues. © Copyright 2008, The Aluminum Association, Inc. Unauthorized reproduction by photocopy or any other method is illegal.

1-1

Standards For Aluminum Sand and Permanent Mold Castings

INDEX



CHAPTER 1, ENGINEERING SERIES (E)

Page

E-1

LINEAR TOLERANCES—One Side of Parting Line

1-4

E-2

LINEAR TOLERANCES—Across Parting Line

1-5

E-3

LINEAR TOLERANCES—Cored Areas; Sand and Moving Parts

1-6

E-4

DRAFT REQUIREMENTS AND INTERPRETATION

1-7

E-5

FLATNESS—STRAIGHTNESS

1-9

E-6

HOLES AND POCKETS—Sand Cast

1-10

E-7

HOLES AND POCKETS—Permanent Mold

1-11

E-8

PROFILE TOLERANCE

1-12

E-9

EJECTOR PIN MARKS

1-15

E-10 FLASH REMOVAL—Snagging, Grinding, Removal of P/L,   Chill Marks, Gates and Risers

1-16

E-11

ANGULARITY - PERPENDICULARITY - PARALLELISM

1-17

E-12

CONCENTRICITY

1-21

E-13

MACHINE FINISH ALLOWANCE

1-24

E-14

POSITIONAL TOLERANCE

1-25

E-15

WALLS, FILLETS & RIBS

1-27

E-16

LETTERING

1-28

E-17 E-18

CAST SURFACE SMOOTHNESS

1-30

E-19

METAL THICKNESS

1-31

E-20

DATUMS - TARGET POINTS - LINES

1-32

E-21

PRODUCT REQUIREMENT FORM

1-36



CHAPTER 2, METALLURGICAL SERIES (M)

M-1

ALLOY CROSS REFERENCE CHARTS

2-2

M-2

CHEMICAL COMPOSITION LIMITS

2-3

M-3

MECHANICAL PROPERTY LIMITS

2-4

M-4

CHARACTERISTICS OF ALUMINUM ALLOYS

2-6

M-5

ALUMINUM CASTING QUALITY STANDARD

2-8

M-6

RADIOGRAPHY

2-11

M-7

PENETRANT AND OTHER INSPECTION TECHNIQUES

2-13

M-8

IMPREGNATION OF CASTINGS

2-14

M-9

WELDING OF CASTINGS

2-15

M-10

TYPICAL PHYSICAL PROPERTIES

2-16

M-11

RECOMMENDED HEAT TREATMENTS

2-17



APPENDIX 1 - ALLOY REGISTRATION

2-21



APPENDIX 2 - TEMPER REGISTRATION

2-22

This index lists all Standards currently planned. Standards not now included will be issued as approved. Symbols used on drawings are shown at left and conform to ANSI Y14.5 M—1982 (R1989) 1-2

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) INTRODUCTION

Permanent mold and sand castings can be produced with a variety of surface finishes, dimensional precision, finish allowances and drafts. The flexibility of these forms of castings give the engineer and manufacturer wide latitude in design to meet specific requirements. The Engineering Series is established for the individual requirements involved in producing a usable, unmachined casting consistent with normal production practices, reproducibility, reasonable mold or pattern life and maintenance costs, normal inspection, packing and shipping procedures. Special requirements for finish, tolerances, etc., beyond the standard may be specified where required although additional costs may be involved. Consultation with the foundry will usually result in such requirements being properly considered in the quotation and mutually understood. Conversely, more liberal values should be indicated where acceptable since they tend to keep costs to a minimum. These Engineering Standards are not designed to reduce quality level, lessen competition, restrict customer requirements or increase costs. On the contrary, for the types of castings to which they may be applied, the program will improve understanding of quality levels, widen the area of available sources of supply, increase the customer’s ability to distinguish special requirements, and reduce costs by eliminating the specification of unnecessary rigid limits where they are not required.

1-3

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E1* LINEAR TOLERANCES — One Side of Parting Line

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

TOLERANCE, in., mm Sand Casting*

Permanent Mold

in.

mm

Fully machined mold cavities mm in.

in.

mm

in.

mm

Basic Tolerance up thru

6

152

± .030

± 0.76

Basic Tolerance up thru

1

25

± .015

± 0.38

Additional Tolerance for each additional inch over

6

152

± .002

± 0.051

Additional Tolerance for each additional

1

25

± .002

± 0.051

*Calculated for castings produced from mounted wood or metal matchplate pattern equipment. NOTE: The tolerances shown above must be modified when dimensions are affected by a parting line, cores and/or moving mold parts. See E2 and E3.

DRAFT: A dimension pertaining to a surface requiring draft is measured at one point on that surface only. Draft will increase or decrease such dimensions as indicated in E4. STARTING DIMENSIONS: The points or planes from which inspection and/or machining layouts are started, should be indicated on the drawing by symbol or other means. Such designation tends to control the accumulation of tolerances, in addition to the prime purpose of establishing a common location from which to work. The points on which the casting rests for inspection should be located close to its extremities to minimize variations in alignment. See E20 for details.

1-4

*Formerly AA-CS-E1-92 in previous editions

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E2* LINEAR TOLERANCES— Across Parting Line

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

Parting line tolerances must be added to the linear tolerances, indicated in E1, on all dimensions which cross the parting line of the casting. The tolerances in E1 reflect only the variations caused by expansion and contraction of the mold itself, the metal during solidification, patternmaking tolerances and vibration of the pattern during its removal from the mold. Dimensions crossing a parting line are affected by all of these, plus the hydrostatic pressure of the fluid metal, which acts as a hydraulic fluid in a cylinder, attempting to force the mold halves apart and, in sand, the tendency of the top half of the mold to ‘sag’ from its own weight. The amount of additional variation across the parting line therefore, is related to the ‘projected area’ of the casting at the parting line and the values shown below must be added to the tolerances listed in E1 on dimensions crossing the parting line. For multiple cavity molds the projected area will be the area of the mold occupied by the cavities including the area between the cavities. E2 dimensions parallel to the parting plane, as well as those which are perpendicular, are affected if the surfaces are on opposite sides of the parting line.

(E2) ADDITIONAL TOLERANCE, in., mm Projected Area in.2

cm2

in.2

cm2

Sand Casting

Permanent Mold

in.

mm

in.

mm

± .020

± 0.50

± .010

± 0.25

Up thru

10

65

Over

10

65

thru 50

320

± .035

± 0.90

± .015

± 0.38

Over

50

320

thru 100

650

± .045

± 1.10

± .020

± 0.50

Over

100

650

thru 250

1600

± .060

± 1.50

± .025

± 0.60

Over

250

1600

thru 500

3200

± .090

± 2.30

± .030

± 0.80

For over 500 in.2 (3200 cm2) of projected area, consult foundry. Additional tolerances, in the case of cores or moving mold parts, are shown in Standard E3.

*Formerly AA-CS-E2-92 in previous editions

1-5

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E3* LINEAR TOLERANCES—Cored Areas; Sand and Moving Parts

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

The use of sand and/or metal cores broaden the design flexibility of sand and permanent mold castings by allowing a hole or undercut to be produced in a surface of a casting perpendicular to the parting plane. Since these cores are separate from the sand or metal mold there must be a clearance allowance for placement or movement. Such allowances create an added variation in dimensions of a surface produced by the core to a surface produced by the mold. The amount of this additional tolerance is governed by the projected area of the core.

ADDITIONAL TOLERANCE, in., mm Projected Area in.2

cm2

in.2

cm2

Sand Mold Sand Core

PM to Sand Core

PM to Metal Core

in.

mm

in.

mm

in.

mm

± .020

± 0.50

± .015

± 0.38

± .010

± 0.25

Up thru

10

65

Over

10

65

thru

50

320

± .035

± 0.90

± .025

± 0.60

± .015

± 0.38

Over

50

320

thru

100

650

± .045

± 1.10

± .030

± 0.80

+ .015

± 0.38

Over

100

650

thru

250

1600

± .060

± 1.50

± .040

± 1.00

+ .022

± 0.60

Over

250

1600

thru

1000

6500

± .090

± 2.30

± .060

± 1.50

+ .032

± 0.80

For over 1000 in.2 (6500 cm2) of projected area, consult foundry. NOTE: The above tolerances are to be added to those determined for a dimension as provided in Standards E1 and E2. Dimensions wholly within the area of a single core need not have this tolerance added; linear tolerance, only, would apply.

1-6

*Formerly AA-CS-E3-92 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E4* DRAFT REQUIREMENTS Page 1 of 2

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing. The molding process, the overall casting size and configuration need also be considered when specifying draft requirements.

All walls on castings that are perpendicular to the parting plane require draft or taper. This draft is not constant. It will vary with the length of draw (L). See sketches below and graph on Page 2 which applies to all surfaces except cored holes and pockets.

Fig. 1

Fig. 2

Normally the drawing does not show draft (Figure 1). Standard foundry practice is to ‘add’ draft to the part. To avoid misunderstanding, this is synonymous with saying it will add metal to the casting, thereby increasing its size and weight. Draft “d” will be ‘added’ to “A”, increasing its size to “A1”. Note that ‘added’ draft affects dimension “B” by decreasing its size to “B1”. This is shown in Figure 2.

Fig. 3

Fig. 4

Draft may be ‘removed’ if desired but must be specified on drawing, as shown in Figure 3. In holes, draft will be ‘added’ to “a” decreasing its size to “a1”; see Figure 4. When the designer desires a hole dimension to become larger for reasons such as clearance, he should so indicate.

Fig. 5

Fig. 6

The ‘direction’ in which draft is applied is governed by the location of the parting line and will be at the foundry’s option unless otherwise specified; see Figure 5. When a parting line interrupts a surface to which draft is applied, the amount of draft to be added will be determined by the longer portion of surface to be drawn. Drafts will be applied to the remainder of the surface to provide a match at the parting line; see Figure 6. *Formerly AA-CS-E4-92 in previous editions

1-7

ENGINEERING SERIES (E) E4* DRAFT REQUIREMENTS Page 2 of 2

NOTE: Figures shown in degrees are recommended angular draft for a given length of draw.

Standards For Aluminum Sand and Permanent Mold Castings

1-8

*Formerly AA-CS-E4-92 in previous editions

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E5* FLATNESS-

  STRAIGHTNESS-

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

FLATNESS: Flatness is that condition which exists when all points on a surface lie in the same plane. The surfaces of castings can be measured for flatness by supporting the surface in question on three widely separated points to establish the basic plane. The flatness variation is the deviation from that plane as measured by mutually accepted methods. FLATNESS TOLERANCE: A flatness tolerance is that total deviation permitted from a plane and consists of the distance between two parallel planes within which the entire surface so toleranced must lie.

Greatest Dimension in.

Permanent Mold Tolerance mm

in.

mm

Sand Tolerance in.

mm

0 thru

6

150

within 0.020

within 0.50

within 0.030

within 0.80

each additional

1 thru 24

25 thru 600

0.003 per inch

0.08 per 25 mm

0.003 per inch

0.08 per 25 mm

For castings over 24 inches (600 mm), consult foundry. Checking for flatness will be performed only on those surfaces specified. On castings of such configuration and/or alloy where it becomes impossible or impractical to straighten, exceptions to the above tolerances are required. In such cases the foundry should be consulted. Tolerances closer than the above can at times be obtained. Special gauges and fixtures requiring extra costs may be needed. STRAIGHTNESS: Straightness is that condition which, when matched with a true straight edge of a true flat surface, will permit full line contact along the full length. Tolerance should be discussed with foundry.

*Formerly AA-CS-E5-92 in previous editions

1-9

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E6* HOLES AND POCKETS—SAND CAST

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

Holes and pockets in sand castings may be produced either by incorporation as integral features of the pattern equipment (provided size limitations, draft requirements and direction of draw are satisfactory), or by insertion of separately made sand cores. These sand cores will give a flexibility of design to the pattern equipment (see figure above), but generally at a higher production cost. The limiting factors in casting holes and pockets are depth, degree of draft and the narrowest dimension across the hole. The table below lists limiting sizes, depths and drafts for holes as produced with or without separate sand cores. Note that as in the above figure, “a” refers to the shortest dimension across the base of the hole or pocket.

in. 0.25

mm 6

‘a’ Base—Hole diameter or Minimum dimension of recess in., mm in. mm in. mm in. mm 0.50 12 1.0 25 2.0 50

in. 4.0

mm 100

12 0.75 19 1.50 38 2.0 12 2.0 50 4.0 100 8.0 ‘d’ Draft Required Per Side, Deg. 10 10 10 7 7 5 Same as Standard E4 for Sand Castings

50 200

‘L’ Maximum Depth, in., mm

1-10

Sand Mold Sand Core

Solid Solid

Solid Solid

0.50 0.50

Sand Mold Sand Core

— —

— —

10

*Formerly AA-CS-E6-2000 in previous editions

5

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E7* HOLES AND POCKETS—PERMANENT MOLD

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

Holes and pockets in permanent mold castings are preferably produced by steel cores which are so incorporated in the mold design that they can be withdrawn manually or mechanically during the casting cycle. Such cores require draft for withdrawal. Sand cores may be used where normal draft cannot be tolerated, or where internal chambers are required which do not permit withdrawal of steel cores. Thus modified, the process is known as “Semi-permanent” mold. In special circumstances steel cores may be collapsed and removed in sections to accomplish a similar result. Loose pieces can be used to form undercuts or provide non-drafted surfaces. In such cases consultation with the foundry is advisable. The table below gives desired values for core depths and drafts in relation to diameters.

in. 0.25

mm 6.0

Base—Hole diameter or Minimum dimension of recess in., mm in. mm in. mm in. mm 0.50 12.0 1.00 25.0 2.00 50.0

Permanent Core Sand Core

0.25 Solid

6 Solid

1.0 0.50

Permanent Core Sand Core

10 —

10 —

7

*Formerly AA-CS-E7-2000 in previous editions

in. 4.00

Maximum Depth, in., mm 25 2.0 50 4.0 100 8.0 12 2.0 50 4.0 100 8.0 Draft Required Per Side, Deg. 7 5 5 3 3 3 Same as Standard E4 for Sand Castings

mm 100.0 200 200 3

1-11

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E)



E8* PROFILE TOLERANCES Page 1 of 3

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

A profile is the outline of an object in a given plane. Profiles are formed by projecting a three-dimensional figure onto a plane or by taking cross sections through the figure. The elements of a profile are straight lines, arcs, and other curved lines. The profile tolerance specifies the width of a uniform zone (one half on each side of the basic profile) within which the elements of the surface must lie. Where applicable, a general profile tolerance requirement may be specified in a note on the drawing. The general profile tolerance should specify the datum system (usually defined by datum target points—See AA-CS-E20-92, Page 32) from which the basic profile of the toleranced surfaces are located. (Figure 1) In determining the amount of tolerance to be specified in a general profile tolerance requirement, consideration must be given to a number of factors. The general profile tolerance should be broad enough to reflect the variations caused by expansion and contraction of the mold itself, the metal during solidification, patternmaking tolerances and vibration of the pattern during its removal. TABLE 1 shows recommended tolerance values which should be attainable between features that are contained within the same mold half. The general profile tolerance should also allow for variance in dimensions which cross the parting line. These dimensions are affected by all of the above factors plus the hydrostatic pressure of the fluid metal which acts similar to hydraulic fluid in a cylinder trying to force the mold halves apart. The amount of additional variation across the parting line, therefore, is related to the “projected area” of the casting at the parting line. For multiple cavity molds the projected area is the area of the mold occupied by the cavities including the area between the cavities. TABLE 2 shows recommended tolerance values which should be added to those found in TABLE 1 for dimensions crossing the parting line. TABLE 3 shows recommended tolerance values which should be added to those found in TABLE 1 for dimensions which include areas formed by sand or metal cores. Specific features which require a more stringent tolerance than the general profile tolerance should be toleranced separately in the appropriate views on the drawing. (Figure 2)

Figure 1 1-12

*Formerly AA-CS-E8-92 in previous editions

Figure 2

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E8* PROFILE TOLERANCES Page 2 of 3



TABLE 1: Basic Tolerance Sand Casting* *Calculated for castings produced from mounted wood or metal matchplate pattern equipment

Permanent Mold Fully machined mold cavities

Cast to size molds

Basic Tolerance up thru 6 in.

.06

Basic Tolerance up thru 1 in.

.03

.06

Basic Tolerance up thru 150 mm

1.5

Basic Tolerance up thru 25 mm

.8

1.5

.003

.005

.080

.12

Additional Tolerance for each additional inch over 6 in. Additional Tolerance for each additional 25 mm over 150 mm

.004 .10

Additional Tolerance for each additional in. Additional Tolerance for each additional 25 mm

Linear Tolerances for cm2 expressed in mm TABLE 2: Additional Tolerance for Dimensions Across Parting Line Projected Area

Sand Casting

Permanent Mold

Up thru 10 in.

.04

.02

Up thru 65 cm

1.0

.5

Over 10 thru 50 in.

.06

.03

65 thru 320 cm

1.5

.8

Over 50 thru 100 in.

.08

.04

320 thru 650 cm

2.0

1.0

Over 100 thru 250 in.

.10

.05

650 thru 1600 cm

2.5

1.2

Over 250 thru 1000 in.

.15

.07

1600 thru 6500 cm

3.8

1.8

TABLE 3: Additional Tolerance for Cored Features Projected Area

Sand Core Sand Mold

Metal Core To Perm Mold

Sand Core To Perm Mold

Up thru 10 in.

.04

.02

.03

Up thru 65 cm

1.0

.5

.8

Over 10 thru 50 in.

.05

.03

.04

65 thru 320 cm

1.2

.8

1.0

Over 50 thru 100 in.

.07

.03

.06

320 thru 650 cm

1.8

.8

1.5

Over 100 thru 250 in.

.09

.05

.08

650 thru 1600 cm

2.2

1.2

2.0

Over 250 thru 1000 in.

.13

.07

.12

1600 thru 6500 cm

3.3

1.8

3.0

*Formerly AA-CS-E8-92 in previous editions

1-13

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E)



E8* PROFILE TOLERANCES—Cored Areas; Sand and Moving Parts Page 3 of 3

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

The use of sand and/or metal cores broaden the design flexibility of sand and permanent mold castings by allowing a hole or undercut to be produced in a surface of a casting perpendicular to the parting plane. Since these cores are separate from the sand or metal mold there must be a clearance allowance for placement or movement. Such allowances create an added variation in dimensions of a surface produced by the core to a surface produced by the mold. The amount of the additional tolerance is governed by the projected area of the core.

1-14

*Formerly AA-CS-E8-92 in previous editions

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E9* EJECTOR PIN MARKS

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

EJECTOR PIN MARKS: Ejector pin marks on permanent mold castings are formed by the movable pins which eject the castings from the mold. The number, location, and size of the ejector pins required will vary with the size and complexity of the casting. LOCATION OF EJECTOR PINS: Locations shall be at the option of the foundry unless otherwise specified. Areas of possible interference should be specified on the drawing. EJECTOR PIN MARK TOLERANCES: The ejector pin marks will vary from the adjoining surface by the amount shown in the table below. Marks may be specified as raised or depressed. If so specified, the permissible variations of the marks will be the total of the given tolerance band. Ejector Pin Mark Tolerances, in., mm Projected Area in.2

Tolerance cm2

in.

mm

Up thru

50

320

± 0.020

± 0.50

Over

50 thru 100

320 thru 650

± 0.030

± 0.80

Over

100 thru 200

650 thru 1300

± 0.045

± 1.10

Over

200

1300

CONSULT FOUNDRY

EJECTOR PIN FLASH: Ejector pin marks may be surrounded by a ring of metal that may extend up to 0.060/inch (1.5 mm) in height. This metal is not be removed unless specified by the customer.

*Formerly AA-CS-E9-92 in previous editions

1-15

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E10* SNAGGING, GRINDING, REMOVAL OF P/L, CHILL MARKS, GATES AND RISERS

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

A parting line is that line on a casting caused by the junction or separation between mold sections in either sand or permanent mold. A similar line is produced at the juncture between mold sections and sand cores or moving metal parts. In addition to the parting line generally some mismatch or shift between two mold halves or mold sections is inherent with the casting process. Flash, fins and shifts will be removed and adjoining surfaces blended to the limits specified below or otherwise specified by the customer. Chill marks and vent marks normally will not be removed unless they exceed the values set forth below, or unless specified by the customer. Gates and risers will be removed to within limits indicated. Additional grinding or snagging will be performed only when specified. Minimizing the requirements for snagging and grinding will result in a more economical part. In general, less trimming will be performed on those surfaces that subsequently will be machined. In the absence of specific requirements regarding snagging and grinding, it will be considered normal to blend excess material into the casting contour within the plus values shown below.

Nonmachined Surface

Casting Weight lb.

kg

in.

mm

in.

mm

Up thru

10

5

0.031

0.80

0.063

1.60

Over

10 thru 25

5 thru 12

0.047

1.20

0.063

1.60

Over

25 thru 50

12 thru 25

0.063

1.60

0.094

2.40

Over

50 thru 100

25 thru 45

0.125

3.20

0.188

4.80

Over

100

45

CONSULT FOUNDRY

Where the casting configuration is complex, consult foundry. 1-16

Machined Surface

*Formerly AA-CS-E10-2000 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) ANGULARITY— PARALLELISM—

E11* PERPENDICULARITY— Page 1 of 4

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

The angularity (including perpendicularity & parallelism) tolerance is the total deviation between two planes within which the entire surface, so toleranced, must lie. The planes of deviation (tolerance zone) forms the basic angle to the datum plane which is expressed by the symbol

The tolerances indicated (Page 2 & Page 3) are for those surfaces or planes that are normally considered to be free of any draft requirements. Engineering Standard E-5, Flatness and Straightness, tolerances must be considered in establishing planes, and must be added to the above. ANGULARITY: Angularity refers to the angular departure from the designed relationship between the elements of a casting. The angular accuracy is affected by numerous factors including the size of the casting, the strength and rigidity of the mold and mold parts under conditions of high temperature, positioning of mold members, distortion during handling, and heat treating the casting. The angularity of cored holes may vary as a result of distortion and wear of metal cores and wear of core boxes. This standard may be applied to plane surfaces of, or cored holes in, permanent mold or sand castings. Where applicable, consideration of E4, Draft Requirements, and E5, Flatness and Straightness, is required in their effect on angularity tolerances.

*Formerly AA-CS-E11-92 in previous editions

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Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E11* PERPENDICULARITY— Page 2 of 4

ANGULARITY— PARALLELISM—

PLANE SURFACES: Tolerances required vary with the length of the casting surface and the relative location of the surface in the mold cavity. All tolerances in inches are Total Indicator Reading (T.I.R.) in inches. All tolerances in metric are Full Indicator Movement (F.I.M.) in millimeters. PM in. mm

in.

Sand mm

in.

mm

Surfaces in fixed relationship in same mold section or member. Surface length up thru

3

75

0.020

0.50 0.045 1.10

Additional tolerance per length in excess of

1 3

25 75

0.002

0.05 0.003 0.08

Surface length up thru

3

75

0.025

0.60 0.060 1.50

Additional tolerance per length in excess of

1 3

25 75

0.0025 0.65 0.005 0.12

Surface length up thru

3

75

0.025

Additional tolerance per length in excess of

1 3

25 75

0.0025 0.065 0.005 0.12

Surface length up thru

3

75

0.030

0.80 0.075 1.90

Additional tolerance per length in excess of

1 3

25 75

0.003

0.08 0.006 0.15

Surface formed across a parting line.

PERMANENT MOLD: One surface formed by a mold section, and the other surface by a moving mold member in the same mold section SAND: One surface formed by a mold section, and the other surface by a core set in the same mold section. 0.60 0.060 1.50

PERMANENT MOLD: One surface formed by a mold section, and the other surface by a moving mold member located across the parting line, or surfaces formed by two moving mold members in the same mold section. SAND: One surface formed by a mold section, and the other surface by a core located across the parting line, or surfaces formed by two cores in the same mold section.

For Angularity Tolerances for Cored Holes, see page 19. 1-18

*Formerly AA-CS-E11-92 in previous editions

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E11* PERPENDICULARITY— Page 3 of 4

ANGULARITY— PARALLELISM—

CORED HOLES: The alignment tolerances are applicable only when proportions of the cored holes conform to the diameter-to-depth ratios and draft requirements of Engineering Standards E6 and E7. The values shown refer to deviation from the normal axis of the cored hole. In some instances additional angularity tolerance will be necessary if the measuring methods used involve Engineering Standard E5, Flatness. ANGULARITY TOLERANCES—(DEVIATION FROM NORMAL AXIS, in., mm)—CORED HOLES in.

Permanent Mold mm

Sand

in.

mm

Tolerance for hole depth up thru

3

75

0.020

0.50

0.030

0.80

Tolerance for hole depth greater than

3

75

0.020 plus 0.005 per in. of depth over 3 in.

0.50 plus 0.12 per 25 mm of depth over 75 mm

0.030 plus 0.007 per in. of depth over 3 in.

0.8 mm plus 0.18 mm per 25 mm of depth over 75 mm

*Formerly AA-CS-E11-92 in previous editions

in.

mm

1-19

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) ANGULARITY— PARALLELISM—

E11* PERPENDICULARITY— Page 4 of 4

HOW TO APPLY THIS STANDARD: In the examples shown below, permanent mold tolerances have been used. For sand castings tolerance is applied in the same manner. 1.  Surfaces in fixed relationship: Surface B and the datum plane are formed by the same mold section. If surface B is 5 in. (125 mm) long, it will be parallel to the datum plane within 0.024 inch (0.6 mm) (e.g., 0.020 inch for the first 3 in. + 2 × 0.002 [0.50 mm for the first 75 mm + 2 × .050]). 2. Surfaces formed by mold surfaces across parting line: Surface B and the datum plane are formed in opposite mold sections. If surface B is 7 in. (175 mm) long, it will be parallel to the datum plane within 0.035 inch (0.9 mm) (e.g., 0.025 inch for the first 3 in. + 4 × 0.0025 [0.6 mm for the first 75 mm + 4 × .065]). 3. One surface formed by a mold section, and the other by a moving mold member in the same mold section: Surface B is formed by a moving mold member in the same mold section as the datum plane. If surface B is 5 in. (125 mm) long, it will be perpendicular to the datum plane within 0.030 inch (0.7 mm) (e.g., 0.025 for the first 3 in. + 2 × 0.0025 [0.6 mm for the first 75 mm + 2 × .065]). 4. One surface formed by a mold section, and the other by a moving mold member located across the parting line; or surfaces formed by two moving mold members. Surface B is formed by a moving mold member and the datum plane is formed by the opposite mold section. If surface B is 5 in. (125 mm) long, it will be perpendicular to the datum plane within 0.036" (1.0 mm) (e.g., 0.030 for the first 3 in. + 2 × 0.003 [0.6 mm for the first 75 mm + 2 × .080]). Surfaces B and C are formed by two moving mold members. If surface B is used as the datum plane and surface C is 5 in. (125 mm) long, surface C will be parallel to the datum plane within 0.036 inch (1.0 mm) (e.g., 0.030 inch for the first 3 in. + 2 × 0.003 [0.8 mm for the first 75 mm + 2 × .080]).

1-20

*Formerly AA-CS-E11-92 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E12* CONCENTRICITY—



Page 1 of 3

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

Concentricity is the relative position of two or more cylindrical surfaces in respect to a common axis. Concentricity tolerance is one half the difference in the diameters of a cylindrical tolerance zone about which axis the feature so toleranced must lie and is expressed    See figure below. Concentricity requirements in inches are usually expressed as “Total Indicator Readings” (T.I.R.). Concentricity requirements in metric are always expressed as “Full Indicator Movement” (F.I.M.).

*Formerly AA-CS-E12-92 in previous editions

1-21

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E12*

CONCENTRICITY—



Page 2 of 3

Concentricity of cylindrical surfaces is affected by the design of the casting. Factors involved include the size, wall thickness, shape and complexity of the casting. APPLICABILITY OF STANDARD: This standard applies to castings having maximum rigidity and uniformity of shape and wall thickness. Under these conditions castings may be slightly out-of-round but this ovality is included in the concentricity tolerances. NOTE: Castings containing inserts are not covered by this standard. Concentricity tolerances will only apply when specified on drawing.

TOLERANCE FOR CONCENTRICITY OF CAST SURFACES: Concentricity of cast surfaces is affected by the type of mold or pattern construction. These include surfaces in fixed relationship (formed by one mold member), by opposite mold sections, by auxiliary mold members such as slides and cores, or combinations of these. All tolerances in inches are Total Indicator Reading (T.I.R.). All tolerances in metric are Full Indicator Movement (F.I.M.). BASIC TOLERANCES, in., mm Diameter of Largest Surface (A) in.

mm

5 or less

125 or less

Over 5 add

Over 125 add

Tolerance, T.I.R., F.I.M. PM

Sand

in.

mm

in.

mm

.025

0.60

.050

1.20

.003

0.08

.005

0.12

per addt’l in. or 25 mm

ADDITIONAL TOLERANCE— ADD TO BASIC TOLERANCE *Projected Area (C) Additional Over of Casting Basic Tolerance PM sq. in.

sq. cm

Less than 50

Less than 320

.025

0.60 .045 1.10

50 thru 100

320 thru 650

.030

0.80 .050 1.20

.035

0.90 .065 1.70

Over 200 thru 300 Over 1300 thru 1900 .045

1.10 .080 2.00

Over 100 trhu 200 Over 650 thru 1300

in.

mm

Sand in.

mm

ADDITIONAL TOLERANCE—ADD TO BASIC TOLERANCE—EACH MOLD MEMBER *Projected Area (C, D) Additional Over of Moving Member Basic Tolerance sq. in.

1-22

*Formerly AA-CS-E12-92 in previous editions

sq. cm

in.

PM mm

Sand in. mm

Less than 10

Less than 60

.015 0.38 .030 0.80

10 thru 20

60 thru 130

.020 0.50 .040 1.00

Over 20 thru 50

Over 130 thru 320

.030 0.80 .050 1.20

Over 50 thru 100

Over 320 thru 650

.040 1.00 .060 1.50

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E12*

CONCENTRICITY—



Page 3 of 3

CONCENTRICITY TOLERANCES: How to apply this standard. Example below is for permanent mold casting. 1.  Basic Tolerances—Surfaces in fixed mold relationship: Cylindrical surfaces A and B are formed by the same mold section. If diameter A is 7 in. (175 mm) and diameter B is 4 in. (100 mm), diameter A will be concentric with diameter B within .031 in. T.I.R. (8 mm F.I.M.) (e.g., .025 in. + (2 × .003) = .031 in. [.6 mm for the first 125 mm + (2 × .080)]). 2.  Surfaces formed by opposite mold sections: Diameters A and B are formed by opposite mold halves. If the projected area C of the casting is 10 × 15 in. or 150 sq. in. (1000 cm2), cylindrical surface A is 8 in. (200 mm) in diameter and cylindrical surface B is 6 in. (150 mm) in diameter, diameter A will be concentric with diameter B within .069 in. T.I.R. (1.7 mm F.I.M.).

Projected area allowance .035 in. + basic tolerance [.025 in. + (3 × .003)] = .069 in. Projected area allowance .9 mm + basic tolerance [.6 mm + (3 × .080)] = 1.70 mm

3.  Surfaces formed by two moving mold members: Diameters A and B are formed by moving mold members. If diameter A is 5 in. (125 mm) and diameter B is 2 in. (50 mm), projected area of member C is 25 sq. in. (160 cm2) and projected area of mold member D is 12 sq. in. (75 cm2), diameter A will be concentric with diameter B within .075 in. T.I.R. (1.9 mm F.I.M.).

Basic tolerance for 5 in. (125 mm) diameter – .025............................ .025 in. Projected area allowance for member C (25 sq2 or 160 cm2)............. .030 in. Projected area allowance for member D (12 sq2 or 75 cm2)............... .020 in.

0.60 mm 0.80 mm 0.50 mm



Total..................................................................................................... .075 in.

1.90 mm

*Formerly AA-CS-E12-92 in previous editions

1-23

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E13* MACHINE FINISH ALLOWANCE

Drawings furnished for the manufacture of castings usually picture the finished part after machining or the casting prior to machining. CASTING DRAWINGS: Drawings showing the casting prior to machining should have the finish allowance indicated in table included in the dimensions shown and no finish symbols added. It is recommended that an undimensioned phantom line be used to represent surfaces after machining, thus enabling the foundry to recognize them for processing reference.

FINISHED PART DRAWINGS: The symbols which follow represent those most commonly used on finished part drawings to indicate those surfaces requiring allowance for subsequent machine operations. Generally, only surfaces so marked will have such allowance added.

CAUTION: Confusion arises when the tolerances on the decimal dimensions specified for a surface cannot be held without machining, yet no finish symbol is shown on the surface. It is recommended that the designer’s intent be clearly indicated to avoid costly misunderstandings. Following is a table showing the amount of metal normally added for machining. The amount of material to be added is related to the overall size of the casting rather than varying with individual dimensions. The designer should select that line on the table below showing the range within which the casting’s greatest dimension falls. The finish allowance shown next to this range is then used on all surfaces requiring machining. MACHINE FINISH ALLOWANCE, in. mm Greatest Dimension

Cores in PM’s Sand

in.

mm

Sand

Shell

Permanent Mold

in.

mm

in.

mm

in.

mm

in.

mm

Up thru 6

150

.060

1.50

.060

1.50

.060

1.50

.045

1.10

Over

6 thru 12

150 thru 300

.090

2.30

.090

2.30

.060

1.50

.060

1.50

Over

12 thru 18

300 thru 450

.120

3.00

.120

3.00

.090

2.30

.075

1.90

Over

18 thru 24

450 thru 600

.150

3.80

.180

4.50

.120

3.00

.090

2.30

Over

24

600

CONSULT FOUNDRY

The values given in above table are based on a maximum “build-up” or a “safety factor” for average casting variations of flatness, squareness, concentricity, etc., as well as linear tolerance. The values are minimum recommended and foundry draft when required must be added to above values.

1-24

*Formerly AA-CS-E13-92 in previous editions

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings



E14* POSITIONAL TOLERANCE Page 1 of 2

NOTE: The values shown herein represent normal production practice at the most economic level. Greater accuracy involving extra close work or care in production should be specified only when and where necessary since additional costs may be involved. Conversely, more liberal values should be indicated when acceptable, as these tend to keep costs to a minimum. Any variations in these values shall not be binding on the foundry unless accepted in writing.

A positional tolerance defines a zone within which the center, axis, or center plane of a feature of size is permitted to vary from true (theoretically exact) position. Basic dimensions establish the true position from specified datum features and between interrelated features. A positional tolerance is indicated by the position symbol, a tolerance, and appropriate datum references placed in a feature control frame. (5.2) See Figure 1.

Figure 1

Regardless of Feature Size S , where applied to the positional tolerance of circular features, requires the axis of each feature to be located within the specified positional tolerance regardless of the size of the feature. (5.3.4) Where positional tolerancing at Least Material Condition L is specified, the stated positional tolerance applies when the feature contains the least amount of material permitted by its toleranced size dimension. Specification of L further requires perfect form at L . Where the feature departs from its L size, an increase in positional tolerance is allowed, which is equal to the amount of such departure. (5.3.5) It is only when the feature (hole) is at Maximum Material Condition M that the specified positional tolerance applies. Where the actual size of the feature is larger, additional positional tolerance results. This increase of positional tolerance is equal to the difference between the specified maximum material limit of size and the actual size of the feature. (5.3.2.1) *Above as defined in ANSI Y14.5M-1982 (R1989).

*Formerly AA-CS-E14-92 in previous editions

1-25

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E14* POSITIONAL TOLERANCE Page 2 of 2



TABLE 4: Positional Tolerance Sand Positional Tolerances Required

Fully Machined in. mm

Cast to Size in. mm

in.

mm

.085

2.20

.040

1.00

.085

2.20

Additional tolerance required over basic in./in. (mm/25 mm)

.008

0.20

.005

0.12

.008

0.20

Additional for a separate core

.060

1.50

.030

0.80

.050

1.20

Additional over a parting line

.060

1.50

.045

1.10

.060

1.50

Basic tolerance up to

1-26

Permanent Mold

6" greatest dim. (1" PM)

150 mm greatest dim. (25 PM)

*Formerly AA-CS-E14-92 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E15* WALLS, FILLETS & RIBS

NOTE: The following is not to be considered an Engineering Standard but rather a guide to good casting design.

A production problem of fundamental importance to foundries is establishing a sequence of progressive solidification that will compensate for the change in unit volume as the cast shape solidifies. The designer should, wherever possible, use sections that are tapered to increase in thickness toward points accessible to feed metal. If it is necessary to join light and heavy sections, a gradual increase in thickness is most desirable. If tapered sections are not practical or the increased expense of building the pattern or mold is not warranted, a uniform section should be maintained. Intersecting surfaces forming junctions of metal thickness should be joined with fillets in order to obtain improved foundry characteristics and a more uniform distribution of stress in service.

*Formerly AA-CS-E15-92 in previous editions

1-27

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E16* LETTERING (SAND CASTING) Page 1 of 2

NOTE: The values shown herein represent normal production practices. Fine detail may involve additional costs.

Lettering, trademarks, and identification symbols may be reproduced on the surfaces of sand castings. This lettering can be added to the pattern by means of metal or plastic ribbons, spiked or glued letters, engraved inserts, by casting or stamping the information integrally to the pattern or by the use of inserted plugs that can be replaced if a change is required. RAISED LETTERS: This is the preferred method of casting lettering on a surface.

RAISED LETTERS IN A RECESS: A satisfactory alternative if raised letters on the cast surface are objectionable.

DEPRESSED LETTERS: Depressed letters are more difficult to cast legibly and are not recommended for wood patterns.

Sharp face letters will be used unless otherwise specified as this type makes a good impression in the sand and reproduces well on the casting. When lettering is to be highlighted, specify a flat face letter. Lettering should be placed on a flat surface, parallel to the parting line, with adequate space allowed (see below) and should not run into fillets or radii. Readability is reduced when placed on a curved surface or in a core.

The above illustration indicates the spacing required for 1/2 in. (12 mm) and 1/4 in. (6 mm) letters. The table below indicates the minimum width required for standard letters, in inches and millimeters. in.

mm

in.

mm

in.

mm

in.

mm

in.

mm

in.

mm

0.125

3

0.188

5

0.25

6

0.31

6

0.38

10

0.50

12

Min. Width 10 Letters 1.44

36

1.94

50

2.38

60

2.88

75

3.38

85

4.25

110

Height

0.8

0.047

1.2

0.047

1.2

0.047

1.2

0.063

1.6

0.078

2.0

*Size

0.031

All dimensions in inches and millimeters. *Minimum sizes: Raised—1/8 in. (3 mm) minimum with 1/4 in. (6 mm) preferred. Depressed—3/16 in. (5 mm) minimum with 5/16 in. (8 mm) preferred. 1-28

*Formerly AA-CS-E16-2000 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E16* LETTERING (PERMANENT MOLD) Page 2 of 2

NOTE: The values shown herein represent normal production practices. Fine detail may involve additional costs.

Lettering, trademarks, and identification symbols may be reproduced on the surfaces of permanent mold castings by stamping or engraving the mold. Letters can be incorporated integrally on the surface of the mold or as an inserted plug that can be replaced if a change is required. RAISED LETTERS: This is the preferred method of casting lettering on a surface. It is the least expensive to incorporate into the mold and requires minimum maintenance.

RAISED LETTERS IN A RECESS: A satisfactory alternative if raised letters on the cast surface are objectionable. This requires additional work on the mold.

DEPRESSED LETTERS: Depressed letters should be avoided. They increase mold costs as they must be raised on the mold surface. In addition, maintenance costs are increased since this type of lettering is more subject to wear and damage.

Flat face letters will be used unless otherwise specified. Lettering should be located on a flat surface, parallel to the parting line, with adequate space allowed and should not run into fillets or radii.

SIZE—Raised—0.156 in. (4 mm) minimum; Depressed—0.25 in. (6 mm) minimum LINE—.015 in. (0.40 mm) minimum HEIGHT—0.15 in. (4 mm) minimum but shall not exceed the line FLANK ANGLE—20 deg. minimum All dimensions in inches and millimeters.

*Formerly AA-CS-E16-2000 in previous editions

1-29

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E18* CAST SURFACE SMOOTHNESS 

Cast surface smoothness depends on the molding process used. Ranges of smoothness normally obtained by the three processes—sand, permanent mold, and shell—are shown in the figure below. Values shown apply to major portion of the casting surfaces. Areas of gating, risering, fillets, and parting lines are not included. The surface smoothness required shall be expressed by a numerical surface “roughness-height-rating” (RHR) in microinches and in microns adjacent to and at left of long leg: for example 300

7 .5

The value of the number is maximum as specified and indicates the maximum permissible sustained height rating. Any lesser rating is acceptable. A microinch is one millionth (0.000001) of an inch. A micron is one millionth (0.000001) of a meter. It is the designer’s responsibility to differentiate clearly between those surfaces on which he wants to specify “machine finish” and those surfaces on which he wants to specify “as cast smoothness.” If the basic symbol XX

is used on the field of drawing, stock will be allowed for machining. When the designer’s intention is to control the function as cast smoothness of specific areas, it should be indicated in the list of drawing notes. Example:

Cast surface comparator blocks for visual and touch inspection are available. One type, shown in the figure below, may be obtained from the American Foundry Society, Inc. It is necessary, of course, that inspections be made against the actual comparator block. Microinch and micron values are recommended for designating surface smoothness ratings.

1-30

*Formerly AA-CS-E18-92 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E19* METAL THICKNESS

Many conditions and specifications affect the ability of foundries to cast to a desired metal wall thickness i.e. (1)  fluidity of alloy (2)  metallurgical quality (3)  design (4)  surface finish (5)  pattern or mold equipment The figures in the graph below show desired minimum metal thickness that should be specified for aluminum castings of minimum complexity. When metal flow is restricted, or other factors become more important, an increase in values shown may be required.

Reference to E-4 (Draft), E-15 (Fillets) and E-18 (Surface Finish) is necessary for consideration of this

Reference to E-4 (Draft), E-15 (Fillets) and E-18 (Surface Finish) is necessary for consideration of this specification.

*Formerly AA-CS-E19-92 in previous editions

1-31

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E20* DATUM IDENTIFICATION DATUM TARGET  



Page 1 of 4

A “DATUM” is a feature or a group, of features of a part, selected for use as a base from which other features or points are located within specified limits. To achieve consistency in the manner in which measurements are made in all stages of production; i.e.; pattern making, casting layout, tooling layout, etc., a system known as target points or datum lines, or datum planes has been devised. For the purpose of this standard, “target point” and “tooling point” are synonymous. This system relates all significant dimensions to a common reference (datum plane). It is strongly recommended that those points or planes from which inspection and/or machining layouts are started, be indicated on the drawing by symbol or other means. Where datum planes or target points are not indicated they shall be selected by the foundry, which will choose surfaces formed by the most stable portion of the mold. Such designations tend to control the accumulation of tolerances in addition to their prime purpose of establishing a common location from which to work. It is preferred that they be surfaces not affected by mold parting. Also, the surfaces at which gates and risers are to be placed are unsuitable as target points as a result of trimming and rough grinding operations. Target points should be avoided if possible on cored or tapered surfaces. They should be located close to the extremities of the casting whenever possible to eliminate variations in alignment due to projecting small surface irregularities. The designer of a casting, the tooling engineer and the foundry should work together in establishing target points or datum planes because they directly influence casting cost not only from tooling standpoint but also from the foundry standpoint.

Fig. 1  Schematic illustration showing the perpendicular relations among the three planes in a system

1-32

*Formerly AA-CS-E20-92 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E20* DATUM IDENTIFICATION DATUM TARGET  



Page 2 of 4

Fig. 2.  Schematic illustration of the establishment of datum planes by means of a datum target system. Dimensions for locating the datum points are omitted here

Fig. 3.  A practical illustration of Fig. 2

*Formerly AA-CS-E20-92 in previous editions

1-33

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E20* DATUM IDENTIFICATION DATUM TARGET  



Page 3 of 4

DATUM PLANE C The amount of draft must be taken into consideration when locating the “Datum Targets” on applicable surfaces

Datum targets define points, lines, or areas on a part used in establishing datum planes. To apply the threeplane concept to certain parts, specific points, lines, or areas on features are designated to establish datum planes. Datum targets may vary from the conventional three point, two point, one point target orientation to assure a fixed position of the part. Datum targets, while intended for use on parts having irregular surfaces, may be applied to any part where the design requirements dictate use of specific datum points, lines, or areas on surfaces rather than use of entire surfaces as datums.

Fig. 4.  Satisfactory method for showing datum targets and locations on drawing

1-34

*Formerly AA-CS-E20-92 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E20* DATUM IDENTIFICATION DATUM TARGET  



Page 4 of 4

V-TYPE LOCATORS: Certain designs require the use of V-type locators. These are fixture accessories used to locate radial sections relative to the theoretical center of the V-block. Figure 5 illustrates a casting whose center line location is important; because of the function for which it was intended, it is mandatory that a symmetry be maintained, within tolerances, about the center line. To satisfy this condition, a V-type locator is used as part of the fixturing and provided datum targets 1 and 2. The locator served to center the round boss “M” so that the drilled hole “G” was concentric with the surrounding wall as required. Proper location of datum target 3 positioned the casting so that the machining surface “P” would be in relation to the center line of the hole “G”.

Fig. 5.  Illustration of the use of V-type locators

*Formerly AA-CS-E20-92 in previous editions

1-35

Standards For Aluminum Sand and Permanent Mold Castings

ENGINEERING SERIES (E) E21* PRODUCT REQUIREMENT FORM Page 1 of 2

This Product Requirement Form has been prepared by the Aluminum Association for the convenience of purchasers of aluminum sand and permanent mold castings and is designed for use in conjunction with the Aluminum Association Standards for Aluminum Sand and Permanent Mold Castings. This Form is intended to achieve a higher level of understanding between supplier and purchaser and is not intended to limit or restrict casting requirements. The use of this Form by any prospective purchaser, any member of the Aluminum Association or any other supplier is voluntary and the Form is not intended to prevent any purchaser from issuing specifications which differ from those set forth in the Form or to prevent any supplier from manufacturing or selling products made to specifications which differ from the Form. The check list, on page 2, provides supplemental data on specific product requirements that affect the basis on which a casting quotation is prepared. It will be to the advantage of both the purchaser and the foundry if this check list accompanies prints submitted for quotation. The Aluminum Association or member foundries can supply check lists for this purpose. The information may also be indicated on prints by coding with the applicable requirement numbers such as A1, B2, C1, etc.

1-36

*Formerly AA-CS-E21-74 in previous editions

ENGINEERING SERIES (E)

Standards For Aluminum Sand and Permanent Mold Castings

E21* PRODUCT REQUIREMENT FORM Page 2 of 2

Customer’s name _________________________________________________________________ Date _________________ Casting Process:  Sand _______________ Permanent Mold _______________ Semi-Permanent Mold ______________ Prints Attached  h yes,   h no.   Part Number __________________________________ Rev. __________________ Is part in present production?   h yes,   h no.   Sample available? If not __________________________________ Estimated weight Anticipated total order ____________________________ Quantity per release _____________________________________ Anticipated annual requirement ________________ daily ________________ or weekly _________________ requirements Quotation due date __________________________________ Surface treatment

A

______ 1. None required. ______ 2. Blasted. ______ 3. Other requirements.

Cast surface smoothness

B

______ 1. No significant requirements. ______ 2. Per AA Standard AA-CS-E18. ______ 3. Other requirements.

Gates, risers, chill marks, P/L

C

______ 1. No specific requirement. ______ 2. Per AA Standard AA-CS-E10. ______ 3. Other requirements.

Flash removal, cored holes

D

______ 1. Not removed. ______ 2. Per AA Standard AA-CS-E10. ______ 3. Other.

_________________________

Ejector pin marks and flash pin removal P.M. only

E

______ 1. No specific requirements. ______ 2. Per AA Standard AA-CS-E9. ______ 3. Other requirements.

_________________________

Pressure tightness

F

______ 1. No requirement. ______ 2. Pressure tight to agreed upon psi, time, testing medium; repair permitted. ______ 3. Other requirements.

Flatness and straightness

G

______ 1. No requirement. ______ 2. Per AA Standard AA-CS-E5. ______ 3. Other requirements.

Dimensional tolerances

H

______ 1. No specific requirement. ______ 2. Per applicable AA Standards. ______ 3. Other requirements.

Casting quality

I

______ 1. No specific requirement. ______ 2. Per AA Standard AA-CS-M5. Quality Level _____. Frequency Level _____ ______ 3. Other requirements.

Packaging

J

______ 1. Bulk packaged. ______ 2. Layer packaged-with separators. ______ 3. Other requirements.

Welding

K

______ 1. Foundry controlled welding permitted per AA Standard AA-CS-M9. ______ 2. Special permission required to weld. ______ 3. Other requirements.

Machining

L

______ 1. Not by foundry. ______ 2. Machine in accordance with blueprint specifications ______ 3. Other requirements

Other requirements

M

______ 1. ______________________________________ ______ 2. ______________________________________ ______ 3. ______________________________________

Aluminum Alloy ___________ Temper __________________ Per AA Standard AA-CS-M2 and AA Standard AA-CS-M3 Other specifications or requirements _____________ _________________________

_________________________ _________________________

Remarks: ________________ _________________________ _________________________ _________________________

*Formerly AA-CS-E21-74 in previous editions

1-37

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) INTRODUCTION

Permanent mold and sand castings can be produced to a variety of metallurgical standards. This series is established to provide a guide for the metallurgical requirements involved in producing a casting of material and quality available within normal production procedures. These standards are in no way intended to supplant any standards that are in existence but rather to establish a common understanding between the foundry and the user. These metallurgical standards are designed to provide criteria of quality to the buyer and the foundry which will be consistent with the application of the casting. When further information is required, consultation with the foundry should establish a mutual understanding of customer requirements. However, the final designation of the material and the standards will be the responsibility of the purchaser. The data in the following pages are representative of that from separately cast test bars. Special consideration should be given to using test bars cut from castings as a determinant of casting strength or casting quality. The casting process, casting design, heat treatment and location of test specimens can produce internal properties exceeding those indicated in AA-CS-M3-2000 when required, but can also result in properties lower than indicated. Alloy designations and associated chemical composition limits conforming to the requirements of ANSI H35.1/H35.1(M) are registered with the Aluminum Association and published in the Registration Record of Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingot. Similarly, tempers for aluminum alloy products are registered with the Association and published in the Registration Record of Tempers For Aluminum and Aluminum Alloy Products, which contains registered property data that complements property data contained in these metallurgical standards. Templates for the proposed registration of new alloys and tempers are included in Appendix 1 and 2 at the end of this metallurgical section.

2-1

METALLURGICAL SERIES (M)

Standards For Aluminum Sand and Permanent Mold Castings

M1* ALLOY CROSS REFERENCE CHART

CROSS REFERENCE CHART OF COMMONLY USED SPECIFICATIONS

Former Designation

UNS

Federal (QQ-A-596) (QQ-A-601)

201.0

—

A02010

—

204.0

—

A02040

—

206.0

—

A02060

B206.0

—

208.0

108

213.0

Former SAE (J453c)

Military (MIL-A-21180)

CQ51A

382

—

—

—

—

—

—

—

—

A22060

—

—

—

—

A02080

108

CS43A

—

—

C113

A02130

113

CS74A

  33

—

222.0

122

A02220

122

CG100A

  34

—

242.0

142

A02420

142

CN42A

  39

—

295.0

195

A02950

195

C4A

  38

—

296.0

B295.0

A02960

B195

—

380

—

308.0

A108

A03080

A108

—

—

—

319.0

319, Allcast

A03190

319

SC64D

326

—

328.0

Red X-8

A03280

Red X-8

SC82A

327

—

332.0

F332.0

A03320

F132

SC103A

332

—

333.0

333

A03330

333

SC94A

331

—

336.0

A332.0

A03360

A132

SN122A

321

— C354

ANSI AA

354.0

354

A03540

—

—

—

355.0

355

A03530

355

SC51A

322

—

C355

A33550

C355

SC51B

335

C355

C355.0 356.0

356

A03560

356

SG70A

323

—

A356

A13560

A356

SG70B

336

A356

B356.0

—

A23560

—

—

—

—

357.0

357

A03570

357

—

—

—

A357

A13570

—

—

—

A357

A356.0

A357.0

2-2

Former ASTM (B26) (B108)

359.0

359

A03590

—

—

—

  359

443.0

43

A04430

—

S5B

  35

—

B443.0

43

A24430

43

S5A

—

—

A444.0

—

A14440

—

—

—

—

512.0

B514.0

A05120

B214

GS42A

—

—

513.0

A514.0

A05130

A214

GZ42A

—

—

514.0

214

A05140

214

G4A

320

—

520.0

220

A05200

220

G10A

324

—

535.0

Almag 35

A05350

Almag 35

GM70B

—

—

705.0

603, Ternalloy 5

A07050

Ternalloy 5

ZG32A

311

—

707.0

607, Ternalloy 7

A07070

Ternalloy 7

ZG42A

312

—

710.0

A712.0

A07100

A612

ZG61B

313

—

711.0

C721.0

A07110

—

ZC60A

314

—

712.0

D712.0

A07120

40E

ZG61A

310

—

713.0

613, Tenzaloy

A07130

Tenzaloy

ZC81A

315

—

771.0

Precedent 71A

A07710

Precedent 71A

—

—

—

850.0

750

A08500

750

—

—

—

851.0

A850.0

A08510

A750

—

—

—

852.0

B850.0

A08520

B750

—

—

—

*Formerly AA-CS-M1-85 in previous editions

METALLURGICAL SERIES (M)

Standards For Aluminum Sand and Permanent Mold Castings

M2* CHEMICAL COMPOSITION LIMITS

CHEMICAL COMPOSITION LIMITS FOR COMMONLY USED SAND AND PERMANENT MOLD CASTING ALLOYS a b Alloy 201.0 204.0 206.0 A206.0 208.0 222.0 242.0 295.0 296.0 308.0 319.0 328.0 332.0 333.0 336.0 354.0 355.0 C355.0 356.0 A356.0 B356.0 357.0 A357.0 359.0 443.0 B443.0 A444.0 512.0 513.0 514.0 520.0 535.0 705.0 707.0 710.0 711.0 712.0 713.0 771.0 850.0 851.0 852.0

Product S S&P S&P S&P S&P S&P S&P S P P S&P S P P P S&P S&P S&P S&P S&P S&P S&P S&P S&P S&P S&P P S P S S S&P S&P S&P S P S S&P S S&P S&P S&P

c

Silicon

Iron

Copper

0.10 0.20 0.10 0.05 2.5–3.5 2.0 0.7 0.7–1.5 2.0–3.0 5.0–6.0 5.5–6.5 7.5–8.5 8.5–10.5 8.0–10.0 11.0–13.0 8.6–9.4 4.5–5.5 4.5–5.5 6.5–7.5 6.5–7.5 6.5–7.5 6.5–7.5 6.5–7.5 8.5–9.5 4.5–6.0 4.5–6.0 6.5–7.5 1.4–2.2 0.30 0.35 0.25 0.15 0.20 0.20 0.15 0.30 0.30 0.25 0.15 0.7 2.0–3.0 0.40

0.15 0.35 0.15 0.10 1.2 1.5 1.0 1.0 1.2 1.0 1.0 1.0 1.2 1.0 1.2 0.20 0.6 d 0.20 0.6 d 0.20 0.09 0.15 0.20 0.20 0.8 0.8 0.20 0.6 0.40 0.50 0.30 0.15 0.8 0.8 0.50 0.7–1.4 0.50 1.1 0.15 0.7 0.7 0.7

4.0–5.2 4.2–5.0 4.2–5.0 4.2–5.0 3.5–4.5 9.2–10.7 3.5–4.5 4.0–5.0 4.0–5.0 4.0–5.0 3.0–4.0 1.0–2.0 2.0–4.0 3.0–4.0 0.50–1.5 1.6–2.0 1.0–1.5 1.0–1.5 0.25 0.20 0.05 0.05 0.20 0.20 0.6 0.15 0.10 0.35 0.10 0.15 0.25 0.05 0.20 0.20 0.35–0.65 0.35–0.65 0.25 0.40–1.0 0.10 0.7–1.3 0.7–1.3 1.7–2.3

Manganese Magnesium Chromium 0.20–0.50 0.10 0.20–0.50 0.20–0.50 0.50 0.50 0.35 0.35 0.35 0.50 0.50 0.20–0.6 0.50 0.50 0.35 0.10 0.50 d 0.10 0.35 d 0.10 0.05 0.03 0.10 0.10 0.50 0.35 0.10 0.8 0.30 0.35 0.15 0.10–0.25 0.40–0.6 0.40–0.6 0.05 0.05 0.10 0.6 0.10 0.10 0.10 0.10

0.15–0.55 0.15–0.35 0.15–0.35 0.15–0.35 0.10 0.15–0.35 1.2–1.8 0.03 0.05 0.10 0.10 0.20–0.6 0.50–1.5 0.05–0.50 0.7–1.3 0.40–0.6 0.40–0.6 0.40–0.6 0.20–0.45 0.25–0.45 0.25–0.45 0.45–0.6 0.40–0.7 0.50–0.7 0.05 0.05 0.05 3.5–4.5 3.5–4.5 3.5–4.5 9.5–10.6 6.2–7.5 1.4–1.8 1.8–2.4 0.6–0.8 0.25–0.45 0.50–0.65 0.20–0.50 0.8–1.0 0.10 0.10 0.6–0.9

— — — — — — 0.25 — — — — 0.35 — — — — 0.25 — — — — — — — 0.25 — — 0.25 — — — — 0.20–0.40 0.20–0.40 — — 0.40–0.6 0.35 0.06–0.20 — — —

Nickel

Zinc

Titanium

— 0.05 0.05 0.05 0.35 0.50 1.7–2.3 — 0.35 — 0.35 0.25 0.50 0.50 2.0–3.0 — — — — — — — — — — — — — — — — — — — — — — 0.15 — 0.7–1.3 0.30–0.7 0.9–1.5

— 0.10 0.10 0.10 1.0 0.8 0.35 0.35 0.50 1.0 1.0 1.5 1.0 1.0 0.35 0.10 0.35 0.10 0.35 0.10 0.05 0.05 0.10 0.10 0.50 0.35 0.10 0.35 1.4–2.2 0.15 0.15 — 2.7–3.3 4.0–4.5 6.0–7.0 6.0–7.0 5.0–6.5 7.0–8.0 6.5–7.5 — — —

0.15–0.35 0.15–0.30 0.15–0.30 0.15–0.30 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.20 0.25 0.20 0.25 0.20 0.04–0.20 0.20 0.04–0.20 0.20 0.25 0.25 0.20 0.25 0.20 0.25 0.25 0.10–0.25 0.25 0.25 0.25 0.20 0.15–0.25 0.25 0.10–0.20 0.20 0.20 0.20

Others Each Total 0.05 0.05 0.05 0.05 — — 0.05 0.05 — — — — — — 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 — 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.10 0.05 — — —

h i

e

f

g g g

k

0.10 0.15 0.15 0.15 0.50 0.35 0.15 0.15 0.35 0.50 0.50 0.50 0.50 0.50 — 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.35 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.20 0.25 0.15 0.30 0.30 0.30

a   The alloys listed are those which have been included in Federal Specifications QQ-A-596d, ALUMINUM ALLOYS PERMANENT AND SEMI-

PERMANENT MOLD CASTINGS, QQ-A-601E, ALUMINUM ALLOY SAND CASTINGS, and Military Specification MIL-A-21180c, ALUMINUM ALLOY CASTINGS, HIGH STRENGTH. Other alloys are registered with The Aluminum Association and are available. Information on these should be requested from individual foundries or ingot suppliers. b   Except for “Aluminum” and “Others,” analysis normally is made for elements for which specific limits are shown. For purposes of determining conformance to these limits, an observed value or calculated value obtained from analysis is rounded off to the nearest unit in the last right hand place of figures used in expressing the specified limit, in accordance with the following:  When the figure next beyond the last figure or place to be retained is less than 5, the figure in the last place retained should be kept unchanged. When the figure next beyond the last figure or place to be retained is greater than 5, the figure in the last place retained should be increased by 1.  When the figure next beyond the last figure or place to be retained is 5 and  (1) there are no figures or only zeros, beyond this 5, if the figure in the last place to be retained is odd, it should be increased by 1; if even, it should be kept unchanged.  (2) if the 5 next beyond the figure in the last place to be retained is followed by any figures other than zero, the figure in the last place retained should be increased by 1; whether odd or even. c   S = Sand Cast P = Permanent Mold Cast d   If iron exceeds 0.45 percent, manganese content shall not be less than one-half the iron content. e   Also contains 0.04–0.07 percent beryllium. f   Also contains 0.003–0.007 percent beryllium, boron 0.005 percent maximum. g   Also contains 5.5–7.0 percent tin. h   Also contains 0.40–1.0 percent silver. i   Also contains 0.05 max. percent tin. k   The sum of those “Others” metallic elements 0.010 percent or more each, expressed to the second decimal before determining the sum.

*Formerly AA-CS-M2-84 in previous editions

2-3

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M3* MECHANICAL LIMITS Page 1 of 2

MECHANICAL PROPERTY LIMITS FOR COMMONLY USED ALUMINUM SAND CASTING ALLOYS 1

Alloy

Temper 2

201.0 204.0 206.0 A206.0 208.0 222.0 222.0 242.0 242.0 242.0 242.0 295.0 295.0 295.0 295.0 319.0 319.0 319.0 328.0 328.0 355.0 355.0 355.0 355.0 C355.0 356.0 356.0 356.0 356.0 356.0 A356.0 B356.0 357.0 A357.0 359.0 443.0 B433.0 512.0 514.0 520.0 535.0 705.0 707.0 707.0 710.0 712.0 713.0 771.0 771.0 771.0 771.0 771.0 771.0 850.0 851.0 852.0

T7 T4 — — F 0 T61 0 T571 T61 T77 T4 T6 T62 T7 F T5 T6 F T6 T51 T6 T7 T71 T6 F T51 T6 T7 T71 T6 — — — — F F F F T4 5 F or T5 F or T5 T5 T7 F or T5 F or T5 F or T5 T5 T51 T52 T53 T6 T71 T5 T5 T5

ksi 60.0 45.0 — — 19.0 23.0 30.0 23.0 29.0 32.0 24.0 29.0 32.0 36.0 29.0 23.0 25.0 31.0 25.0 34.0 25.0 32.0 35.0 30.0 35.0 19.0 23.0 30.0 31.0 25.0 34.0 — — — — 17.0 17.0 17.0 22.0 42.0 35.0 30.0 33.0 37.0 32.0 34.0 32.0 42.0 32.0 36.0 36.0 42.0 48.0 16.0 17.0 24.0

MINIMUM PROPERTIES Tensile Strength Ultimate Yield (0.2% Offset) ( Mpa ) ksi ( Mpa ) ( 415 ) 50.0 ( 345 ) ( 310 ) 28.0 ( 195 ) — — — — — — ( 130 ) 12.0 ( 85 ) ( 160 ) — — ( 205 ) — — ( 160 ) — — ( 200 ) — — ( 220 ) 20.0 ( 140 ) ( 165 ) 13.0 ( 90 ) ( 200 ) 13.0 ( 90 ) ( 220 ) 20.0 ( 140 ) ( 250 ) 28.0 ( 195 ) ( 200 ) 16.0 ( 110 ) ( 160 ) 13.0 ( 90 ) ( 170 ) — — ( 215 ) 20.0 ( 140 ) ( 170 ) 14.0 ( 95 ) ( 235 ) 21.0 ( 145 ) ( 170 ) 18.0 ( 125 ) ( 220 ) 20.0 ( 140 ) ( 240 ) — — ( 205 ) 22.0 ( 150 ) ( 250 ) 25.0 ( 170 ) ( 130 ) — — ( 160 ) 16.0 ( 110 ) ( 205 ) 20.0 ( 140 ) ( 215 ) 29.0 ( 200 ) ( 170 ) 18.0 ( 125 ) ( 235 ) 24.0 ( 165 ) — — — — — — — — — — — — ( 115 ) 7.0 ( 50 ) ( 115 ) 6.0 ( 40 ) ( 115 ) 10.0 ( 70 ) ( 150 ) 9.0 ( 60 ) ( 290 ) 22.0 ( 150 ) ( 240 ) 18.0 ( 125 ) ( 205 ) 17.0 ( 115 ) ( 230 ) 22.0 ( 150 ) ( 255 ) 30.0 ( 205 ) ( 220 ) 20.0 ( 140 ) ( 235 ) 25.0 ( 170 ) ( 220 ) 22.0 ( 150 ) ( 290 ) 38.0 ( 260 ) ( 220 ) 27.0 ( 165 ) ( 250 ) 30.0 ( 205 ) ( 250 ) 27.0 ( 185 ) ( 290 ) 35.0 ( 240 ) ( 330 ) 45.0 ( 310 ) ( 110 ) — — ( 115 ) — — ( 165 ) 18.0 ( 125 )

% Elongation in 2 inches or 4 times diameter

Typical Brinell Hardness 4 500 – kgf load 10 – mm ball

3.0 6.0 — — 1.5 — — — — — 1.0 6.0 3.0 — 3.0 1.5 — 1.5 1.0 1.0 — 2.0 — — 2.5 2.0 — 3.0 — 3.0 3.5 — — — — 3.0 3.0 — 6.0 12.0 9.0 5.0 2.0 1.0 2.0 4.0 3.0 1.5 3.0 1.5 1.5 5.0 2.0 5.0 3.0 —

110–140 — — — 40–70 65–95 100–130 55–85 70–100 90–120 60–90 45–75 60–90 80–110 55–85 55–85 65–95 65–95 45–75 65–95 50–80 70–105 70–100 60–95 75–105 40–70 45–75 55–90 60–90 45–75 70–105 — — — — 25–55 25–55 35–65 35–65 60–90 60–90 50–80 70–100 65–95 60–90 60–90 60–90 85–115 70–100 70–100 — 75–105 105–135 30–60 30–60 45–75

1 Values represent properties obtained from separately cast lest bars and are derived from ASTM 8-26, Standard Specification for AluminumAlloy Sand Castings; Federal Specification QQ-A-601e, Aluminum Alloy Sand Castings; and Military Specification MIL-A-21180c, Aluminum Alloy Castings, High Strength. Unless otherwise specified, the tensile strength, yield strength and elongation values of specimens cut from castings shall be not less than 75 percent of the tensile and yield strength values and not less than 25 percent of the elongation values given above. The customer should keep in mind that (1) some foundries may offer additional tempers for the above alloys, and (2) foundries are constantly improving casting techniques and, as a result, some may offer minimum properties in excess of the above. 2 F indicates “as cast” condition; refer to AA-CS-M11 for recommended times and temperatures of heat treatment for other tempers to achieve properties specified. 3 Footnote no longer in use. 4 Hardness values are given for information only; not required for acceptance. 5 The T4 temper of Alloy 520.0 is unstable; significant room temperature aging occurs within life expectancy of most castings. Elongation may decrease by as much as 80 percent.

2-4

*Formerly AA-CS-M3-2000 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M3* MECHANICAL PROPERTY LIMITS Page 2 of 2

MECHANICAL PROPERTY LIMITS FOR COMMONLY USED ALUMINUM PERMANENT MOLD CASTING ALLOYS 1

Alloy

Temper 2

204.0 208.0 208.0 208.0 222.0 222.0 242.0 242.0 298.0 308.0 319.0 319.0 332.0 333.0 333.0 333.0 333.0 336.0 336.0 354.0 354.0 355.0 355.0 355.0 355.0 355.0 C355.0 356.0 356.0 356.0 356.0 356.0 A356.0 B356.0 357.0 A357.0 359.0 359.0 443.0 B443.0 A444.0 513.0 535.0 705.0 707.0 711.0 713.0 850.0 851.0 851.0 852.0

T4 T4 T6 T7 T551 T65 T571 T61 T6 F F T6 T5 F T5 T6 T7 T551 T65 T61 T62 T51 T6 T62 T7 T71 T61 F T51 T6 T7 T71 T61 T6 T6 T61 T61 T62 F F T4 F F T5 T7 T1 T5 T5 T5 T6 T5

ksi 48.0 33.0 35.0 33.0 30.0 40.0 34.0 40.0 35.0 24.0 28.0 34.0 31.0 28.0 30.0 35.0 31.0 31.0 40.0 48.0 52.0 27.0 37.0 42.0 36.0 34.0 40.0 21.0 25.0 33.0 25.0 25.0 37.0 37.0 45.0 45.0 45.0 47.0 21.0 21.0 20.0 22.0 35.0 37.0 45.0 28.0 32.0 18.0 17.0 16.0 27.0

MINIMUM PROPERTIES Tensile Strength Ultimate Yield (0.2% Offset) ( Mpa ) ksi ( Mpa ) ( 330 ) 29.0 ( 200 ) ( 230 ) 15.0 ( 105 ) ( 240 ) 22.0 ( 150 ) ( 230 ) 16.0 ( 110 ) ( 205 ) — — ( 275 ) — — ( 230 ) — — ( 275 ) — — ( 240 ) — — ( 165 ) — — ( 195 ) 14.0 ( 95 ) ( 235 ) — — ( 215 ) — — ( 195 ) — — ( 205 ) — — ( 240 ) — — ( 215 ) — — ( 215 ) — — ( 275 ) — — ( 330 ) 37.0 ( 255 ) ( 360 ) 42.0 ( 290 ) ( 185 ) — — ( 255 ) — — ( 290 ) — — ( 250 ) — — ( 235 ) 27.0 ( 185 ) ( 275 ) 30.0 ( 205 ) ( 145 ) — — ( 170 ) — — ( 230 ) 22.0 ( 150 ) — ( 170 ) — ( 170 ) — — ( 255 ) 26.0 ( 180 ) ( 255 ) 27.0 ( 185 ) ( 310 ) — — ( 310 ) 36.0 ( 250 ) ( 310 ) 34.0 ( 235 ) ( 325 ) 38.0 ( 260 ) ( 145 ) 7.0 ( 50 ) ( 145 ) 6.0 ( 40 ) ( 140 ) — — ( 150 ) 12.0 ( 85 ) ( 240 ) 18.0 ( 125 ) ( 255 ) 17.0 ( 120 ) ( 310 ) 35.0 ( 240 ) ( 195 ) 18.0 ( 125 ) ( 220 ) 22.0 ( 150 ) ( 125 ) — — ( 115 ) — — ( 125 ) — — ( 185 ) — —

% Elongation in 2 inches or 4 times diameter

Typical Brinell Hardness 3 500 – kgf load 10 – mm ball

8.0 4.5 2.0 3.0 — — — — 2.0 2.0 1.5 2.0 — — — — — — — 3.0 2.0 — 1.5 — — — 3.0 3.0 — 3.0 3.0 3.0 5.0 7.0 3.0 3.0 4.0 3.0 2.0 2.5 20.0 2.5 8.0 10.0 3.0 7.0 4.0 8.0 3.0 8.0 3.0

— 60–90 75–105 65–95 100–130 125–155 90–120 95–125 75–105 55–85 70–100 75–105 90–120 65–100 70–106 65–115 75–105 90–120 110–140 — — 60–90 75–105 90–120 70–100 85–95 75–105 40–70 55–85 65–95 60–90 60–90 70–100 — 75–105 85–115 75–105 85–115 30–60 30–60 — 45–75 60–90 55–85 80–110 55–86 60–90 30–60 30–60 — 55–85

1 Values represent properties obtained from separately cast test bars and are derived from ASTM B-108, Standard Specification for Aluminum-Alloy Permanent Mold Castings; Federal Specification QQ-A-596d, Aluminum Alloy Permanent and Semi-Permanent Mold Castings; and Military Specification MIL-A-21180c, Aluminum Alloy Castings, High Strength. Unless otherwise specified, the average tensile strength, average yield strength and average elongation values of specimens cut from castings shall be not less than 75 percent of the tensile strength and yield values and not less than 25 percent of the elongation values given above. The customer should keep in mind that (1) some foundries may offer additional tempers for the above alloys, and (2) foundries are constantly improving casting techniques and, as a result, some may offer minimum properties in excess of the above. 2 F indicates “as cast” condition; refer to AA-CS-M11 for recommended times and temperatures of heat treatment for other tempers to achieve properties specified. 3  Hardness values are given for information only; not required for acceptance.

*Formerly AA-CS-M3-2000 in previous editions

2-5

METALLURGICAL SERIES (M)

Standards For Aluminum Sand and Permanent Mold Castings

M4* CHARACTERISTICS OF ALUMINUM ALLOYS Page 1 of 2

Selection of an alloy for a particular application requires consideration not only of mechanical properties, but also of numerous other characteristics, such as behavior in the casting process or subsequent treatments in the course of manufacture, and response to the environmental conditions of service. The following table includes several significant characteristics which deserve consideration in the selection of an alloy. The characteristics are comparatively rated from 1 to 5 in decreasing order of performance.

Alloy

Product

Fluidity

201.0 204.0 206.0 A206.0 208.0 222.0 242.0 295.0 296.0 308.0 319.0 328.0 332.0 333.0 336.0 354.0 355.0 C355.0 356.0 A356.0 B356.0 357.0 A357.0 359.0 443.0 B443.0 A444.0 512.0 513.0 514.0 520.0 535.0 705.0 707.0 710.0 711.0 712.0 713.0 771.0 850.0 851.0 852.0

S S&P S S S S&P S&P S P P S&P S P P P P S&P S&P S&P S&P S&P S&P S&P S&P S&P S&P P S P S S S S&P S&P S P S S&P S S&P S&P S&P

3 3 3 3 2 3 3 3 3 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 4 4 4 5 4 4 4 4 3 3 3 4 4 4

Strength Resisat tance Normally Elevated Corrosion Anodizing to Hot Pressure Heat TemperaResisMachinAppearCracking Tightness Treated tures tance ability Polishing ance 4 4 4 4 2 3 4 4 4 2 2 1 2 2 2 1 1 1 1 1 1 1 1 2 1 1 1 3 4 4 4 4 4 4 5 5 5 4 4 5 5 5

3 3 3 3 2 3 4 4 3 2 2 2 2 2 2 1 1 1 1 1 1 1 1 2 1 1 1 4 4 5 5 5 4 4 4 4 4 4 4 5 5 5

Yes Yes Yes Yes Optional Yes Yes Yes Yes No Optional Optional Yes Optional Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No Optional No No No Yes Optional No No No Yes No No Yes Yes Yes Yes

*Information not available.

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*Formerly AA-CS-M4-84 in previous editions

1 1 1 1 3 1 1 3 2 3 3 2 1 2 1 2 2 2 3 3 3 3 2 2 4 4 4 3 3 3 5 3 4 4 4 5 4 4 4 5 5 5

4 4 4 4 4 4 4 4 4 3 3 3 3 3 3 3 3 3 2 2 2 2 2 2 3 2 2 1 1 1 1 1 2 2 4 2 3 3 3 4 4 4

1 1 1 1 3 1 2 2 3 3 3 3 4 3 4 4 3 3 3 3 3 3 3 4 5 5 5 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 2 1 1 3 2 2 2 2 3 4 3 4 3 4 4 3 3 4 4 4 4 4 4 4 4 4 2 1 1 1 1 2 2 2 1 2 1 1 3 3 3

2 3 2 2 3 3 3 2 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 2 1 1 1 1 2 2 2 1 2 1 1 * * *

Weldability 4 4 4 4 2 3 4 3 3 2 2 1 2 3 3 3 1 1 1 1 1 1 1 1 1 1 1 3 3 3 4 4 4 4 4 4 4 4 4 5 5 5

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M4* CHARACTERISTICS OF ALUMINUM ALLOYS Page 2 of 2

Fluidity is the ability of a liquid metal to flow (into a mould). It is equivalent to “mold filling” capacity. Resistance to Hot Cracking is the property of an alloy to withstand stresses from contraction while cooling through the final (“hot short”) stage of solidification. Pressure Tightness is the absence of leakage at a specified pressure. Response to Heat Treatment is a characteristic dependent upon composition. Some of the alloys listed as “not normally heat treated” may show some improvement of properties when heat treated. Moreover, alloys listed as normally heat treated are frequently used without heat treatment if their as-cast properties are adequate for a specific application. Corrosion Resistance is the resistance of alloys to loss of volume strength and surface appearance upon exposure to various environments. The comparative ratings given here are based in general upon performance in various industrial or sea coast atmospheres. Exposures to specific corroding agents should be investigated in further detail. Strength at Elevated Temperatures is a rating based upon tests made at temperatures up to 500ºF after prolonged exposure at such temperatures. Machinability is based upon ease of cutting, chip characteristics, quality of finish and tool life. For the heat treated alloys, the ratings are based upon the T6 temper. Naturally aging alloys are rated after room temperature aging to their stable condition. Polishing characteristic is a composite rating based on the ease and speed of polishing, and finish quality, after various standard polishing techniques. Anodizing Appearance is based upon visual examination after a standard anodizing treatment. Weldability rating is based upon the ease of joining parts by gas and arc welding, and the quality of the final welded joint. Brazing, a related process, is applicable to some of the 7XX.X series alloys which have the unique property of withstanding the brazing temperature, and regaining their original strength after room temperature aging.

*Formerly AA-CS-M4-84 in previous editions

2-7

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M5* ALUMINUM CASTING QUALITY STANDARD Page 1 of 3

The purpose of this standard is to establish quality standards for aluminum castings, so that purchasers may specify and expect a product consistent with their needs. TO BE IN EFFECT, THIS STANDARD, AA-CS-M592, INCLUDING THE QUALITY AND FREQUENCY LEVELS, MUST BE CALLED OUT ON THE DRAWING. When using this standard, two factors should be determined by the person responsible for designating the proper level. These are: 1.  QUALITY LEVEL: The inherent quality of the casting having the capability of doing the job for which the part was designed. 2.  FREQUENCY LEVEL: The amount of inspection necessary to determine compliance, or that number of parts to be inspected that will satisfy the requirement of quality level. Both of these factors may affect cost and should not be higher than necessary for the application of the part. Workmanship, tolerances, drafts and other features of castings produced to this standard will be within the limits set forth in the Engineering Series. Special requirements such as sealing surfaces, high stress areas, anodic or chemical finishes and pressure testing, shall be designated on print. Welding, peening, plugging and impregnation are acceptable methods of processing unless specifically prohibited. The foundry will use those controls necessary to produce the casting to the quality level indicated. Example Drawing Callout (blanks to be filled in to levels described in Tables I and II)

All castings produced to this standard will be visually inspected. No cracks will be permitted. Cold shuts, laps and surface discontinuities of linear nature will be investigated. In most applications, no greater degree of inspection is necessary, but when the function of the casting indicates that it will require some additional degree of examination, frequency levels calling for radiographic and penetrant inspection may be used. Certification of chemical composition and mechanical properties, if required, to be agreed on between the supplier and purchaser.

2-8

*Formerly AA-CS-M5-92 in previous editions

METALLURGICAL SERIES (M)

Standards For Aluminum Sand and Permanent Mold Castings

M5* ALUMINUM CASTING QUALITY STANDARD Page 2 of 3

Quality levels as indicated in Table I and referenced in ASTM E 155 show the type of discontinuity and maximum size or degree allowed in each case. An illustration of a typical reference radiograph as contained in ASTM E 155 is shown in Standard AA-CS-M6. TABLE I—MAXIMUM PERMISSIBLE RADIOGRAPHIC SEVERITY LEVELS FOR DISCONTINUITIES IN ALUMINUM CASTINGS3,4 Grade A Grade B Grade C Grade D Inch Inch Inch Inch Discontinuity Gas holes Gas porosity (round)

None None

¼ 1 1

Gas porosity (elongated)

None

1

2

Shrinkage cavity Shrinkage (sponge)

None None

1 1

NA 1

2 2

NA 2

3 4

NA2 3

Foreign material (less dense material)

None

1

1

2

2

4

4

Foreign material (more dense material)

None

1

1

2

1

4

3

Cracks

None

Cold shuts1 Surface irregularity1

None

1

¼

¾

¾ 1 1 2

None

¼ 2 3

¾ 2 3

3

4 2

None

None None Not to exceed drawing tolerance

¼ 5 7

¾ 5 7

5

5

None None

Not to exceed drawing tolerance

Core shift1

No reference radiographic plates available. Not available, use the ¼ inch reference radiographic plate thickness with a severity level 2 units greater than the one shown for the ¼ inch column. 3 ASTM E 155 Volume I reference radiographic plates. 4 For feature thicknesses greater than two inches, the ¾ inch reference radiographic plates may be used. 1 2

TABLE II—FREQUENCY LEVELS Frequency Level** 1 2 3 4

Radiographic Penetrant 100% 100% See Table III See Table III Foundry Control Visual Inspection Only

**Differing frequency levels for radiographic and penetrant inspection may be negotiated.

TABLE III—SAMPLING PLAN Lot Size†

Sample Size

2–50 51–500 501–Over

 2  8 13

Acceptable Number 0 1 2

Rejection Number 1 2 3

†Unless otherwise specified, a lot shall consist of all castings of a specific design of one alloy produced at one facility by the same production technique and submitted for inspection at one time.

*Formerly AA-CS-M5-85 in previous editions

2-9

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M5* ALUMINUM CASTING QUALITY STANDARD Page 3 of 3

EXAMPLE: A drawing callout is for a Quality Level of “C” and a Frequency Level of “2”. The lot size to be inspected is 300 castings. In Table II, Frequency Level 2 refers you to Table III. Table III indicates that a lot of 51–500 castings requires a sample lot of eight castings. If interpretation of the radiographs shows that not more than one of the eight castings failed to meet the Quality Levels set forth in Table I, the lot would pass without further X-ray inspection. If two or more of the castings failed to meet these standards, the foundry would either scrap the lot or X-ray and evaluate each of the castings. NOTE: Where requirements dictate, higher quality levels may be specified when mutually agreed upon between supplier and purchaser.

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*Formerly AA-CS-M5-85 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M6* RADIOGRAPHY Page 1 of 2

Radiography is a non-destructive technique which may be used to reveal discontinuities inside casting walls. This method of inspection provides a permanent record for cross reference to established standards, and promotes confidence as to the integrity of aluminum castings. Radiography serves best when customer and supplier agree on procedures and references. Radiography is used: 1)  For foundry control (to develop gating systems) 2) For systematic inspection during production as specified by the customer or the foundry quality control procedure. 3) For inspection of welding, plugging, detection of fins, steel shot, pockets of core sand, etc. To produce radiographs, the desired technique is to penetrate the casting thickness with the lowest voltage in a reasonable exposure time, and provide an image of maximum detail and resolution. Films used vary in speed, contrast and graininess. Better quality images are produced with high-contrast, fine-grained films. The interpretations of discontinuities as exhibited by radiographic films can be based on ASTM E 155 reference radiographs for inspection of aluminum castings. Common indications encountered are gas holes, gas porosity (round or elongated), shrinkage (cavity or sponge or porosity), and foreign material (less dense or more dense). Each indication is rated in a series of 8 levels, which are then used for inspection criteria.

*Formerly AA-CS-M6-85 in previous editions

2-11

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M6* RADIOGRAPHY Page 2 of 2

DEFINITION OF COMMON RADIOGRAPHIC TERMS Back Scatter The deflection of particles or of radiation by scattering processes through angles greater than 90 degrees with respect to the original direction of motion. Cassett A lightproof container used for holding the radiographic films in position during the radiographic exposure. Contrast

The difference in film blackening from one area to another.

Definition

The sharpness of outline of the image.

Densitometer An instrument for measuring density of exposed film to standardize techniques. Density

The degree of blackening of a film.

Discontinuity An undesirable variation of structure of composition hidden within the interior of the part being inspected. Dosimeter A precision instrument for cumulatively measuring the amount of X-ray and gamma radiation received by the wearer. Film Size

Usually vary from 14″ × 17″ to 5″ × 7″—also special strip cuts.

Focal Film Distance The distance in inches between the focal spot of the X-ray tube or the radiation source and the film. Focal Spot Area of anode where electrons impinge on the target (usually rectangular in shape). The apparent focal spot is usually square when viewed in the central beam because of the angle of the anode. Focal Spot Size in mm

1–10 mm in the voltage range of 100–200KV.

Grain Image on X-ray film formed by countless minute silver grains. The “clumping” together of these small particles produces the visual impression which is called graininess. Intensifying Screen A layer of material placed in contact with the film to increase the effect of the radiation, thus shortening the exposure time. Kilovolt (kv) Unit of electromotive force or potential equal to 1000 volts (commonly used to rate radiographic equipment). Lead Room Radiation-producing equipment is located in a lead-lined or concrete enclosure to provide protection against radiation. Milliampere

Unit of electric current equal to one thousandth of an ampere.

Mottling A special form of scattering on radiographic film due to X-ray diffraction of incident X-rays by the subject material. Penetrameter A strip of metal of essentially the same composition as that of the metal being tested, representing a percentage of object thickness and provided with a combination of steps, holes or slots. When placed in the path of rays, its image provides a check on the sensitivity of the radiographic technique employed. Radiography

Recording of an X-ray image pattern on a film.

Screen Filter A layer of absorptive material which is placed in the beam of radiation for the purpose of absorbing rays of certain wave lengths and thus controlling the quality of the radiographs. Sensitivity The percent ratio of the thickness of the smallest detectable defect to the thickness of the specimen. Viewer

2-12

An illuminator used for the examination of finished radiographs.

*Formerly AA-CS-M6-85 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M7* PENETRANT AND OTHER NON-DESTRUCTIVE INSPECTION TECHNIQUES

There are several non-destructive testing techniques adaptable to use with aluminum alloy castings. Perhaps the most widely used, other than radiography, is the fluorescent penetrant method. Although no interpretive standards have been established, this method of inspection is relatively reliable for finding surface discontinuities, and, when properly applied, permits some evaluation of both the source and severity of such discontinuities. With the additional application of radiography, it is possible to further determine the depth and extent of a discontinuity. Fluorescent penetrant techniques can vary. To avoid misunderstandings in interpretation, it is imperative that (1) methods and interpretation be agreed upon between supplier and purchaser, (2) carefully controlled materials and procedures are used, (3) definitive interpretation be applied, and (4) limitations of the method be recognized. Generally, penetrant inspection is performed per the applicable ASTM standards. For your general information, basic procedure includes the following: 1.  Clean the casting. 2.  Apply fluorescent penetrant and allow time for penetration. 3.  Remove penetrant from the surface of the casting. 4.  Apply developer to absorb penetrant bleeding out of surface discontinuities, allowing time for development. 5.  Inspect the casting using ultra-violet light. Extended delays in inspection after development time will give enlarged and false surface readings. Tooling of the surface, within limits of drawing tolerance, to remove indications of discontinuities is permissible. Dye penetrant inspection follows the same basic technique except for the use of a colored penetrant permitting examination in normal light. Non-linear discontinuities should be evaluated by radiographic techniques to determine the extent and acceptability of the discontinuity. Some efforts have been made to apply ultrasonic techniques to inspection of castings. Other specialized tests such as electrical conductivity, magnetic flux hysteresis and the like are sometimes specified to fulfill specific requirements.

*Formerly AA-CS-M7-85 in previous editions

2-13

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M8* IMPREGNATION OF CASTINGS

Impregnation is an accepted method of sealing aluminum alloy castings. It can be used to avoid the loss of serviceable castings, to achieve pressure tightness, or to promote high quality paint coatings. Equipment needed for impregnation may vary with the type of impregnant used and the size and volume of castings being treated. Impregnation is usually accomplished through the vacuum-pressure method which provides effective filling of channels by pressure after they are evacuated of air or testing liquids. Typical equipment used for impregnation includes an autoclave tank, cleaning and rinsing tanks, a vacuum pump and in most cases a curing oven or heated oil or water tank. There are numerous impregnating materials in use and precise information regarding the relative merits of each can be obtained from the suppliers of these materials. It is generally agreed that an ideal impregnating material should possess the following characteristics. 1.  Thermosetting (infusible on reheating) 2.  Capable of plasticizing to avoid formation of brittle solids 3.  Good penetrating properties 4.  Low viscosity before setting 5.  Minimum contraction on setting 6.  Insoluble in water, coolants, solvents, gasoline and oil after setting 7.  Chemically inert to aluminum alloys Commonly used impregnants include synthetic resins such as polyester styrene, acrylics, methacrylics, and epoxy. Other satisfactory impregnating materials are also available. Anodizing, painting, or other coating procedures may be affected by impregnation. Films of impregnant remaining on the surface of castings will interfere with the formation of uniform, continuous coatings. If proper cleaning is performed, interference by the impregnant should not occur. In some instances, impregnation is used to fill small surface voids in castings prior to painting to achieve high quality paint coatings. The curing at elevated temperatures of impregnated castings may change dimensions and mechanical properties. Therefore, it is important that the user and impregnator agree on the sealants and procedures. For best sealing results, impregnation should be performed after final machining and the casting retested to check for pressure tightness. In many cases the casting supplier is responsible for an initial impregnation but if machining exposes further porosity, the casting buyer assumes responsibility for any additional impregnations. If impregnation is done after user machines, user is responsible for any leaks.

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*Formerly AA-CS-M8-85 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M9* WELDING OF ALUMINUM CASTINGS

In many instances it is necessary to weld aluminum sand or permanent mold castings, and, when the welding is carried out under controlled conditions, castings and assemblies of high integrity can be expected. Examples of most frequent use of welding are: the fabrication of welded assemblies, the closing of openings which are not pertinent to the design of the casting except to provide core prints and access for core removal, and the repair of certain defects in casting. Welding is usually accomplished using an inert gas shielded are either with tungsten electrode (TIG) or by using the welding rod as the electrode (MIG). The most commonly used gases are argon and helium. The oxy-acetylene torch method may also be used. However, it is difficult to consistently achieve high quality welds with this method. Carefully controlled conditions are a requisite for good quality in welding. Surfaces to be welded must be clean and dry. To repair a defective area and make a sound weld, the defect must be completely removed. If the area to be welded is large, it may be necessary to preheat the casting before welding. Temperatures and time used to preheat castings must be carefully controlled. Castings are usually welded before heat treatment; when castings are to be welded after heat treatment, care should be taken to keep the temperature of the casting as low as possible to minimize any changes in mechanical properties. Welding rod alloy must be compatible with the alloy or alloys of the parts being joined or prepared. If the casting is to be anodized, and uniform appearance is an important consideration, welding should be avoided because, even though the same alloy rod is used, the structure of the metal in the welded area is different enough so that the welded area will be discolored. Improper welding techniques can result in poor bond, excessive oxide, gas holes, tungsten inclusions, or cracks. Foundries will usually dress welded areas to conform to the casting contour and dimensional requirements. All welded areas should be visually inspected after the welds are dressed. Foundries normally control operating procedures by periodic radiographic inspection for excessive oxide, gas holes, and tungsten inclusions and by periodic penetrant inspection of welds to sampling plans or even to 100% coverage. Radiographic and penetrant standards should be the same for welds and welded areas as for the rest of the casting or assembly. Good quality welds within a casting will normally provide mechanical properties comparable to those of the parent metal. Users of castings should confidently accept welding as a technique for fabrication, closing of openings and repair of castings. Reference may be made to Standard AA-CS-M4 for the relative weldability characteristics of casting alloys.

*Formerly AA-CS-M9-74 in previous editions

2-15

METALLURGICAL SERIES (M)

Standards For Aluminum Sand and Permanent Mold Castings

M10* TYPICAL PHYSICAL PROPERTIES

TYPICAL PHYSICAL PROPERTIES OF COMMONLY USED SAND AND PERMANENT MOLD CASTING ALLOYS These typical properties are not guaranteed, and should not be used for design purposes but only as a basis for general comparison of alloys and tempers with respect to any given characteristic.

Alloy 201.0 204.0 208.0 222.0 242.0 295.0 296.0 308.0 319.0 328.0 332.0 333.0

336.0 354.0 355.0

C355.0 356.0

A356.0 357.0 A357.0 359.0 443.0 B443.0 A444.0 512.0 513.0 514.0 520.0 535.0 705.0 707.0 710.0 711.0 712.0 713.0 771.0 850.0 851.0 852.0

Temper T6 T7 T4 F T61 T571 c T77 T6 T6 c F F F T5 c F c T5 c T6 c T7 c T551 c T61 T51 T6 T6 c T61 T62 c T7 T71 T61 T51 T6 T6 c T7 T7 c T61 F T61 T6 F F F F F c F T4 F F F F F c F F F T5 c T5 c T5 c

Specific Gravity a 2.80 2.80 — 2.79 2.95 2.81 2.81 2.81 2.80 2.79 2.79 2.70 2.76 2.77 2.77 2.77 2.77 2.72 2.71 2.71 2.71 2.71 2.71 2.71 2.71 2.71 2.71 2.68 2.68 2.68 2.68 2.68 2.67 2.67 2.67 2.67 2.69 2.69 2.68 2.65 2.68 2.65 2.57 2.62 2.76 2.77 2.81 2.84 2.81 2.81 2.81 2.88 2.83 2.88

Density a lb. per cu. in. 0.101 0.101 — 0.101 0.107 0.102 0.102 0.102 0.101 0.101 0.101 0.098 0.100 0.100 0.100 0.100 0.100 0.098 0.098 0.098 0.098 0.098 0.098 0.098 0.098 0.098 0.098 0.097 0.097 0.097 0.097 0.097 0.097 0.097 0.097 0.097 0.097 0.097 0.097 0.096 0.097 0.096 0.093 0.095 0.100 0.100 0.102 0.103 0.101 0.100 0.102 0.104 0.103 0.104

Approximate Melting Range ºF 1060–1200 1060–1200 985–1200 970–1160 965–1155 990–1175 990–1175 970–1190 970–1170 970–1135 960–1120 1025–1105 970–1080 960–1085 960–1085 960–1085 960–1085 1000–1050 1000–1105 1015–1150 1015–1150 1015–1150 1015–1150 1015–1150 1015–1150 1015–1150 1015–1150 1035–1135 1035–1135 1035–1135 1035–1135 1035–1135 1035–1135 1035–1135 1035–1135 1045–1115 1065–1170 1065–1170 1070–1170 1090–1170 1075–1180 1110–1185 840–1120 1020–1165 1105–1180 1085–1165 1105–1195 1120–1190 1135–1200 1100–1180 1120–1190 435–1200 440–1165 400–1175

Electrical Conductivity % IACS 27–32 32–34 — 31 33 34 38 35 33 37 27 30 26 26 29 29 35 29 32 43 36 39 37 38 42 39 39 43 39 41 40 43 39 39 39 35 37 37 41 38 34 35 21 23 25 25 35 40 35 30 37 47 43 45

Thermal Conductivity at 25 ºC, CGS b 0.29 0.29 — 0.30 0.31 0.32 0.36 0.33 0.31 0.35 0.26 0.29 0.25 0.25 0.28 0.28 0.33 0.28 0.30 0.40 0.34 0.36 0.35 0.35 0.39 0.36 0.36 0.40 0.36 0.38 0.37 0.40 0.36 0.36 0.36 0.33 0.35 0.35 0.38 0.35 0.32 0.33 0.21 0.23 0.25 0.25 0.33 0.37 0.33 0.29 0.33 0.43 0.40 0.41

Coeff. of Thermal Expansion, per ºF × 10–6 68–212 ºF 19.3 — — 12.4 12.3 12.6 12.6 12.7 12.2 11.9 11.9 11.9 11.5 11.4 11.4 11.4 11.4 11.0 11.6 12.4 12.4 12.4 12.4 12.4 12.4 12.4 12.4 11.9 11.9 11.9 11.9 11.9 11.9 11.9 11.9 11.6 12.3 12.3 12.1 12.7 13.4 13.4 13.7 13.1 13.1 13.2 13.4 13.1 13.7 13.4 d 13.7 13.0 12.6 12.9

68–572 ºF 24.7 — — 13.4 13.1 13.6 13.6 13.8 13.3 12.9 12.7 12.9 12.4 12.4 12.4 12.4 12.4 12.0 12.7 13.7 13.7 13.7 13.7 13.7 13.7 13.7 13.7 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.7 13.4 13.4 13.2 13.8 14.5 14.5 14.8 14.8 14.3 14.4 14.6 14.2 14.8 d 14.6 d 14.8 d e e e

a  Assuming

solid (void-free) metal. Since some porosity cannot be avoided in commercial castings, the actual values will be slightly less than those given. centimeter of thickness per degree centigrade.

b  Cgs units equals calories per second per square centimeter per c  Chill cast samples; all other samples cast in green sand mold. d  Estimated value. e  Exceeds operating

temperature. Reference: Aluminum, Volume I. Properties, Physical Metallurgy and Phase Diagrams, American Society for Metals, Metals Park, Ohio (1967). Data for alloy 771.0 supplied by the U.S. Reduction Company, East Chicago, Indiana.

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*Formerly AA-CS-M10-84 in previous editions

Standards For Aluminum Sand and Permanent Mold Castings

METALLURGICAL SERIES (M) M11* RECOMMENDED HEAT TREATMENTS Page 1 of 3

RECOMMENDED TIMES AND TEMPERATURES FOR HEAT TREATING COMMONLY USED ALUMINUM SAND AND PERMANENT MOLD CASTINGS The heat treat times and temperatures given in this standard are those in general use in the industry. The times and temperatures shown for solution heat treatment are critical. Quenching must be accomplished by complete immersion of the castings with a minimum delay after the castings are removed from the furnace. Under certain conditions complex castings which might crack or distort in the water quench can be oil or air blast quenched. When this is done the purchaser and the foundry must agree to the procedure and also agree on the level of mechanical properties which will be acceptable. Aging treatments can be varied slightly to attain the optimum treatment for a specific casting or to give agreed upon slightly different levels of mechanical properties. Temper designations for castings are as follows: F As fabricated. Applies to the products of shaping processes in which no special control over thermal conditions or strain hardening is employed. (For cast products, this is the as cast condition in which castings have been cooled from the mold with no special control over thermal conditions and given no further heat treatments.) O Annealed. Applies to cast products that are annealed to improve ductility and dimensional stability. T4 Solution heat-treated* and naturally aged to a substantially stable condition. Applies to products that are not cold worked after solution heat-treatment, or in which the effect of cold work in flattening or straightening may not be recognized in mechanical property limits. T5 Cooled from an elevated temperature shaping process and then artificially aged. Applies to products that are not cold worked after cooling from an elevated temperature shaping process or in which the effect of cold work in flattening or straightening may not be recognized in mechanical property limits. (Applies to castings which have been naturally cooled from the mold and then artificially aged.) T6 Solution heat-treated* and then artificially aged. Applies to products that are not cold worked after solution heat-treatment, or in which the effect of cold work in flattening or straightening may not be recognized in mechanical property limits. T7 Solution heat-treated* and overage/stabilized. Applies to cast products that are artificially aged after solution heat-treatment to provide dimension and strength stability. *Solution heat treatment is achieved by heating cast products to a suitable temperature, holding at the temperature long enough to allow constituents to enter into solid solution and cooling rapidly enough to hold the constituents in solution. The T5, T6, and T7 designations are sometimes followed by one or more numbers which indicate changes from the originally developed treatment.

*Formerly AA-CS-M11-85 in previous editions

2-17

METALLURGICAL SERIES (M)

Standards For Aluminum Sand and Permanent Mold Castings

M11* RECOMMENDED* HEAT TREATMENTS Page 2 of 3

Solution Heat Treatment Alloy

Temper

Product

a

Aging Treatment

b

201.0

T6

S

201.0

T7

S

204.0 208.0 208.0 208.0 222.0 222.0 222.0 222.0 242.0 242.0 242.0 242.0 242.0 295.0 295.0 295.0 295.0 296.0 319.0 319.0 319.0 328.0 332.0 333.0 333.0 333.0 336.0 336.0

T4 T4 T6 T7 O i T61 T551 T65 O k T571 T77 T571 T61 T4 T6 T62 T7 T6 T5 T6 T6 T6 T5 T5 T6 T7 T551 T65

S or P P P P S S P P S S S S or P S or P S S S S P S S P S P P P P P P

Metal Temperatures ± 10F c 950–960 then 980–990 950–960 then 980–990 970 940 940 940 — 950 — 950 — — 960 — 960 960 960 960 960 950 — 940 940 960 — — 940 940 — 960

355.0 355.0 355.0 355.0 355.0 355.0 355.0 355.0 C355.0 C355.0

T51 T6 T7 T71 T6 T62 T7 T71 T6 T61

S or P S S S P P P P S P

— 980 980 980 980 980 980 980 980 980

— 12 12 12 4–12 4–12 4–12 4–12 12 6–12

356.0 356.0 356.0 356.0 356.0 356.0 356.0 A356.0 A356.0

T51 T6 T7 T71 T6 T7 T71 T6 T61

S or P S S S P P P S P

— 1000 1000 1000 1000 1000 1000 1000 1000

— 12 12 10–12 4–12 4–12 4–12 12 6–12

357.0

T6

P

1000

8

440 310 440 475 310 340 440 475 310 Room Temperature then 310 440 310 400 475 310 440 475 310 Room Temperature then 310 330

A444.0 520.0 535.0

T4 T4 T5

P S S

1000 810 —

8–12 18 g —

— — 750

k

Time Hours 2 14–20 2 14–20 10 4–12 4–12 4–12 — 12 — 4–12 — — 5 d — 4–12 d 12 12 12 12 8 — 12 4–12 12 — — 6–12 6–12 — 8

Metal Temperatures ± 10F c Room Temperature then 310 Room Temperature then 370 Room Temperature — 310 500 600 310 340 340 650 400 625–675 400 400–450 — 310 310 500 310 400 310 310 310 400 400 310 500 400 400

Time Hours 14–24 20 12–14 5 5 days — 2–5 4–6 3 11 16–22 7–9 3 8 2 minimum 7–9 3–5 — 3–6 12–24 4–6 1–8 8 2–5 2–5 2–5 7–9 7–9 2–5 4–6 7–9 7–9 7–9 3–5 3–5 4–6 2–5 14–18 3–9 3–6 3–5 8 minimum 10–12 7–9 3–5 3–5 3 2–5 7–9 3–6 3–5 8 minimum 6–12 6–12 — — 5

*These are temperatures and times that are often used; however, specific practices must be developed, and may vary for specific configurations and applications.

2-18

*Formerly AA-CS-M11-85 in previous editions

METALLURGICAL SERIES (M)

Standards For Aluminum Sand and Permanent Mold Castings

M11* RECOMMENDED HEAT TREATMENTS Page 3 of 3

Aging Treatment

Solution Heat Treatment b Alloy

Temper

705.0

T5

Product S

a

Metal Temperatures ± 10F c

Time Hours

Metal Temperatures ±10F c

—

—

Room Temperature

Time Hours 21 days or

705.0

T5

P

—

—

210 Room Temperature

8 21 days 10 4–10 4–10 21 days 21 days 21 days

or 707.0

T7

S

990

8–16

210 350

707.0 710.0 711.0 712.0

T7 T5 T1 T5

P S P S

990 — — —

4–8 — — —

350 Room Temperature Room Temperature Room Temperature

—

315 Room Temperature

— — — — 6 h 6 i — — 6 —

250 355 405 330 360 265 285 430 430 430 430

or 713.0

T5

S or P

—

6–8 21 days or

771.0 771.0 771.0 771.0 771.0 771.0 850.0 851.0 851.0 852.0 a  S

T5 T51 T52 T53 T6 T71 T5 T5 T6 T5

i i

= Sand cast

S S S S S S S or P S or P P S or P

— — — — 1090 1090 — — 900 —

16 3–5 h 6 6–12 h 4 h 3 15 7–9 7–9 4 7–9

P = Permanent mold cast.

b 

Unless otherwise noted, quench in water at 150–212F. c   Temperature range unless otherwise noted. d   Use air blast quench.

Footnote no longer in use. Footnote no longer in use.

g 

Quench in water at 150–212 for 10–20 seconds only. Cool in still air outside furnace to room temperature. i  Stress relieve for dimensional stability in following manner: (1) Hold at 775±25ºF for 5 hrs. Then (2) furnace cool to 650ºF for 2 or more hrs. Then (3) furnace cool to 450ºF for not more than ½ hr. Then (4) furnace cool to 250ºF for approximately 2 hr. Then (5) cool to room temperature in still air outside the furnace. k   No quench required. Cool in still air outside furnace.

h 

*Formerly AA-CS-M11-85 in previous editions

2-19

Standards For Aluminum Sand and Permanent Mold Castings

APPENDIX 1

PLEASE READ THE FOLLOWING ELIGIBILITY REQUIREMENTS PRIOR TO APPLYING FOR REGISTRATION

E*

1. The aluminum or aluminum alloy shall be offered for sale(1) currently and shall have been sold within the previous 12 months, in both cases in commercial quantities(2); 2. The complete chemical composition limits must be disclosed. 3. The composition must be different from that of any casting or ingot for which a designation has already been assigned. 4. The composition limits for the xxx.1 ingot must accompany the request for xxx.0 casting registration. Composition limits for xxx.1 ingot are identical to those for the corresponding xxx.0 registration except for grain refiner elements and specific provisions for minimum magnesium limit, maximum iron limit, and maximum zinc limit described in the registration record, Designations and Chemical Composition Limits in the Form of Castings and Ingot (Pink Sheets). Ingot with chemical composition limits which differ from, but fall within the limits for a registered or proposed xxx.1 registration may be registered as xxx.2 ingot. 5. Except in the case of rotor and aluminizing alloy ingot, composition limits for ingot will not be accepted for registration in the absence of limits for castings of the same designation. 6. The product (Sand, Permanent Mold, Die, or Investment Castings) must be shown at the time of registration.

FOOTNOTES

PL

For detailed information on the registration rules and procedures, refer to the registration record, “Designations and Chemical Composition Limits in the Form of Castings and Ingot” (Pink Sheets). ____________________

(1) Sale of an alloy shall have been made to external users/customers (i.e. internal use and/or transfer of an alloy within a company does not meet the stated criteria) (2) Guidelines for compliance with “Commercial Quantity”: • The alloy has undergone bona fide mill production and is NOT a “laboratory” scale volume used for evaluations or experimental purposes. • The alloy is cast and fabricated in standard production facility and is NOT a one-time production. • There is an expected and ongoing commercial demand and/or need for the alloy. • The alloy must be purchased and sold in a standard business context, which indicates that the alloy is actually “sold” and not “given away” for uses such as promotional evaluations

M

ALLOY REGISTRATION REQUEST CASTINGS AND INGOT



Date:

Manager Alloy and Product Standards Registrations The Aluminum Association, Inc. 1525 Wilson Blvd., Suite 600 Arlington, VA 22209 Re:

Request for Registration of a New Casting Alloy

SA

The following Chemical Composition limits are being submitted for registration as a new casting alloy. Element

Casting



Ingot(s) Limits % max (unless shown as a range)

Silicon Iron Copper Manganese Magnesium Chromium Nickel Zinc Titanium Tin

Others, Each Others, Total Aluminum

Remainder

Remainder

NOTE: This form is intended to assist applicants and reviewers of alloy registration requests. It is not intended to cover all registration requirements and additional information may be requested to complete the registration.

* See: “www.aluminum.org/registrationtemplates” for the latest form.

2-21

Standards For Aluminum Sand and Permanent Mold Castings

APPENDIX 2

PLEASE READ THE FOLLOWING ELIGIBILITY REQUIREMENTS PRIOR TO APPLYING FOR REGISTRATION 1. The alloy is registered with The Aluminum Association. 2. The Temper Designation conforms to American National Standard H35.1, “Alloy and Temper Designation System for Aluminum.” 3. The material is offered for sale in the proposed temper and is available for use by more than one user. 4. The mechanical property limits applicable to the temper are included. (Limits are shown as tentative unless established in accordance with the data base criteria outlined under “Mechanical Properties”, in Section 6, “Standards Section” Aluminum Standards and Data). Testing is performed in accordance with the procedures outlined in Section 4, “Quality Control”, Aluminum Standards and Data. 5. Additional information(1) is provided when characteristics in addition to mechanical properties are specified for the temper. 6. Metric values, which are derived, based on the established Guidelines(2) are to be included for registration.

E*

For detailed information on the registration rules and procedures, refer to the registration record, “Tempers for Aluminum and Aluminum Alloy Products” and “Aluminum Standards and Data”. ____________________ (1) Refer to registration record, Tempers for Aluminum and Aluminum Alloy Products (Yellow Sheets), “Tempers Registration”, “Procedure for Individual Registration of Tempers”. (2) Refer to registration record, Tempers for Aluminum and Aluminum Alloy Products ­– Metric Edition (Tan Sheets), APPENDIX A, “Guidelines for Metric Conversion of Yellow Sheets”.

TEMPER REGISTRATION REQUEST (For listing in the Yellow Sheets and Tan Sheets)

PL

Manager Alloy and Product Standards Registrations The Aluminum Association, Inc. 1525 Wilson Blvd., Suite 600 Arlington, VA 22209

Date:

Re:   Request for Temper Registration for

wishes to register . The tensile limits were determined in accordance with the requirements shown in lines 1-6 in the above shaded area. Other mechanical property limits are shown as appropriate. US CUSTOMARY UNITS

Tensile Strength, ksi

M

Alloy Temper

Product

Thickness ln.

Basis

Ult.

Yield

Elongation Percent in 2 inches or 4 D (Note 2) (Note 3)

SA

(Note 1)

Thickness, mm

Alloy Temper

Product

Over

Thru

Remarks

METRIC UNITS

Tensile Strength, Mpa Basis (Note 1)

Ult.

Yield

Elongation Percent in 50 mm

5D or 5.65 √ A

Remarks (Note 2) (Note 3)

Note: This form is intended to assist applicants and reviewers of temper registration requests. It is not intended to include all registration requirements and additional information may be requested to complete the registration. 2-22

* See: “www.aluminum.org/registrationtemplates” for the latest form.