LM0 ALUMINIUM CASTING ALLOY

99.50+% ALUMINIUM Colour Code - WHITE

This alloy conforms to BS 1490:1988 LM0.

CHEMICAL COMPOSITION
% Copper ---------------------- 0.03 Magnesium --------------- 0.03 Silicon ----------------------- 0.30 Iron --------------------------- 0.40 Manganese ---------------- 0.03 Nickel ------------------------ 0.03 Zinc -------------------------- 0.07 Lead ------------------------- 0.03 Tin ---------------------------- 0.03 Aluminium ----------------- 99.50* Others: total -------------- 0.50 max, max, max, max. max. max. max. max. max. mm. max.

* The Aluminium content shall be determined by difference, i,e. by subtracting the total of all other elements listed,

MECHANICAL PROPERTIES
0.2% Proof Stress (N/mm ) 2 Tensile Stress (N/mm ) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness 7 2 Endurance Limit (5x10 cycles; N/mm ) 3 2 Modulus of Elasticity (x10 N/mm ) 2 Shear Strength (N/mm )
2

LM0-M Sand Cast Chill Cast 30 30 80 80 30 40 25 25 69 69 55 55

The values shown are typical for sand and chill cast test bars produced to the requirement of B.S. 1490. There are no minimum specification values.

79

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 0.000024 Coefficient of Thermal Expansion (perC at 20-600C) 0.0000285 2 Thermal Conductivity (cal/cm /cm/C at 0C) 0.50 2 Thermal Conductivity (cal/cm /cm/C at 100C) 0.51 ElectrIcal Conductivity (% copper standard at 20C)* 57 3 Density (g/cm ) 2.70 Freezing Range (C) approx 657-643 * Value is approximate and will vary with the soundness of the casting.

MACHINABILITY
Pure Aluminium, because of its softness and ductility, is more difficult to machine than aluminium alloys and more care is required to obtain a good finish and to overcome gumminess. Aluminium tends to build up on the edge of the cutting tool but this can be reduced by the use of cutting compounds and the maintenance of keen cutting surfaces free from grinding marks. Turnings tend to be long and continuous, and must be directed away from the work by generous side and top rake angles.

CORROSION RESISTANCE
Castings of pure Aluminium have excellent resistanceto corrosion in a very wide range of conditions and media.

ANODIZING
Colourless transparent films of adequate thickness can readily be pro duced on LM0, The anodic coatings are particularly suitable for dyeing to give a coloured finish. Anodizing may also be employed to produce an electrically insulating surface.

80

CASTING CHARACTERISTICS
FLUIDITY Fair, but not recommended for very thin castings.
-

PRESSURE TIGHTNESS Fair, it may be difficult to produce leak tight castings.

-

HOT-TEARING Fair, there is a tendency to hottearing depending on the casting configuration, and feeding arrangements, LM0 has a very short solidification range and a high solidification shrinkage; therefore special attention must be given to providing optimum temperature gradients for directional solidification.
-

TYPICAL POURING TEMPERATURE - 730-760C for sand and permanent

mould castings. Higher temperatures may result in coarse grained castings and an increase in hot tearing. Die casting optimum temperatures are machine dependent. PATTERNMAKERS SHRINKAGE - 1.6% or 1/62, This is high.

HEAT TREATMENT
This alloy is not heat treated.

APPLICATIONS
The use of pure Aluminium castings is comparatively small. The main fields are electrical applications, food and chemical plant, including slush cast spouts, and to a lesser degree, jewellery and light trim. The greatest use is undoubtedly electrical, where the high conductivity of the unalloyed metal offers obvious advantages; in addition, ductility enables it to be readily deformed under pressure and use is made of this, for example, in cable clamps. It is widely used for cast rotors for electric motors but a composition having a higher Iron content than is allowed in LM0, would have better castability and is generally preferred.

81

LM2 (EN 1706 AC-46100) ALUMINIUM CASTING ALLOY

(A1-Si10Cu2) Colour Code
-

RED/WHITE

This alloy conforms to BS 1490:1988 LM2.

CHEMICAL COMPOSITION
EN 1706 AC-46100
%

Copper -----------------------------------------------Magnesium --------------------------------------Silicon -------------------------------------------------Iron -------------------------------------------------------Manganese -------------------------------------Nickel --------------------------------------------------Zinc ------------------------------------------------------Lead ----------------------------------------------------Tin -------------------------------------------------------Titanium --------------------------------------------Aluminium ----------------------------------------Others: total -------------------------------------

0.7-2.5 0.30 max. 9.0-11.5 1.0 max. 0.5 max. 0.5 max. 2.0 max 0.3 max. 0.2 max 0.2 max. Remainder 0.50 max.

1.5-2.5 0.30 10.0-12.0 1.1 (0.45-1.0) 0.55 0.45 1.7 0.25 0.25 0.25 (0.20) 0.50

Figures in brackets are ingot compositions where they differ from the casting, single figures are maxima,

MECHANICAL PROPERTIES
LM2-M
0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Charpy (Nm) Brinell Hardness Endurance Limit (5x107 cycles;N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2) Chill Cast 90-130 150-200 2-3 65-90 70-100 71 200 Die Cast 130 300 1-3 2.9 65-90 70-100 71 200

The values shown are typical ranges for chill cast test bars produced to the requirement of B.S. 1490. Die cast values obtained on 6mm test bars. Those in heavier type are minimum specification values.

82

STRENGTH AT ELEVATED TEMPERATURES

The reduction in strength of the alloy at elevated temperatures depends upon composition. If the amounts of the elements present, particularly Copper, Nickel and Manganese, are low, the strength is greatly reduced at temperatures of the order of 250C but, if the maximum permissible amounts of these elements are present, the alloy retains moderate strength at this temperature. It should be noted that other factors may restrict the use of die castings at elevated temperatures. The maximum service temperature is 150C.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) Thermal Conductivity (cal/cm2/cm/C at 25C) Electrical Conductivity (% copper standard at 20C) Density (g/cm3) Freezing Range (C) approx 0.000020 0.24 26 2.74 570-525

MACHINABILITY
This alloy is a little difficult to machine since the high Silicon content causes rapid tool wear, It is, however, far easier than the LM6 and LM20 alloys, as the tendency to drag is practically eliminated by the presence of Copper and the other elements. Carbide-tipped tools are advocated but high speed steel tools give good results. A cutting lubricant and coolant should be employed.

CORROSION RESISTANCE
Resistance to corrosion by ordinary atmospheric conditions is good and by marine atmospheres fairly good. It is inferior in this respect to LM6 but can be improved by anodic treatment.

ANODIZING
LM2 can be anodically treated to give a protective surface of a dark grey colour. The surfaces of die castings, however, are not generally suitable for decorative anodizing.

83

CASTING CHARACTERISTICS
FLUIDITY - Good, can be cast easily into thin and intricate sections. PRESSURE TIGHTNESS - Excellent for leak tight castings, HOT-TEARING - Excellent, this alloy is virtually free from hot tearing. TYPICAL POURING TEMPERATURE - 615-700C Temperatures for die castings are machine dependent, Melts should not be allowed to stand at temperatures just above the freezing range or the bottom of the melt will become enriched in alloying elements such as Iron and Manganese. PATTERNMAKERS SHRINKAGE - 1.3% or 1/75 Solidification shrinkage is approximately 3.7%.

HEAT TREATMENT
Castings in this alloy are not normally heat treated, Castings may be annealed at temperatures between 260-370C, held at temperature be tween 4-6 hours and furnace cooled.

APPLICATIONS
Essentially a die casting alloy, LM2 is not normally used for other types of casting. As a general purpose alloy, its applications are extremely varied and widespread and it may be used for almost any component which can be die cast, unless the service conditions demand a higher resistance to corrosion or slightly greater ductility, in which case LM6 or LM20 may be preferred. For most applications LM2 and LM24 are interchangeable, but LM2 has a slightly lower density, LM6 and LM20 would be betterthan LM2 in a corrosive environment, unless it can be protected by anodizing. LM2 has poor weldability and poor brazeability.

84

LM4 (EN 1706 AC-45200) ALUMINIUM CASTING ALLOY

(Al-Si5Cu3Mn0.5) Colour Code - RED This alloy conforms to BS 1490:1988 LM4. Castings are standardized in the as cast (M) condition or fully heat treated (TF) condition.

CHEMICAL COMPOSITION
EN 1706 AC-45200 Copper - - - - - - - - - - - - - - - - - - - - - - - - - - Magnesium - - - - - - - - - - - - - - - - - - - - Silicon - - - - - - - - - - - - - - - - - - - - - - - - - - - Iron - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Manganese - - - - - - - - - - - - - - - - - - - - Nickel - - - - - - - - - - - - - - - - - - - - - - - - - - - Zinc - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Lead - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Titanium - - - - - - - - - - - - - - - - - - - - - - - - Aluminium - - - - - - - - - - - - - - - - - - - - - - Others: each - - - - - - - - - - - - - - - - - - - Others: total - - - - - - - - - - - - - - - - - - - - % 2.0-4.0 0.20 max. 4.0-6.0 0.8 max. 0.2-0.6 0.3 max. 0.5 max. 0.1 max. 0.1 max. 0.2 max. Remainder 0.05 max. 0.15 max 2.5-4.0 0.40 4.5-6.0 0.8(0.7) 0.20-0.55 0.30 0.55 0.20
0.10

0.20 (0.15) 0.05 0.25

Figures in brackets are ingot compositions where they differ from the casting, single figures are maxima.

MECHANICAL PROPERTIES
LM4-M 0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)
Sand Cast Chill Cast

70-110 140-170 2-3 1.4 65-80 75 71 150

80-110 160-220 2-4 2.1 70-90 85 71 165

85

LM4-TF
Sand Cast Chill Cast

0.2% Proof Stress (N/mm ) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brirtell Hardness Endurance Limit (5x107 cycles;N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

200-300 230-290 0-2 90-120 60-90 71 200

200-300 280-370 1-5 90-120 70-1 00 71 185

The values shown are typical ranges for sand and chill cast test bars produced to the requirement of B.S. 1490. Those in heavier type are minimum specification values.

STRENGTH AT ELEVATED TEMPERATURES

Room temperature tensile strength of LM4-M is largely retained up to 200C and falls to about half at 300C.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) Density (g/cm ) Freezing Range (C) approx
3 2

0. 000021 0.29 32 2.75 625-525

MACHINABILITY
This alloy has fairly good machining properties, being intermediate be tween the rather difficult Aluminium-Silicon alloys and the easily machi nable Aluminium-Copper group. Liberal cutting lubricant and coolant should be employed. Castings show improved machinability after heattreatment.

CORROSION RESISTANCE
Resistance to attack under normal atmospheric conditions is fairly good. Considerable improvement in resistance to corrosion is effected by anodic treatment; a small increase in resistance is obtained when the alloy is solution heat-treated.

86

ANODIZING
Treatment by the chromic acid process will give a resistant but generally greyish coloured surface, but a lighter film suitable for dyeing can be obtained with the sulphuric acid method. The colour and quality of the coating depend to some extent upon the condition of the castings, i.e. whether sand or chill cast and whether heat-treated, and also on the thickness of the film.

CASTING CHARACTERISTICS
FLUIDITY - Good, PRESSURE TIGHTNESS - Excellent, suitable for leak tight castings. HOT-TEARING - Good, but the placing of feeders or chills at heavy sections of the casting is essential. TYPICAL POURING TEMPERATURE - 720C Temperatures above or below this value may be used depending on the mould configuration. Too high a temperature must be avoided. This alloy may be grain refined. PATTERNMAKERS SHRINKAGE - 1.3% or 1/75.

HEAT TREATMENT
This alloys response to heat treatment is dependent on the presence of Magnesium; therefore for such treatment, the Magnesium content should be near the maximum. A very considerable increase in mechanical properties is obtained by Solution heat treatment and artificial ageing. LM4-TF (fully heat treated) - Heat for 6-16 hours at 505-520C, quench in hot water and heat for 6-18 hours at 150-170C and air cool. If bending or straightening of castings is necessary, this should be carried out after the solution heat treatment, since in this state the castings exhibit greatly increased ductility.

87

APPLICATIONS
This alloy is widely used and is suitable for most general engineering purposes including cylinder-heads, crank-cases, junction boxes, gear boxes, clutch-cases, switch gear covers, instrument cases, tool-handles and household fittings, office equipment and electrical tools etc., where moderate mechanical properties are desirable. Its casting characteristics permit it to be used forthe production of thick and moderately thin forms and also for castings required to be pressure tight. In the heat treated state, it may be used for castings required to maintain a relatively high static loading. It has good weldability. LM4 is equally suitable for the production of sand and permanent mould castings but the higher Silicon alloys such as LM2 and LM24 are generally to be preferred.

88

LM5 (EN 1706 AC-51300) ALUMINIUM CASTING ALLOY

(Al -Mg5Mn0.5) Colour Code - BLACK

This alloy conforms to BS 1490:1988 LM5.

CHEMICAL COMPOSITION
EN 1706 AC-51300 % Copper - - - - - - - - - - - - Magnesium - - - - - - - - - Silicon - - - - - - - - - - - - - Iron - - - - - - - - - - - - - - - Manganese - - - - - - - - - Nickel - - - - - - - - - - - - - Zinc - - - - - - - - - - - - - - Lead - - - - - - - - - - - - - - Tin - - - - - - - - - - - - - - - Titanium - - - - - - - - - - - Aluminium - - - - - - - - - - Others: each - - - - - - - - Others: total - - - - - - - - - figures are maxima.

0.1 max. 3.0-6.0 0.3 max. 0.6max. 0.3-0.7 0.1 max. 0.1 max. 0.05 max. 0.05 max. 0.2 max. Remainder 0.05 max. 0.15 max.

0.10 (0.05) 4.5-6.5 (4.8-6.5) 0.55 (0.35) 0.55 (0.45) 0.45 0.10 0.20 (0.15) 0.05 0.15

Figures in brackets are ingot compositions where they differ from the casting, single

MECHANICAL PROPERTIES
LM5-M
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles;N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)
1490. Those in heavier type are minimum specification values.

90-110 140-170 3 7.9 50-70 54 71 140

90-120 170-280 5 12.6 60-70 100 71

The values shown are typical ranges for sand and chill cast test bars produced to the requirement of B.S.

STRENGTH AT ELEVATED TEMPERATURES

Room temperature properties are largely maintained up to 200C, but fall rapidly above 300C.

89

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.000023 0.33 31 2.65 642-580

MACHINABILITY
LM5 machines very well and takes an excellent polish.

CORROSION RESISTANCE
This alloy is highly resistant to corrosion under most conditions and is superior to all other Aluminium alloys for marine use.

ANODIZING
LM5 may be anodized by any of the more common processes. A transparent colourless-to-whitish film is obtained according to the process used, and is suitable for decorative finishing.

CASTING CHARACTERISTICS
FLUIDITY Fair, not recommended for very thin castings. PRESSURE TIGHTNESS Poor, it may be difficult to obtain pressure tightness in castings other than those of a simple shape. HOT-TEARING Fair, the alloy shows a pronounced tendency towards hot-tearing and precautions should be taken to minimise constraint to contraction in the mould. TYPICAL POURING TEMPERATURE 700C This temperature should not be greatly exceeded. PATTERNMAKERS SHRINKAGE 1.3% or 1/75. NOTE This alloy is rather more difficult than most others to melt and cast satisfactorily. Special care must be taken to avoid oxidation during melting and during the actual pouring operation. The alloy must be thoroughly de-gassed and, for sand castings of heavy section, the incorporation of Boric acid as an inhibitor in the sand is advocated to prevent the reaction of the alloy with the moisture of the mould which can lead to gas porosity and dross inclusions.
-

HEAT TREATMENT
LM5 alloy is not heat-treated.

90

APPLICATION
The alloy is used where very high resistance to corrosion from sea water or marine atmospheres is required, for equipment used for the manufacture of foodstuffs, cooking utensils and chemical plant, and for castings required to exhibit and maintain a surface of high polish. Applications include, for example, door furniture, car fittings and trim, and similar castings where a colourless anodic film is required. It is mainly used for sand castings and, to a lesser extent, for permanent mould castings but die castings of a relatively simple shape have been made.

91

LM6 (EN 1706 AC-44100) ALUMINIUM CASTING ALLOY

(Al-Si12) Colour Code
-

YELLOW

This alloy conforms to BS 1490:1988 LM6.

CHEMICAL COMPOSITION
EN 1706 AC-44100 Copper- - - - - - - - - - - - - Magnesium- - - - - - - - - - Silicon- - - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - - Nickel- - - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - - Aluminium- - - - - - - - - - - Others: each- - - - - - - - - Others: total- - - - - - - - - - % 0.1 max. 0.10 max. 10.0-13.0 0.6 max 0.5 max. 0.1 max. 0.1 max. 0.1 max. 0.05 max 0.2 max Remainder 0.05 max. 0.15 max 0.15 (0.10) 0.10 10.5-13.5 0.65 (0.55) 0.55 0.10 0.15 0.10 0.20 (0.15) 0.05 0.15

Figures in brackets are ingot compositions where they differ from the casting, single figures are maxima.

MECHANICAL PROPERTIES
LM6-M
Sand Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

60-70 160-190 5 6.0 50-55 51 71 120

92

LM6-M
Chill Cast Die Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

70-80 190-230 7 9.0 55-60 68 71 -

120 280 2-5 55-60 70-100 71

The values shown are typical ranges for sand and chill cast test bars produced to the requirement of B.S. 1490. Die cast values are obtained from 6mm diameter test bars. Those in heavier type are minimum specification values.

STRENGTH AT ELEVATED TEMPERATURES

Tensile strength and hardness decrease fairly regularly with increasing temperature and become relatively poor at 250C.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.000020 0.34 37 2.65 575-565

MACHINABILITY
Alloys of this and similar compositions are rather is due to their tendency to drag and to the rapid high Silicon content. Carbide-tipped tools with relativelylow cutting speeds give comparatively lubricant and coolant should be employed. difficult to machine. This tool wear caused by the large rake angles and good results. A Cutting

CORROSION RESISTANCE
LM6 exhibits excellent resistance to corrosion under both ordinary atmos pheric and marine conditions. For the severest conditions, this property can be further enhanced by anodic treatment.

ANODIZING
LM6 can be anodized by any of the common processes, the resulting film ranging in colour from grey to dark brown.

93

CASTING CHARACTERISTICS
FLUIDITY Excellent, can be cast into thinner and more intricate sections than other casting alloys, which makes it useful for producing complex castings of large surface area and thin walls. PRESSURE TIGHTNESS Excellent, especially suitable for leak tight castings. HOT-TEARING Excellent, castings in sand or chill moulds are completely free from hot tearing. TYPICAL POURING TEMPERATURE 725C Sand and permanent mould pouring temperatures may be varied in practice. Die casting pouring temperatures are machine dependent The molten metal should not be allowed to stand at temperatures just above the solidification temperature, as the base of the melt will become enriched in alloying elements such as Iron and Manganese. PATTERNMAKERS SHRINKAGE - 1.3% or 1/75. Die casting shrinkage may be considerably less in some instances. Solidification shrinkage is approximately 3.7%
-

HEAT TREATMENT
Ductility can be improved slightly by heating at 250-300C, but, apart from stress relieving, the heat treatment of LM6 is of little industrial interest.

APPLICATIONS
This alloy, having high resistance to corrosion and excellent castability, is most suitable for marine on deck castings, watercooled manifolds and jackets, motor car and road transport fittings, thin section and intricate castings such as motor housings, meter cases and switch boxes, for very large castings, e.g., cast doors and panels where ease of casting is essential, for chemical and dye industry castings, e.g., pump parts, for paint industry and food and domestic castings. It is especially suitable for castings that are to be welded. The ductility of LM6 alloy enables castings to be rectified easily or even modified in shape, e.g., simple components may be cast straight and later bent to the required contour. It is equally adaptable for sand and permanent mould castings and for die castings. This alloy has excellent resistance to corrosion in marine environments, possesses excellent ductility, but is of medium strength and is not heat treated. Its strength falls off rapidly at high temperatures. Its elastic limit is low and there is difficulty with machining.

94

LM9 (EN 1706 AC-43100) ALUMINIUM CASTING ALLOY

(Al Si12Mg0.5Mn0.5) Colour Code - YELLOW/BROWN This alloy conforms to BS 1490:1988 LM9. Castings are standardized in the as cast (M) condition, in the precipitation treated (TE) condition or in the fully heat treated (TF) condition.

CHEMICAL COMPOSITION
EN 1706 AC-43100 Copper- - - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - - Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - - % 0.20 max. 0.2-0.6max. 10.0-13.0 0.6 max 0.3-0.7 0.1 max. 0.1 max. 0.1 max. 0.05 max 0.2 max Remainder 0.05 max. 0.15 max 0.10 (0.08) 0.25-0.45(0.30-0.45) 9.0-11.0 0.55 (0.45) 0.45 0.05 0.10 0.05 0.05 0.15 0.05 0.15

Figures in brackets are ingot compositions where they differ from the castings, single figures are maxima.

MECHANICAL PROPERTIES
LM9-M
Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

95-120 190 3-5 75-85 70-100

95

LM9-TE
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

150-170 110-130 230 170 2 1.5 2 1.4 85 70 75 55 71 71 120 160 LM9-TF

Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (2x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

220-250 240 0 -1 0.7 95 70 71 200

270-280 295 0-1 1.4 110 90 71 230

The values shown are typical ranges for sand and chill cast test bars produced to the requirement of B.S. 1490. Those in heavier type are minimum specification values.

STRENGTH AT ELEVATED TEMPERATURES

Tensile properties are unaffected by temperatures up to 150C but pro longed heating at temperatures significantly higher reduces the strength. For example, the tensile strength of chill cast LM9-TF at 200C (after heating for 500 h) is approximately half that at room temperature, and only 25% of the original value at 250C.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx
0.000022

0.35 38 2.68 575-550

MACHINABILITY
Very considerable tool wear occurs in machining this alloy, but there is not the same tendency to drag that occurs with high Silicon alloys containing no other alloying elements, e.g. LM6. Carbide-tipped tools with large rake angles and relatively low cutting speeds give good results. A cutting lubricant and coolant should be employed.

96

CORROSION RESISTANCE
LM9 exhibits excellent resistance to corrosion under both ordinary atmos pheric and marine conditions.

ANODIZING
LM9 can be anodized by any of the common processes, the resulting protective film ranging in colour from grey to dark brown, depending on the method employed.

CASTING CHARACTERISTICS
FLUIDITY Good, suitable for thin and intricate castings.
-

PRESSURE TIGHTNESS Good, suitable for leak tight castings.

-

HOT-TEARING Excellent, castings are completely free from hot tears

-

in sand and chill moulds. TYPICAL POURING TEMPERATURE -710C The mould design will influence the actual pouring temperature. The presence of Magnesium which will oxidize if the melt is at too high a temperature or kept too long at temperature, requires more care to be exercised in the melting and casting of this alloy. Oxide could be introduced into the casting by accident
,

For sand castings and medium and heavy chill castings, the normal practice is to modify the melt with Sodium. PATTERNMAKERS SHRINKAGE 1.3% or 1/75.
-

HEAT TREATMENT
Heat treatment produces high strength and hardness. LM9-TE ( precipitation heat treated ) Heat for 16 hours at 150-170C. LM9-TF (fully heat treated ) Heat for 2-8 hours at 520-535C, and quench in water and heat for 16 hours at 150-170C.
-

APPLICATIONS
LM9 alloy is used where the fluidity and corrosion resistance of LM6 are required with high strength and hardness. It is equally suitable for sand and permanent mould casting and is extensively used for low pressure castings, for cover plates and instrument cases. It is useful for electroplated components. LM9 has poor weldability and brazeability.

97

LM12 ALUMINIUM CASTING ALLOY (A1-Cul0Mg0.3) Colour Code GREEN

-

This alloy conforms to BS 1490:1988 LM12.

CHEMICAL COMPOSITION
Copper- - - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - - Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - - % 9.0-11.0 0.2-0.4 2.5 max. 1.0 max. 0.6 max. 0.5 max. 0.8 max. 0.1 max. 0.05 max 0.2 max Remainder 0.05 max. 0.15 max

MECHANICAL PROPERTIES
LM12-M
Chill Cast

0.2% Proof Stress (N/mm2) 140-170 Tensile Stress (N/mm2) 170 Elongation (%) 0.5-1.5 Impact Resistance Izod (Nm) 1.0 Brinell Hardness 80-95 Endurance Limit (5x107 cycles; N/mm2) 60 Modulus of Elasticity (x103 N/mm2) 71 Shear Strength (N/mm2) The values shown are typical ranges for chill cast test bars produced to the requirement of B.S. 1490. Those in heaviertype are minimum specification values.

STRENGTH AT ELEVATED TEMPERATURES

Tensile strength and a high proof stress/ultimate tensile stress ratio are well maintained at elevated temperatures.

98

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) Coefficient of Thermal Expansion (perC at 20-300C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.000022 0.000024 0.32 33 2.94 625-525

MACHINABILITY
This machines very well and takes a high polish. Ordinary machining methods, as applied for example to gun metal, give very satisfactory results, But high cutting speeds may be used to advantage.

CORROSION RESISTANCE
Resistance to seawater and atmospheric conditions is rather lower than that of the Copper-free Aluminium alloys. This does not detract from the value of LM12 for many applications; for most engineering purposes the resistance is satisfactory. Resistance to corrosion by oils and fatty acids is very good.

ANODIZING
This alloy is not recommended for anodic treatment, although a nonprotective film may be obtained by the sulphuric acid process.

CASTING CHARACTERISTICS
FLUIDITY Fair, not recommended for very thin castings. PRESSURE TIGHTNESS Good, produces very sound castings, especially when chill cast. HOT-TEARING Good, exhibits moderate resistance to hot tearing. TYPICAL POURING TEMPERATURE 710C The mould configuration will influence the optimum temperature. PATTERNMAKERS SHRINKAGE 1.3% or 1/75.
-

HEAT TREATMENT
This alloy will respond to heat treatment to give increased strength and hardness. BS 1490 does not specify heat treated properties for this alloy.

99

APPLICATIONS
In the past, the main uses for LM12 were for pistons in intemal combustion engines, but in this field it has been superseded by LM1 3 and LM26 which have the advantage of a lower thermal expansion. The alloy now finds its main applications where castings are required to withstand high hydraulic pressures or to possess maximum hardness, and where machinability is of first importance. Typical applications are castings for hydraulic brake and similar systems and electric iron sole plates.

100

LM13 (EN 1706 AC-43100) ALUMINIUM CASTING ALLOY

(Al-Si12CulMgl) Colour Code
-

YELLOW/BLACK

This alloy conforms to BS 1490:1988 LM13. Castings are standardized in the precipitation treated (TE) condition, solution treated, artificially aged and stabilized (TF7) condition and the fully heat treated (TF) condition.

CHEMICAL COMPOSITION
EN 1706 AC-43100 Copper- - - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - - Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - - % 0.7-1.5 0.8-1.5 10.0-13.0 1.0 max 0.5 max. 1.5 max. 0.1 max. 0.1 max. 0.1 max 0.2 max Remainder 0.05 max. 0.15 max 0.8-1.5 0.8-1.5(0.9-1.5) 10.5-13.5 0.7 (0.6) 0.35 0.7-1.3 0.35 0.25 (0.20) 0.5 0.15

Figures in brackets are ingot composilions wnere they clutter trom the casting, single figures are maxima.

MECHANICAL PROPERTIES
LM13-TF
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

160-190 170-200 0.5 100-150 85 73 -

270-300 280-310 1 1.4 100-150 100 73 190

101

LM13-TF7
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

130 140 1 65-90 70-110 71 -

190 200 1 65-90 70-110 71

LM13-TE
Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

210 1 90-130 70-110 71

The values shown are typical ranges for sand and chill cast test bars produced to the requirement of B.S. 1490. Those in heavier type are minimum specification values.

STRENGTH AT ELEVATED TEMPERATURES

Strength and hardness, at temperatures met in internal combustion engine pistons, are high enough to allow the alloy to be used satisfactorily for such applications, but strength is halved at 250C.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) Coefficient of Thermal Expansion (perC at 20-300C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 25C) 3 Density (g/cm ) Freezing Range (C) approx 0.000019 0.000021 0.28 29 2.70 560-525

MACHINABILITY
In machining this alloy, there is less tendency to drag than with high Silicon alloys containing no other alloying elements, for example LM6. Ordinary steel tools tend to wear rather quickly and should not be used. Carbidetipped tools with large rake angles and relatively low cutting speeds give good results. A cutting lubricant and coolant should be employed. Diamond tools are commonly used for finish machining.

102

CORROSION RESISTANCE
This alloy shows high resistance to corrosion under atmospheric condi tions.

ANODIZING
LMI3 may be anodized satisfactorily by the sulphuric acid process. The anodic coating is dark grey. Anodizing, which produces an oil absorbing surface, is sometimes used to give improved bearing qualities to pistons made of LM13.

CASTING CHARACTERISTICS
FLUIDITY Good, this alloy can be cast into thin sections. PRESSURE TIGHTNESS Fair, suitable for leak tight castings. HOT-TEARING Excellent, resistance to hot tearing is high. TYPICAL POURING TEMPERATURE -700C
-

The actual temperatures may range between 670-780C and will depend on the mould configuration. This alloy may form internal shrinkage pipes in heavy sections. PATTERNMAKERS SHRINKAGE 1.3% or 1/75.
-

HEAT TREATMENT
LM13-TF (fully heat treated)- heat for 8 hours at 515-525C, quench in hot water, and heat for 4-16 hours at 160-180C. For large castings it may be necessary to increase the solution heat treatment time. A stabilizing treatment is commonly employed for pistons. LM13-TF7 (solution heat treat, quench and stabilize)- Solution heat treat and quench as described for LM13-TF then heat for 4-16 hours at 200 250C or for such time as will give the desired hardness.
-

LM13-TE (precipitation hardened)- heat for4-16 hours at 160-180C, or for such duration as is required to reach the specified Brinell hardness.

APPLICATIONS
LM13 alloy is used for pulleys (sheaves), for pistons for all types of diesel and petrol engines, and for other engine parts operating at elevated temperatures. It has the advantage of good resistance to wear, good bearing properties and a low coefficient of thermal expansion.

103

LM16 (EN 1706 AC-45300) ALUMINIUM CASTING ALLOY

(Al -Si5CulMg0.5) Colour Code RED/BLACK
-

This alloy conforms to BS 1490:1988 LM16. Castings are standardized in the solution treated and naturally aged (TB) condition and in the fully heat treated (TF) condition.

CHEMICAL COMPOSITION
EN 1706 AC-45300
% Copper- - - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - - Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - - -

1.0-1.5 0.4-0.6 4.5-5.5 0.6 max 0.5 max 0.25 max 0.1 max 0.1 max 0.05 max 0.2 max Remainder 0.05 max 0.15 max

1.0-1.5 0.35-0.65(0.40-0.65) 4.5-5.5 0.65 (0.55) 0.55 0.25 0.15 0.15 0.05 0.05-0.25(0.05-0.20) 0.05 0.15

*If Titanium alone is used as a grain refiner, the amount present shall not be less than 0.05% Figures in brackets are ingot compositions where they differ from the casting, single figures are maxima.

MECHANICAL PROPERTIES
LM13TB
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

120-140 170 2 1.4 80 70 71 -

140-150 230 3 2.7 85 85 71

104

LM16-TF
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

220-280 230- 290 0-1 1.0 100 70 71 200

250-300 280-310 02 1.4 110 93 71 235

The values shown are typical ranges for sand and chill cast test bars produced to the requirement of B.S. 1490. Those in heavier type are minimum specification values.

STRENGTH AT ELEVATED TEMPERATURES

LM16 retains its strength well, up to 200C.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20 -100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx
0.000023 0.34 39 2.70 620-550

MACHINABILITY
The heat-treated alloy has fairly good machining properties, but tools, which should preferably be of high speed steel, must be kept sharp. A moderately high rate of tool wear may be expected. Liberal cutting lubricant should be employed.

CORROSION RESISTANCE
The alloy has fairly good resistance to corrosion under atmospheric conditions.

ANODIZING
A protective film, usually grayish in colour, may be obtained by either the sulphuric or chromic acid process.

105

CASTING CHARACTERISTICS
FLUIDITY Good, suitable for fairly thin castings. PRESSURE TIGHTNESS Good, suitable for leak tight castings. HOT TEARING Good, hot tears are seldom encountered with this alloy.
-

TYPICAL POURING TEMPERATURE -710C The actual temperature may range between 675-790C dependent on the mould configuration. Care needs to be taken to avoid oxide inclusions in the casting due to the presence of 0.5% Magnesium in this alloy. PATTERNMAKERS SHRINKAGE 1.3% or 1/75.
-

HEAT TREATMENT
Full heat treatment gives high strength and hardness: LM16-TB ( solution heat treated ) - 12 hours at 520-530C and quenched in hot water. LM16-TF ( precipitation heat treated ) - 12 hours at 520-530C and quenched in hot water followed by 8-10 hours at 160-170C.

APPLICATIONS
LM16 alloy is used for water-cooled cylinder heads, valve bodies, water jackets, cylinder blocks, fire hose couplings, air compressor pistons, fuel pump bodies, aircraft supercharger covers and similar applications where leak-proof castings having the high strength produced by heattreatment are required. It is equally suitable for sand casting and for permanent mould casting. LM16 has good weldability.

106

LM20 (EN 1706 AC-47000) ALUMINIUM CASTING ALLOY

(Al-Si12) Colour Code
-

YELLOW/GREEN

This alloy conforms to BS 1490:1988 LM20.

CHEMICAL COMPOSITION
EN 1706 AC-47000
% Copper- - - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - - Chromium Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - - -

0.4 max. 0.2 max. 10.0 -13.0 1.0 max 0.5 max. 0.1 max. 0.2 max. 0.1 max. 0.1 max. 0.2 max. Remainder 0.05 max. 0.20 max.

1.0 (0.9) 0.35 10. 5-1 3. 5 0.8 (0.7) 0.05-0.55 0.30 0.55 0.20 0.10 0.20 (0.15) 0.10 0.05 0.25

Figures in brackets are ingot compositions where they differ from the casting, single figures are maxima

MECHANICAL PROPERTIES
LM20-M
Chill Cast Sand Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

70-80 190 - 230 5 9.0 55 - 65 80 - 100 71 -

120 280 1-3 4.0 65 75 80 100 71

The values shown are typical ranges for Chill and Die cast test bars produced to the requirement of B.S. 1490. The die cast test bars were of 6mm diameter. Those in heavier type are minimum specification values.

107

STRENGTH AT ELEVATED TEMPERATURES

Tensile strength and hardness decrease fairly regularly with increasing temperature and become relatively poor at temperatures of the order of 200C, with a corresponding increase in elongation.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.000020 0.37 37 2.68 575-565

MACHINABILITY
LM20 alloy is rather difficult to machine because of the rapid tool wear caused by the high Silicon content and because of its tendency to drag. The small amount of Copper present results in a slight superiority in this latter respect over LM6. Carbide-tipped tools with large rake angles and relatively low cutting speeds give comparatively good results. A cutting lubricant and coolant should be employed.

CORROSION RESISTANCE
LM20 exhibits high resistance to corrosion under both ordinary atmos pheric and marine conditions, being only slightly inferior in this respect to LM6. Resistance may be considerably increased by anodic treatment.

ANODIZING
LM20 can be anodized by any of the common processes. The resulting protective film ranges in colour from grey to dark brown. The surfaces of die castings are not generally suitable for decorative anodizing.

108

CASTING CHARACTERISTICS
FLUIDITY Excellent, this alloy can be cast into thin and intricate castings.
-

PRESSURE TIGHTNESS Excellent, especially suitable for leak tight castings.

-

HOT-TEARING Excellent, castings are free from hot tearing.

-

TYPICAL POURING TEMPERATURE The practical pouring tem peratures are dependent on the die casting machine and the casting dimensions.
-

The melt should not be allowed to stand at temperatures just above the freezing range as the bottom of the melt will become enriched in Iron and Manganese. PATTERNMAKERS SHRINKAGE 1.3% or 1/75
-

The solidification shrinkage for this alloy is 3.7%.

HEAT TREATMENT
Castings in this alloy are not heat treated.

APPLICATIONS
LM20 is suitable for marine castings, water jackets, meter cases, domestic and office equipment, street lighting and other castings subjected to atmospheric exposure. In general, LM20 alloy is preferred to the more common die casting alloys LM2 and LM24 only when the castings are used in aggressive media, requiring the rather higher corrosion resistance of LM20. Where the very highest resistance to chemical attack is required, LM6 alloy may be superior to LM20. LM20 has slightly better castability than LM6.

109

LM21 (EN 1706 AC-45000) ALUMINIUM CASTING ALLOY

(Al -Si6Cu4Mn0.4Mg0.2) Colour Code RED/GREEN
-

This alloy conforms to BS 1490:1988 LM21.

CHEMICAL COMPOSITION
EN 1706 AC-45000
% Copper- - - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - - Chromium Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - - -

0.4 max. 0.2 max. 10.0 -13.0 1.0 max 0.5 max. 0.1 max. 0.2 max. 0.1 max. 0.1 max. 0.2 max. Remainder 0.05 max. 0.20 max.

3.0-5.0 0.55 5.0-7.0 1.0 (0.9) 0.20-0.65 0.45 2.0 0.30 0.15 0.25 (0.20) 0.15 0.05 0.35

Figures in brackets are ingot compositions where they differ from the casting, single figures are maxima.

MECHANICAL PROPERTIES
LM21-M
Chill Cast Sand Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

80 - 140 150 - 200 12 70 - 100 70 71 175

80 - 140 170 - 230 14 70 - 100 70 71 175

The values shown are typical ranges for sand and chill cast test bars produced to the requirement of B.S. 1490. Those in heavier type are minimum specification values.

110

STRENGTH AT ELEVATED TEMPERATURES

Room temperature strength is largely retained up to 200C and falls to about half at 300C. The creep resistance of the alloy at 200C is not significantly different from that of LM4.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.000021 0.29 32 2.81 615-520

MACHINABILITY
LM21 has fairly good machining properties and is rather superior in this respect to LM4-M. For the best results, tungsten carbide tools are recommended. Liberal applications of cutting lubricant and coolant should be used.

CORROSION RESISTANCE
The alloy shows fairly good resistance to attack under normal atmospheric conditions. Atmospheric exposure tests carried out by the British NonFerrous Metals Research Association indicate that the weathering behaviour of LM21 is similar to that of LM4 alloy.

ANODIZING
Treatment by either the sulphuric or chromic acid process will give a resistant but slightly greyish coloured surface, the colour and quality of the coating depending to some extent upon the condition of the castings, i.e. whether sand or chill cast

CASTING CHARACTERISTICS
FLUIDITY Good. PRESSURE TIGHTNESS Good, suitable for leak tight castings. HOT-TEARING Good. TYPICAL POURING TEMPERATURE 720C The practical pouring temperatures will depend on the mould configuration and may range from 675-790C. PATTERNMAKERS SHRINKAGE 1.3% or 1/75.
-

111

HEAT TREATMENT
The mechanical strength of LM21 can be increased by heat treatment, but the behaviour of castings that have been heat treated may vary considera bly due to variations in composition within the specified range. For this reason, where high mechanical strength and hardness are required, the use of a recognised heat treatable alloy e.g., LM4-TF is recommended. LM21 can be successfully stress relieved. Age hardening which occurs spontaneously at room temperature is rather greater than with LM4 castings. If bending or straightening of castings is necessary, it should be done soon after casting, as at this stage the alloy has the greatest ductility.

APPLICATIONS
LM21 is suitable for many of the applications for which LM4 may be used, i.e., for general engineering purposes. It is mainly used where a high proof stress and rigidity are required without the need for heat-treatment. Its casting characteristics permit it to be used for the production of moderately thin forms and also for castings required to be pressure tight LM21 is equally suitable for sand and permanent mould castings. It is used for crank cases for diesel engines, clutch cases, gear boxes, tool handles, household fittings, electrical tools and office equipment.

112

LM22 (EN 1706 AC-45000) ALUMINIUM CASTING ALLOY

(Al -Si5Cu3Mn0.4) Colour Code RED/BROWN
-

This alloy conforms to BS 1490:1988 LM22. Castings are standardized in the solution treated and naturally aged (TB) condition.

CHEMICAL COMPOSITION
EN 1706 AC-45000
% Copper- - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - single figures are maxima.

2.8-3.8 0.05 max. 4.0-6.0 0.6 max. 0.2-0.6 0.15 max. 0.15 max. 0.1 max. 0.05 max. 0.2 max. Remainder 0.05 max. 0.15 max.

2.6-3.6 0.05 4.5-6.0 0.60 (0.50) 0.55 0.10 0.20 0.10 0.05 0.25 (0.20) 0.05 0.15

Figures in brackets are ingot compositions where they differ tram the casting,

MECHANICAL PROPERTIES
LM22- TB
Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

110-120 245 8 4.8 70-80 70-100 71

The values shown are typical ranges for chill cast test bars produced to the requirement of B.S. 1490. Those in heavier type are minimum specification values.

113

STRENGTH AT ELEVATED TEMPERATURES

Room temperature strength is largely retained up to 200C.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.000021 0.29 32 2.77 625-525

MACHINABILITY
Chill castings in LM22-TB alloy have good machining properties. Moder ately high tool wear must, however, be expected as with other Silicon containing alloys. Liberal cutting lubricant and coolant should be employed.

CORROSION RESISTANCE
Resistance to attack under commonly encountered atmospheric condi tions is fairly good. Solution treatment makes this alloy slightly superior to LM4 in its resistance to corrosion.

ANODIZING
Treatment by the chromic acid process produces a resistant but greyish coloured surface. A lighter film suitable for dyeing is obtainable with the sulphuric acid method.

CASTING CHARACTERISTICS
FLUIDITY Good. PRESSURE TIGHTNESS Good, suitable for leak tight castings. HOT-TEARING - Good. TYPICAL POURING TEMPERATURE 720C In practice the optimum pouring temperature will depend on the mould configuration. PATTERNMAKERS SHRINKAGE 1.3% or 1/75.
-

HEAT TREATMENT
Castings are normally used in the solution heat treated condition. LM22-TB (solution treated) heat for 6-9 hours at 515-530C and quench in hot water.
-

114

APPLICATIONS
The main characteristics of this alloy, in addition to ease of founding, are excellent shock resistance and tensile strength. Limitation of Magnesium to a very small content prevents serious age-hardening and so ensures that a high order of resistance to impact loading is maintained. Castings, normally produced in chill moulds and solution treated, are mainly used for heavy duty service in road transport vehicles, e.g., as cross bearers and other structural components.

115

LM24 (EN 1706 AC-46500) ALUMINIUM CASTING ALLOY

(Al -Si8Cu3.5) Colour Code
-

RED/BLUE

This alloy conforms to BS 1490:1988 LM24.

CHEMICAL COMPOSITION
EN 1706 AC-46500
% Copper- - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - Chromium- - - - - - - - - - Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - -

3.0-4.0 0.30 max. 7.5 9.5 1.3 max. 0.5 max 0.5 max. 3.0 max. 0.3 max. 0.2 max. 0.2 max. Remainder 0.15 max.

2.0-4.0 0.05-0.55 (0.15-0.55) 8.0 -11.0 1.3(0.6 -1.2) 0.55 0.55 3.0 0.35 0.25 0.25 (0.20) 0.15 0.05 0.25

Figures in brackets are ingot compositions where they differ from the casting, single figures are maxima.

MECHANICAL PROPERTIES
LM24- M
Chill Cast Die Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

100-120 180 1.5 85 70-100 71 -

150 320 13 3.4 85 138 71 195

The values shown are typical ranges for Chill and Die cast test bars produced to the requirement of B.S. 1490. Die cast test bars were 6mm diameter. Those in heavier type are minimum specification values.

116

STRENGTH AT ELEVATED TEMPERATURES

Room temperature tensile strength is largely retained up to temperatures in the order of 150C, and approximately halved at 250C. It should be noted that other factors may restrict the use of die castings at elevated temperatures.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.000021 0.23 24 2.79 580-520

MACHINABILITY
Machining practice is similar to that for other Aluminium casting alloys containing Silicon. Whilst there is not the tendency to drag associated with high silicon alloys such as LM6, tool wear is more rapid than in the case of alloys containing relatively small amounts of Silicon. The use of carbidetipped tools is recommended but a good finish can be obtained with high speed steels. Lower alloy steel tools may be used, provided they are frequently reground to maintain a sharp cutting edge. A cutting lubricant and coolant should be employed.

CORROSION RESISTANCE
Resistance to attack under normal atmospheric conditions is similar to that of alloy LM4, i.e. fairly good. In marine atmospheres, or under other severe conditions, castings of this alloy should be protected by painting.

ANODIZING
Anodizing treatment by either the chromic or sulphuric acid process produces an anodic film of a grey colour. The surfaces of die castings are not generally suitable for decorative anodizing. Anodizing would be neces sary if this alloy is for use in a corrosive environment.

117

CASTING CHARACTERISTICS
FLUIDITY Good, this alloy is used successfully for thin sections.
-

PRESSURE TIGHTNESS Excellent, suitable for leak tight castings.

-

HOT-TEARING Excellent, castings can be produced without hot

-

tears. TYPICAL POURING TEMPERATURE 700C

-

Pouring temperatures for die castings depend on the machine and casting dimensions; pouring temperatures may vary between 630 710C. The melt should not be allowed to stand at temperatures just above the freezing range as the bottom of the melt will become enriched in Iron and Manganese. PATTERNMAKERS SHRINKAGE 1.3% or 1/75
-

HEAT TREATMENT
Castings in this alloy are not heat treated.

APPLICATIONS
LM24 is essentially a pressure die casting alloy, for which it has excellent casting characteristics and is generally a little simpler to die cast than the higher Silicon containing alloys. Die castings in LM24 are suitable for most engineering applications and have an advantage over an alloy such as LM6 when maximum mechanical properties are required. In practice LM6 is preferred to LM24 only for die castings in which a high resistance to corrosion is the primary requirement. An alloy of composition similar to LM24 is by far the most widely used die casting alloy in the United States of America, and a similar alloy has recently been adopted by the European Die Casting Committee. It is used for vacuum cleaners, floor polishers, motor frames and housings. LM24 has poor weldability and brazeability. For the vast majority of die castings, the alloys LM2 and LM24 are equally suitable.

118

LM25 (EN 1706 AC-42000) ALUMINIUM CASTING ALLOY

(Al-Si7Mg0.5) Colour Code YELLOW/BLUE
-

This alloy conforms to BS 1490:1988 LM25. Castings are standardized in the as cast (M) condition, the precipitation treated (TE) condition, the solution treated and stabilized (TB7) condition and the fully heat treated (TF) condition.

CHEMICAL COMPOSITION
EN 1706 AC-42000
% Copper- - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - -

0.2 max 0.2-0.6 6.5-7.5 0.5 max 0.3 max 0.1 max 0.1 max 0.1 max 0.05 max 0.2 max. Remainder 0.15 max.

0.20 (0.15) 0.20-0.65(0.25-0.65) 6.5-7.5 0.55 (0.45) 0.35 0.15 0.15 0.15 0.05 0.05-0.25(0.05-0.20) 0.05 0.15

*If Titanium alone is used for grain refining, the amount present shall be not less than 0.05%. Figures in brackets are ingot compositions where they differ from the casting, single figures are maxima.

MECHANICAL PROPERTIES
LM25- M
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

80-100 130-150 2 55-65 70-100 71 -

80-100 160-200 3 55-65 80-100 71

119

LM25- TE
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

120-150 150-180 1 70-75 55 71 140

130-200 190250 2 75-95 80-110 71

LM25- TB7
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

80-110 160 2.5 65-75 70-100 71 -

90-110 230 5 65-75 75 71

LM25- TF
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

200-250 230-280 90-110 60 71 180

220-260 280-320 2 90-110 95 71 205

The values shown are typical ranges for sand and chill cast test bars produced to the requirement of B.S. 1490. Those in heavier type are minimum specification values.

STRENGTH AT ELEVATED TEMPERATURES

The tensile properties of LM25 alloy at elevated temperatures are influ enced by the condition (heat treatment) of the castings and the duration at the elevated temperature. On short term testing e.g., 30 minutes at temperature, the properties fall only slowly and uniformly up to about 200C, at which temperature the strength of LM25-TF is reduced by about 20%. Very prolonged heating e.g., 10,000 hours, results in a sharp loss of strength at about 135C. At 200C the strength of LM25-TF is less than half of that at room temperature. There is therefore no advantage to be gained by heat treatment, if the component is to be used at temperatures above about 130C,for extended periods of time.

120

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.000022 0.36 39 2.68 615-550

MACHINABILITY
The heat-treated alloy has fairly good machining properties, but tools should preferably be of high speed steel and must be kept sharp. A moderately high rate of tool wear may be expected. Liberal cutting lubricant should be employed.

CORROSION RESISTANCE
Resistance to corrosive attack by sea water and marine atmospheres is high.

ANODIZING
A protective anodic film can be obtained by either the sulphuric or chromic acid process, but the grey opaque character of coatings of normal thickness precludes their colouring in light shades for decorative purposes.

CASTING CHARACTERISTICS
FLUIDITY Good, suitable for fairly thin castings. PRESSURE TIGHTNESS Excellent, suitable for castings required to be leak tight
-

HOT-TEARING rarely seen.

Excellent, problems due to hot tearing are

-

TYPICAL POURING TEMPERATURE 710C Practical pouring temperatures will depend on the mould configuration. Care must be taken not to overheat the melt or Magnesium may be lost, resulting in poor properties. Care with Chlorination must also be taken to avoid removing Magnesium. PATTERN MAKERS SHRINKAGE 1.3% or 1/75
-

121

HEAT TREATMENT
There are three heat treated conditions commonly used for this alloy: LM25-TE ( precipitation treated ) heat for 8-12 hours at 155-175C and air cool.
-

LM25-TB7 ( solution treated and stabilized ) heat for 4-12 hours at 525 545C and quench in hot water, then stabilize at 250C for 2-4 hours. The time at temperature must be enough to ensure a reasonable stability of the properties, prior to mechanical testing.
-

LM25-TF (fully heat treated ) heat for 4-12 hours at 525-545C and quench in hot water, then precipitation treat of 8-12 hours at 155-175C.
-

APPLICATIONS
LM25 alloy is mainly used where good mechanical properties are required in castings of a shape or dimensions requiring an alloy of excellent castability in order to achieve the desired standard of soundness. The alloy is also used where resistance to corrosion is an important consideration, particularly where high strength is also required. It has good weldability. Consequently, LM25 finds application in the food, chemical, marine, electrical and many other industries and, above all, in road transport vehicles where it is used for wheels, cylinder blocks and heads, and other engine and body castings. Its potential uses are increased by its availability in four conditions of heat-treatment in both sand and chill castings. It is, in practice, the general purpose high strength casting alloy, whose range of uses is increased by its availability in the as-cast and partially heat-treated condition as well. It is used in nuclear energy installations and for aircraft pump parts. LM25 may be superior for castings, particularly in chill moulds, which are difficult to make to the required standard of soundness. It offers better machinability and mechanical properties than LM6.

122

LM26 ALUMINIUM CASTING ALLOY

(A1-Si10Cu3Mgl) Colour Code BROWN/BLUE
-

This alloy conforms to BS 1490:1988 LM26. Castings are standardized in the precipitation treated and artificially aged (TE) condition.

CHEMICAL COMPOSITION
% Copper- - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - -

2.0-4.0 0.5-1.5 8.5-10.5 1.2 max 0.5 max 1.0 max 1.0 max 0.2 max 0.1 max 0.2 max. Remainder 0.05 max 0.15 max.
LM26- TE
Chill Cast

MECHANICAL PROPERTIES
0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

160-190 210 1 1.4 90-120 60-90 71

The values shown are typical ranges for chill cast test bars produced to the requirement of B.S. 1490. Those in heavier type are minimum specification values.

STRENGTH AT ELEVATED TEMPERATURES

The strength and hardness of LM26 at temperatures met in internal combustion engines are high enough for use in such applications. 2 Tensile strength is halved at 270C and is reduced to 55 N/mm at 370C.

123

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) Coefficient of Thermal Expansion (perC at 100-300C) 2 Thermal Conductivity (caI/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.000021 0.000023 0.25 26 2.76 580-520

MACHINABILITY
In machining this alloy there is less tendency to drag than with high Silicon alloys containing no other alloying elements, for example LM6. The machinability of LM26 is slightly superior to that of LM13. Ordinary steel tools tend to wear rather quickly and should not be used, but carbide-tipped tools with large rake angles and relatively low cutting speeds give good results. A cutting lubricant and coolant should be employed. Diamond tools are commonly used for finish machining.

CORROSION RESISTANCE
Resistance to atmospheric corrosion is fairly good but is of little practical significance for an alloy which is used almost solely for pistons for internal combustion engines.

ANODIZING
LM26 may be anodized satisfactorily by the sulphuric acid process. The anodic coating is dark grey. Anodizing, which produces an oil absorbing surface, is sometimes used to give improved bearing qualities to pistons.

CASTING CHARACTERISTICS
FLUIDITY Good, can be cast into relatively thin sections. PRESSURE TIGHTNESS Fair, suitable for leak tight castings. HOT-TEARING Excellent. Hot tearing is rarely encountered with this alloy. TYPICAL POURING TEMPERATURE- 700C In practice, the actual temperatures may range above or below this value and will depend on the mould configuration. PATTERNMAKERS SHRINKAGE 1.3% or 1/75.
-

124

HEAT TREATMENT
For cast pistons, the heat treatment usually consists of heating the castings at 200-210C for 7-9 hours and air cooling in still air.

APPLICATIONS
The particular characteristics which determine the applications of this alloy are its low coefficient of thermal expansion, its retention of strength and hardness at elevated temperatures and its high resistance to wear. Its main use is in petrol and diesel engine pistons. The alloy is widely employed for such purposes in the USA under the designation SAE 332. It is an alternative to LM13.

125

LM27 (EN 1706 AC-42000) ALUMINIUM CASTING ALLOY

(Al -Si7Cu2Mn0.5) Colour Code GREEN/BLUE
-

This alloy conforms to BS 1490:1988 LM27.

CHEMICAL COMPOSITION
EN 1706 AC-42000
% Copper- - - - - - - - - - - - Magnesium- - - - - - - - - Silicon- - - - - - - - - - - - - Iron- - - - - - - - - - - - - - - Manganese- - - - - - - - - Nickel- - - - - - - - - - - - - Zinc- - - - - - - - - - - - - - - Lead- - - - - - - - - - - - - - Tin- - - - - - - - - - - - - - - Titanium- - - - - - - - - - - Aluminium- - - - - - - - - - Others: each- - - - - - - - Others: total- - - - - - - - -

1.5-2.5 0.35 max 6.0-8.0 0.8 max 0.2-0.6 0.3 max 1.0 max 0.2 max 0.1 max 0.2 max. Remainder 0.05 max 0.15 max.

1.5-2.5 0.35 6.0-8.0 0.8 (0.7) 0.15-0.65 0.35 1.0 0.25 0.15 0.25 (0.20) 0.05 0.15

Figures in brackets are ingot compositions where they differ from the casting, single figures are maxima.

MECHANICAL PROPERTIES
LM27- M
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Impact Resistance Izod (Nm) Brinell Hardness Endurance Limit (5x107 cycles; N/mm2) Modulus of Elasticity (x103 N/mm2) Shear Strength (N/mm2)

80-90 140 1 70-85 50-70 71 -

90-110 160 2 75-90 60-90 71

The values shown are typical ranges for sand and chill cast test bars produced to the requirement of B.S. 1490. Those in heavier type are minimum specification values.

126

STRENGTH AT ELEVATED TEMPERATURES

LM27 alloy retains a high proportion of its original room temperature strength at moderately elevated temperatures. For short period exposure, the tensile strength of chill castings is reduced by only 20% at 200C and by 40% at 250 C. The reduction in proof stress is considerably less.

PHYSICAL PROPERTIES
Coefficient of Thermal Expansion (perC at 20-100C) 2 Thermal Conductivity (cal/cm /cm/C at 25C) Electrical Conductivity (% copper standard at 20C) 3 Density (g/cm ) Freezing Range (C) approx 0.0000215 0.37 27 2.75 605-525

MACHINABILITY
LM27 has fairly good machining characteristics and is similar in this respect to LM4-M. For the best results, tungsten carbide tools are recommended. Liberal use of cutting lubricant and coolant is advised.

CORROSION RESISTANCE
Resistance to attack under normal atmospheric conditions is fairly good.

ANODIZING
Treatment by the more common processes produces a protective surface with a greyish opaque film. Anodizing for decorative purposes is generally impracticable for the depth of anodic coating required to ensure adequate durability.

CASTING CHARACTERISTICS
FLUIDITY Good, suitable for thin castings. PRESSURE TIGHTNESS Excellent, particularly suitable for cast ings required to be leak tight. HOT-TEARING Excellent, hot tearing problems are seldom encountered with this alloy. TYPICAL POURING TEMPERATURE 710C Practical temperatures will vary above or below this value dependent on the mould configuration. PATTERNMAKERS SHRINKAGE 1.3% or 1/75.
-

127

HEAT TREATMENT
This alloy is standardized in the as cast condition, but it has been shown that the tensile properties may be substantially increased by an appropriate heat treatment. The response to heat treatment is dependent on the presence of Magnesium so it is important that castings for heat treating should have a Magnesium content at the top of the range, (0.35% max). LM27 -TB7 ( Solution heat treated and stabilized ) heat for 6-16 hours at 505-525C then quench in hot water, and heat for 6-16 hours at 160 170C. The mechanical properties obtained from this treatment depend on the Magnesium content, and are of the following order:
Sand Cast Chill Cast

0.2% Proof Stress (N/mm2) Tensile Stress (N/mm2) Elongation (%) Brinell Hardness

250-280 280-310 0.5-2 110-130

250-290 280-340 1-3 110-130

APPLICATIONS
LM27 is a very versatile alloy and, with its excellent castability, it is suitable for most general purpose castings where moderate mechanical properties are desirable, such as general engineering components, domestic and office equipment, household fittings, electrical tools and switch gear, automobile engine and transmission components. It is equally suitable for sand and permanent mould castings of thick or thin sections, and for castings required to be pressure tight. In short, it can be used with the advantage of slightly superior castability for all the kinds of applications for which LM4 is used.

128