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- . a+"
MATERIALS DATA HANDBOOK
:I/ n 2c^
Aluminum Alloy 2219 . , r* ►1 -
(2nd Edition) b -
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D F E; -I1
Revised by
R. F. Muraca -
(D H
J. S. Whittick Z" r,
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March 1972 nb
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neap
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Prepared for '
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National Aeronautics and Space Administratio, Stp.
George C. Marshall Space Flight Center ?9^'
Marshall Space Flight Center, Alabama 3581 N SRI ^F^V
Contract No. NAS8 - 26644 ^À̀^

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o,
WESTERN APPLIED RESEARCH & DEVELOPMENT, INC.

1403 - 07 Industrial Road San Carlos, California 94070
_ . r.1"
PREFACE
The revised edition of the Materials Data Handbook on the aluminum

alloy 2219 was prepared by Western Applied Research & Development, Inc.
under contract with the National Aeronautics and Space Administration,
George C. Marshall Space Flight Center, Marshall Space Flight Center,
Alabama. It is a revised and updated version of the Handbook originally
prepared by the Department of Chemical Engineering and Metallurgy at
Syracuse University, March 1966.
It is intended that this Handbook present, in the form of a single
document, a summary of the materials property information presently
available on the 2219 alloy.
The Handbook is divided into twelve (12) chapters. The scope of
the information presented includes physical and mechanical property data
at cryogenic, ambient and elevated temperatures, supplemented with useful
information in such areas as material procurement, metallurgy of the
alloy, corrosion, environmental effects, fabrication and joining techniques.
Design data are presented, as available, and these data are complemented
with information on the typical behavior of the alloy. The major source
used for the design data is the Department of Defense document, Military
Handbook-5A.
Information on the alloy is given in the form of tables and figures,
supplemented with descriptive text as appropriate. Source references for
the information presented are listed at the end of each chapter.
Throughout the text, tables, and figures, common engineering units
(with which measurements were made) are accompanied by conversions to
International (SI) Units, except in the instances where double units would
over-complicate data presentation, or where SI units are impractical (e.g.,
machine tools and machining). In these instances, conversion factors are
noted. A primary exception to the use of SI units is the conversion of 1000
pounds per square inch to kilograms per square millimeter rather than
newtons, in agreement with the ASTM that this unit is of a more practical
nature for worldwide use.
_ _ s@Eb
ACKNOWLEDGMENTS
The second edition of "Materials Data Handbook: Aluminum Alloy

2219 " was prepared by Western Applied Research & Development, Inc.
under Contract No. NAS8-26644 for the George C. Marshall Space Flight
Center of the National Aeronautics and Space Administration. The work
was administered under the technical direction of the Astronautics Lab-
oratory, Materials Division of the George C. Marshall Space Flight Center
with Mr. Wayne R. Morgan acting as Project Manager.
Sincere appreciation is tendered to the many commercial organ-
izations and Government agencies who have assisted in the preparation
of this document.
y
ii
TABLE OF CONTENTS
Page
Preface------------------------------------------------- i
Acknowledgments ---------------------------------------- ii
Table of Contents ---------------------------------------- iii
Tabular Abstract---------------------------------------- iv
Symbols------------------------------------------------ v
Conversion Factors - viii
Chapter 1 General Information ------------------------ 1
Chapter 2 Procurement Information ------------------- 3
Chapter 3 Metallurgy -------------------------------- 7
Chapter 4 Production Practices ----------------------- 15
Chapter 5 Manufacturing Practices -- 19
Chapter 6 Space Environment Effects ------------------ 29
Chapter 7 Static Mechanical Properties ---------------- 37
Chapter 8 Dynamic and Time Dependent Properties ----- 83
Chapter 9 Physical Properties ------------------------ 93
Chapter 10 Corrosion Resistance and Protection --------- 99
Chapter 11 Surface Treatments ------------------------ 107
Chapter 12 Joining Techniques ------------------------- 113
A
iii
TABULAR ABSTRACT
Aluminum Alloy 2219
TYPE:
Wrought, heat treatable aluminum alloy
NOMINAL COMPOSITION:
Al-6.3Cu-0.3Mn-0. 18Zr-0.1V-0.06Ti
AVAILABILITY:
Bare and clad sheet, plate, forgings, extrusions, armor plate, wire,
rod, and bar
TYPICAL PHYSICAL PROPERTIES:

Density--------------------------- 2.84 g/cm3 at room temperature
Thermal Conductivity (O temper) --- 0.41 cal/cm/em2 / 0C /sec
(T62 temper) - -- 0.30 cal/cm/cm'/°C/sec
Av. Coeff. of Thermal Expansion --- 22.3 microin/in/" C (20-1000C)
22.3 µcm/cm/° C
Electrical Resistivity (O temper) --- 3.9 microhm-cm at 20 0 C
(T62 temper) --- 5.7 microhm-cm at 20 0 C
TYPICAL MECHANICAL PROPERTIES:

Ft (O temper) ------------------- 25, 000 psi (17.6 kg/mm2)
T62 temper) ------------------- 60, 000 psi (42.2 kg/mm2)
Fty (O temper) ------------------- 11, 000 psi ( 7.7 kg/mrn 2 )
(T62 temper) ------------------- 42, 000 psi (29.5 kg/mine)
e (2 inch, 50.8 mm) (0 :.emper) ----- 18 percent
(T62 temper) ----- 10 percent
E (tension) ------------------------ 10.6 x 10 6 psi (7.5 x 103 kg/mm2)
FABRICATION CHARACTERISTICS:
Weldability ----------------------- Excellent (fusion and resistance
methods)
Formability ---------------------- Slightly superior to 2014 alloy
Machinability --------------------- Good in annealed condition
COMMENTS:
Alloy has good mechanical properties at cryogenic temperatures and at
elevated temperatures up to 600°F (316°C). Recommended for applic-
ations requiring high strength weldments.
c
J
iv
.Ss"
SYMBOLS
a One-half notch section dimension

A Area of cross section; "A" basis for mechanical
property values (MIL-HDBK-5A)
A Angstrom unit
' AC Air cool
AMS Aerospace Material Specifications
Ann Annealed
ASTM American Society for Testing Methods
Av or Avg Average
B "B" basis for mechanical property values (MIL-
HDBK- 5A)
b Subscript "bending"
bcc Body centered cubic
BHN Brinell hardness number
br Subscript "bearing"
Btu British thermai unit(s )
C Degree(s) Celsius
c Subscript "compression"
CD Cold drawn
CF Cold finished
cm Centimeter
c Specific heat
a Cold rolled
CW Cold worked
CVM Consumable vacuum melted
D or Dia Diameter
DPH Diamond pyramid hardness
e Elongation in percent
F Modulus of elasticity, tension
►_, Ec Modulus of elasticity, compression
e/D Ratio of edge distance to hole diameter
Es Secant modulus
• Et Tangent modulus
eV Electron volt(s)
OF Degree(s) Fahrenheit
f Subscript "fatigue"
Fbru Bearing ultimate strength
Fbry Bearing yield strength i
v
-- .Lo"
fcc Face centered cubic

FC Furnace cool
Fc Compressive yield strength
Fsu Shear stress; shear strength
Ftu Ultimate tensile strength
Fty 0, 216 tensile yield strength (unless otherwise indicated)
g Gram
G Modulus of rigidity
HAZ Heat affected zone in weldments
hcp Hexagonal close pack
hr Hour(s)
HT Heat treat
IACS International annealed copper standard
in Inch
ipm Inches per minute
°K Degree(s) Kelvin
K Stress intensity factor; thermal conductivity
Kc Measure of fracture toughness (plane stress) at point of
crack growth instability
kg Kilogram
KIc Plane strain fracture toughness value
ksi Thousand pounds per square inch
Kt Theoretical elastic stress concentration factor z
L Longitudinal i
lb Pound
LT Long transverse (same as transverse)
M Bending moment
M Meter
M Subscript "mean"
Max Maximum
ml Milliliter
MIL Military
Min Minimum
mm Millimeter
N Cycles to failure
NSR Notch strength ratio
NTS Notch tensile strength
OQ Oil quench
ppm Parts per million
pt Point; part
J
vi
_ .&a"
r Radius
RA Reduction in area; Rockwell hardness A scale
RB Rockwell hardness B scale
RC Rockwell hardness C scale
rpm Revolutions per minute
RT Room temperature
SA Solution anneal
sec Second
S-N S = stress; N = number of cycles
Spec Specifications; specimen
ST Solution treat; short transverse
STA Solution treated and aged
T Transverse
t Thickness; time
Temp Temperature
typ Typical
Var Variable
VHN Vickers hardness number
W Width
WQ Water quench
k,
vii
.iAS"
CONV ERSIUN FACTORS
To Convert To Multiply By
angstrom units millimeters 1 x 10 -7
Btu/lb/"F cal/g/'C 1
Btu/ft`'/ sec /''F-inch cal/g/cm2/sec/°C-cm 1.2404
circular mil square centimeters 5.067 075 x 10 -6
cubic feet cubic meters 0.028 317
cubic feet/minute liters/second 0.4720
cubic inches cubic centimeters 16.387 162
feet meters 0. 304 800 609
foot-pounds kilogram-meters 0. 138 255
gallons (U.S.) liters 3.785 411 784
inches millimeters 25.4
kei (thousand pounds kilograms/square millimeter 0.70307
per square inch
microns millimeters 0.001
mils millimeters 0.0254
ounces (avoir.) grams 28.349 527
ounces (U.S. fluid) milliliters 29.5729
pounds (avoir.) kilograms 0.453 592 37
pounds /foot kilograms /meter 1.488 16
pounds/cubic foot grams /cubic centimeter 0.016 018 463
square feet (U.S. square meters 0.092 903 41
square inches (U.S.) square centimeters 6.451 625 8
Temperature in "C = ('F — 32) (5/9) p

Temperature in °K = "C f 273.15
viii
_gf' i
Chapter 1
GENERAL INFORMATION
1 . 1 Aluminum alloy 2219 is a heat-treatable wrought alloy developed

by the Aluminum Company of America (Alcoa) in 1954 for applic-
ations at temperatures up to 60r O F (3150 C). Tyîcal mechanical
properties of 2219 in the 500" -600° F (260° -315 C) temperature
range are superior to those of any other commercially available
aluminum alloy (ref. 1. 1). The weldability of the alloy is excellent.
Mechanical properties of welded and unwelded 2219 at tempera-
tures down to -4230 F (-2530 C) are also excellent.
1.2 The alloy has flood tensile and yield strength and good fatigue and
creep- rupture properties up to temperatures of 600° F (315 0 C). Its
forming characteristics are similar and slightly superior to 2014
alloy. The alloy has good machining qualities in the annealed con-
dition. It appears not to be susceptible to stress-corrosion cracking
provided that proper heat treating procedures are employed. The
'1219 alloy is available as sheet and plate, forgings, extrusions,
armor plate, wire, rod, and bar; alclad 2219 is available as sheet
and plate (refs. 1. 2, 1.3).
1.3
Typical applications for 2219 alloy are in aircraft and automotive
engine parts; it has special applications in missiles, space vehicles,
and ground support equipment (ref. 1.2).
1.4 General Precautions
1.41 Care should be taken when reheat treatment of clad alloy is required
because copper tends to diffuse through the cladding to the surface,
thereby decreasing resistance to corrosion.
1.42 Any solution heat treatment of clad 2219 should be performed as
quickly as is consistent with MIL-H-6088E. As a general rule, no
more than one complete reheat treatment should be performed.
The number of annealing treatments should he kept to a minimum
and performed as rapidly as possible (ref. 1. 1).
_ . -ms"
31
Chapter 1 - References
1.1 L. W. Mayer, "Aluminum Alloy 2219, " Alcoa Green Letter,

November 1963.
3
1.2 Alloy Digest, "Aluminum 2219," (Filing Code Al-96, Aluminum

Alloy), Engineering Alloys Digest, Inc., New Jersey, October
1960.
ft
1.3 Aluminum Standards and Data, 2nd Edition, The Aluminum

Association, New ur , ew York,1969 (second printing; 1970).
1.4 Aerospace Structural Metals Handbook, J.G. Sessler and V. Weiss,
'Ede., A -ll , 1971 Edition.
- x
I
(
Chapter 2
PROCUREMENT INFORMATION
2.1 General. Aluminum 2219 alloy is available as sheet, plate,

oorgi.igs, extrusions, wire, rod, and bar. Alclad 2219 is
available as sheet and plate. Detailed tables of standard sizes
available and standard tolerances for the various products
are given in references 2.1 and 2.2.
2.2 Procurement Specifications, table 2.2
2.21 NASA Specifications
2.211 MSFC-SPEC-144B, "Aluminum Alloy Forgings, Premium
Quality, Heat Treated," August 13, 1963, and Amendment 1,
September 8, 1964. Terzpers: T4, T6, T31, T352, Tf,'.,
T852. Prepared by George C. Marshall Space Flight Center.
Custodian: NASA-1\4SFC.
2.3 Major Producers of the Alloy (United States only)
Aluminum Company of America
1501 Alcoa Building
Pittsburgh, Pennsylvania
Kaiser Aluminum and Chemical Sales, Inc.
919 North Michigan Avenue
C1:;.c.-tgo, Illinois
Reynolds Metals Company
6601 West Broad Street
Richmond, Virginia
2.4 Available Forms, Sizes, and Conditions
2.41 Commercial sizes available for sheet, sheet circles, plate
and plate circles, table 3.41.
V
3
TABLE 2. 2. — Procurement Specifications (a)
Suurce Ref. 2.3, 2.4, 2.5, 2.6

Alloy 2219
Product Temper Military Federal ASTM SAE
AMS HDBK
Sheet and plate O MIL-A-8920A - B209-71 4031B AA2219
F, T31, T351 MIL-A-8920A - B209-71 - -
T37, T62, T81 MIL-A-8920A - B209-71 - -
T851, T87 MIL-A-8920A - BZ09-71 - -
Forgings T6, T852 - QQ-A-367f - - -
T6 - - B247-70 4143 -
Bar, rod, shapes, O, T62 - - B221-71 - -
tubes (extruded) T8510, T8511 - - B221-71 4162 -
(a) Specifications as of June 1971
4
_ -:v!
TABLE 2.41. —Commercial Sires and Tempers Available for Sheet,

Sheet Circles, Plate, and Plate Circles
Source Ref. 2.1 (a)

Alloy 2219
Product Temper Thickness, Size, max (b, c, d)
inch (d) Width, in Length, in
Alclad and bare O, T31, T8i 0.014-0.022 48 180
sheet and sheet 0.023-0.029 60 180
circles 0.030-0.036 60 180
(flat, mill 0.037-0.059 84 200
finish) 0.060-0.075 90 300
0.076-0.095 90 300
0.096-0.119 96 360
0.120-0.249 102 360
Alclad and bare T37, T87 0.020-0.031 24 -
sheet and sheet 0.032-0.039 36 -
circles 0.040-0.059 48 -
(flat, mill 0.060-0.124 72 72
finish) 0.125-0.249 84 84
Alclad and bare T37, T87 0.250-0.374 90 X10
plate and plate
circles (flat,
mill finish)
(a) Consult producers of alloy for further information.

(b) Maximum diameter of circle same as maximum width o' sheet.
(c) Sizes greater than indicated can be supplied subject to inquiry.
(d) 1 inch = 2. 54 cm.
11.
-i1"
Chapter 2 -- References
2.1 Aluminum Company of America, "Alcoa Aluminum Handbook,"

1.9 62 .
2.2 Aluminum Standards and Data, 1970-71,Second Edition, Aluminum

Association of America, New York, New York.
2.3 SAE Aerospace Material Specifications, Society of Automotive En-
gineers, Inc., latest Index, May 15, 1971.
2.4 Index of Specifications and Standards, Department of Defense, Part I,
Alphabetical Listing, I July 1970; supplement, 1 May 1971.
2.5 ASTM Standards, Part 6, "Light Metals and Alloys," American Society
or Testing Materials, 1971.
2.6 1971 SAE Handbook, Society of Automotive Engineers, Inc., New
York, New York.
i^
e1.

Chapter 3
METALLURGY
3.1 Chemical Composition

3.11 Nominal chemical composition of 2219 in percent (ref. 3. 1):
Cu 6.3
Mn 0.3
Ti 0.06
V 0.10
Zr 0.18
Al Balance
f
3. 111 Sheet and plate are available in the Alclad condition. Cladding
material is 7072 alloy. Nominal composition of 7072 alloy in
percent (ref. 3.2):
Zn 0.9-1.3
Si + Fe 0.7
Mn 0. 1 max
Cu 0. 1 max
Mg 0. 1 max
Others
Each 0. 05 max
Total 0.15
Al Balance
The nominal cladding thickness per side is 10 percent of the total
thickness of the composite if the latter is below 0.040 inch and 5
percent for a total thickness of composite products of 0.040 inch
to 0. 099 inch. Fur a total thickness of 0. 100 inc% -)r more the... noin.-
inal cladding thickness on each side is 2.5 l,_:rcer_t (ref. 3. 3).
Note: 0. 1 inch = Z. 54 mm. )
3.12 Chemical composition limits, in percent (ref. 3.3):
Si 0.20 max
Fe 0. 30 max
Cu 5.8 to 6.8
Mn 0. 2 to 0.4
Mg 0. 02 max
Zn 0.10 max
Ti 0.02 to 0. 10
V 0.05 to 0. 15
Zr 0.10 to 0.25
Others
Each 0.05 max
Total 0.15
Al Balance
.s1OVf
These composition limits are normally checked by spectrochemical

analysis or in accordance with the procedures outlined in ASTM
E34, "Standard Methods for Chemical Analysis of Aluminum and
Aluminum Base Alloys," (ref. 3. 1).
3.13 Alloying elements. Copper is the primary hardening agent, with
vanadium and zirconium acting as grain refiners by increasing the
recrystaliization temperature. Zirconium and manganese improve
the strength properties, particularly at elevated temperatures. The
primary precipitation hardening agent is CuAl, (see figure 3.13).
Since Mg and Si are held to extremely low composition limits, the
occurrence of their low melting, eutectics (Al-Cu-Mn-Si) is essen-
tially eliminated and the alloy can be solution treated just below the
Al-Cu eutectic which occurs at 548 0 C. At this; temperature, most of
the CuA1 4 will go into solution (ref. 3.4). Copper and the other alloy-
ing elements decrease the resistance to corrosion of aluminum. The
Al-Cu constituent is more cathodic than Al and more anodic than the
solid solution containing more than 2. 5% Cu (ref. 3.5, p. 918). Since
initial precipitation usually occurs along grain boundaries, zones
lean in solutes will develop near the grain boundaries. These anodic
zones may corrode selectively by an electrochemical process, pro-
ducing notches that cause stress concentrations. However, this does
not occur in properly heat treated and aged commercial tempers
(ref. 3. 6). As the alloy structure (i. e. , precipitate and solid solution
relationship) is modified by heat treatment, its resistance to corro-
sion, stress corrosion, and weathering will be altered. The amount
of protection provided by the cladding depends on the thickness and
the purity of the cladding material, and also on the annealing and
heat treatment practice (see section 3. 111).
3.2 Strengthening Mechanisms
3.21 General. The alloy can be strengthened by precipitation hardening
and cold work. The precipitation hardening ricchanisms are clearly
evident from the phase diagram in figure 3.13. After quenching from
the solution temperature to room temperature, slow precipitation
occurs in the form of submicroscopic particle- whicii represent
obstacles to plastic flow and thus cause hardening. Cold working
greatly accentuates precipitation hardening in this alloy. This is a
general property of most aluminum alloys and is related to the crys-
tal structure (fcc) and the stacking fault ener^Ty. Various processing
operations utilize the effects of both mechanisms (i. e. , cold working
of the solution treated alloy at room temperature and subsequent
aging at room or elevated temperatures).
Caution should be used when reheat treatment of alloy is contemplated.
Studies at the Naval Air Material Center (ref. 3.7) have indicated that
only one reheat treatment of 2219 -T6 Alclad sheet was possible before
copper began to diffuse through the clad material to the surface.
3.22 Heat Treatment.

Annealing (O Condition): The annealing treatment for precipitation
Marclening alloys is essentially an overaging treatment. Two to
three hours at 400 0 to 413° C followed by slow cooling at 28 0 C/hr
maximum to at least 260" C is recommended (ref. 3. 8). Inter-
rnediate anneals during repeated cold working operations should
be carried out at 3440 C for no more than 30 minutes at a time.
Solution Treatment T4 Condition): Heat. to 532° to 543'C and hold
from 26 m nutes to 4, oursepending on thickness and equip-
ment, following by a rapid cold water quench. The proper desig-
nation is T42 if the operation is performed by the user. It should
be noted that the solution treating temperatures should be closely
controlled. Higher temperatures may cause solid solution grain
boundary melting, high temperature oxidation,and eutectic melting
which cannot be repaired by subsequent heat treating operations.
Lower temperatures may result in incomplete solution of the hard-
ening constituents and thus a loss in hardening potential of the alloy.
Rapid quenching is also important because of possible precipitation
and consequently reduced corrosion resistance on slow cooling
from the solution treating temperature. Maximum allowable
quench delay times are listed below:
Nominal Thickness. Maximum Time, Seconds
<0. 016 inch <0.406 mm

0. 017-0.031 0.432-0.787

0.032-0.090 0.812—Z. 29 10

:0. 091 >_2. 31 15
Aging Treatment (T6 Condition): Heat T4 or T42 condition to 1800

to 194'C and 1T for 36 hours. If performed by user, for plate
and extrusions, the correct temper designation is T62.
Cold Work -nd Combined Treatments: All Cold work and combined
treatments to;-ct er with the so cation and aging treatments for
various products are summarized in table 3.22 (ref. 3. 9).
3.3 Critical Temperatures. Melting range 5430 to 644° C. The oxid-
ation resistance in normal atmosphere is generally good until the
melting temperature is approached.
3.4 Crystal Structure. Face-c"entered cubic. The lattice parameter
epênds primarily on the amount of Cu in solution. For pure alum-
inum, ao = 4.0413 A; for 5. 5% Cu, ao = 4.0290 A (ref. 3. 9, p.49).
-zV ►
3.5 Microstructure. References 3. 10 and 3. 11 are recommended as

excellent sources of information on the identification of constituents
in aluminum alloys.
3.6 Metallo Y ra hic Procedures. In general, mechanical polishing is
preferred to a ectropo is ling, especially where larger microcon-
stituents are present and the material is relatively soft, as ob-
jectionable relief effects produced by the electrolytic polishing
technique may cause a misinterpretation of the microstructure
(ref. 3. 11, p. 106). For homogeneous alloys, and for those condi-
tions containing only finely dispersed particles, the electrolytic
method is excellent. Preparatory polishing on metallographic pol-
ishing papers 0 to 000 should be performed wet with a solution of
50 g paraffin in 1 liter kerosene to keep the specimen bright and
avoid imbedding of grinding compound particles into the soft spec-
imen surface. Rough polishing on a "Kitten's Ear" broadcloth at
250 to 300 RPM with heavy magnesium oxide powder is recom-
mended (refs. 3.10 and 3. 12).
An alternate and popular method consists of she following steps:
a) Wet polishing (flowing water with 210-grit silicon carbide
paper at approximately 250 RPM.
b) Wet polishing with 600-grit silicon carbide paper at
approximately 250 RPM.
c) Polishing with 9-µm diamond paste on nylon cloth at 150
to 200 RPM using a mild soap solution for lubrication.
d) Final polish on a vibratory polisher using a microcloth
containing a slurry of methyl alcohol and 0. 1-µm alum-
inum oxide powder. A slurry of 0. 1-µm aluminum oxide
powder in a 10% solution of glycerine in distilled water
may also be used for this step.
Etching reagents have to be suited to the objective of the study.
Kellers etch reveals microstructural details and grain boundaries
satisfactorily. A 10-percent solution of NaOH gives better detail
of the mic.roscturctural constituents but does not delineate the
grain boundaries. Study of the "as polished" surface prior to etch-
ing may also give valuable information on the types of the consti-
tuents present, especially when attention is paid to the colors of the
various particles. Macroscopic studies for cracks, gross defects,
forging lines and grain structure should be made with the following
etching solutions. 10% NaOH (cracks, gross defects), Tucker's etch,
modified Tucker's etch, and Flick's etch (rof. 3.10, p. 95). These
etching solutions for revealing the macrostructure are given in
table 3. 6.
10
.ritE ^
0 k
N 00
N
to t —e
+ U
N .O V
N v AV
r. ro
b b 00 U
bb a^
iti 1 I
H k H O Id O
U WO
^Q M ►r: O ^+ 1 cd 1 1 N 1 Id of
w Ir O ^
.^ U1 1.4 /4
N ^° U cn ^ c^ H f H^ H^
N cd
3
ro
+ `^ 14 0 0
U
L•i
p b to
y
H 4 4-S 0
M
^ 1 1 x M 1 1 1 1 1
LM ^ i It
U1
• O 8' O
Qi W
1♦ 0
O N
w M
U1
N 0
a^ 0 00 U
v •-4
d ^. ,ti c la ^
ro y VC,
cad too 4
cd 00 1 0
,.^ 1 E-I 1 j 1 1 1 1 1 !d y 1
Jr M O x 14 1 cd O p m
H w µ, u
a) U) M H ,s~
w (n ^ ^Q
i
ro
l^ !A
'b
U ;4
ro
C."
N
41 b,u, U
rd
U
1 H$4 1 00 1 1 1 Ids 1 cd
ri xN ^
H .^ O Id M y
10
WM 0. H Id
04 ^ N
(d
1 N
N + + .0 00 U b
M -4 0
M b)
ro a ^_ ro ro N cd
W ^0
aî
Hv H
Id cd ^' ew O
x y
N
t
1
x t 1
N fn
^ 1 I H
.-i
O t"' O ^ M }r O V-.4
H cn m H H ,:~ 1♦ to
"' a k
t ^ 0
Id td •^ 0
O
UQ, v .r O `^ .-1 O
.a Ln in
-4 .-i
U1 U1 tl N N -4 w 111
-4 .-1
U? U1 t-
wmz
d M Mm M M M er ^D %0 00 0000 00 CO 00
v
to ^' H HH HH H H H H H H HH H H Id ,1?
v v v
11
._ lSx"
TABLE 3.6. — Itching Soltuti,>rns I ' m- R , %caling Macrostructure
Source 12
Alloy — — 2)J t!
Solution Ccmcentrat.i.mi (a) Specific Use
So diuin Hydroxide. Na0I1 10 , Fm cleaning surfaces, revealing;

ater 90 in] unsoundness, cracks, and gross
cicfec:ts
TUCkor's IICI. (cone.) 4 r nil For revealing structure of

IINO,, (cone.) I ti tail castings, forgings, etc.
IIF (=I Ii`r^,) 1') 1111
Water fill
Modified IHC1 (cone.) 10 n,l_ For revealing structure of all

Tucker's IIiNO,. (cone.) 10 nil castings and forgings except
IIF (481 3°,) 5 ml Iii0h silicon alloys
Water i') till
Flick's IICI (cone.) 1 5 nil For revealing grain structure of i

H (48`y„) 10 nil. cluralurnin type alloys. Surface
Water 90 m1 should be machined or rough
polishe d
v
(a) All of these solutions are ttsecl at rooni temperature.
12
-41"
Atomic Percentage Copper

1 e v
'C *f
L 1200
600 (Al t L
tAl) 1000
500
600 800
300 (A0 t (AI-Cu 800

zoo 400
loo 200
0 1 2
AI 3 4 b 8 7 8 8 H
Weight Percentage Copper L
Aluminum—Copper
FIGURE 3.13. — Binary phase diagram of the

aluminum rich portion of the Al-Cu
equilibrium diagram.
(Courtesy Aluminum Co. of America)
a
13
Chnptc • r I - References
3.1 Aluioimim Standards and Data, Second Edition, The Alumin un

Assoc iat i0", New York, N. Y. , 1 909 (second printing; 1970).
;. 2 1971 SAC l tanclliook, Society of Auto>i„o,tive Enôinecrs, Inc.

New York.
;. ; ASTNI Standards, Part 6, 13209-71, American Sc>cioty for

'resting; Materials, 177-
1.
3.4 Martin-Denver Go., "Summary Information Regarding; Aluniinurn

Alloy 2219,' 1 Evaluation Report No. 1, MI-61-44, November 1961.
3. 5 Metals Ilanclbook, Eighth Edition, Vol. I, American Society for

Metals, Metals Marl:, Novelty, Ohio, 1901.
3.6 1. A. Nock, ,I r., et al . , "A New High Strength Aluminum Alloy,"

Metal I'rowrrss, Septcniber I'MI, p. 87.
3. 7 R. G. Mahorter, Jr. and W. 1 , '. Emmons, "A Study of Creep

Resistance, Formability and Heat Ti—citment of Clad X 2219- T6
Aluminum Alloy," Report: No. NAM(,- -AML-AE 1100, Naval Air
Material Center, August 1959.
3.8 Aluminum Company of America, "Alcoa Alloy 2219," March 1959.
3.9 L. W. Mayer, "Alcoa Aluminum Alloy 2219," Alcoa Green Letter,
October 1960, revised November 190i.
3.10 F. J<cller and G.W. Wilco::, "Identification of Constituents of
Aluminum Alloys," Technical Paper No. 7, Aluminum Company
of America, 1942, revised 1958.
3.11 J. P. Vidosic, "Study of Phase Identification in Steel and Aluminum
Allovs," Georr,ia Institute of I t , cl nolog y, Final Report, Project No.
A-+,4 t, NASA Contract NAS8-51 17. September 1963.
14

1-5.10V
Chapter 4
PRODUCTION PRACTICES
4.1 General. In the United States, aluminum and its alloys are pro-
duced from an ore of impure hydrated aluminum oxide known as
"bauxite." Important sources of bauxite are located in Arkansas,
Dutch Guiana, and Jamaica. The impure ore is converted into pure
aluminum oxide (alumina) through a series of chemical processes.
Oxygen is removed from the alumina by smelting in carbon-lined
electric furnaces known as reduction pots. Pure molten aluminum
is deposited at the bottom of the pot, and is periodically siphoned
off and poured into molds to form "pigs" and "sows." A separate
furnace operation is used to form "alloy pig" from the pure alum-
inum by the addition of alloying elements and this metal is cast
into ingots for further processing (ref. 4.1).
For the 2219 allay, the main additional alloying elements are copper
and manganese. Small amounts of titanium, zirconium, and van-
adium are also added. Generally, this phase of production practice
involves carefully-controlled melting, alloying, and casting of
large ingots (20, 000 to 50, 000 pounds ( 9000 to 23, 000 kg)). After
t',e ingots are scalped and preheated in vertical electric soaking
pits, they are ready for further processing to a particular form
of product.
4.2 Manufacture of Wrought Products
4.21 Bar and rod are normally produced by hot rolling or extruding.
Cold finished bar and rod are produced by riot working to a size
slightly larger than specified and reducing to final dimensions by
cold working. A Metter surface finish and closer dimensional tol-
erances are obtained in this manner (ref. 4.2).
4.22 A similar process is used to produce rolled structural shapes,
special rolls being required. Finishing operations include roller
or stretch straightening, and heat treatment.
4.23 Roll-form shapes are produced by passing strip through a series
of roller dies. Each successive pair of rolls cause the work to
assume a cross-section shape more nearly approaching that desired.
The final desired shape is produced at the last pair of rolls.
4.24 Plate is produced by hot rolling of ingots to slabs (approximately
60-percent reduction), usually in a 4-high reversible mill. The
slabs are then further reduced 50 percent in a reversible 2-high
mill. The last stage of hot rolling is done in a hot reversing mill,
15

- •VV"
where the plate is progressively rolled to the final hot mill dimen-
sions. Plate may be subjected to "stress relief" stretching (about
2-percent permanent set) to improve flatness and reduce warpage
upon machining. Plate is then sheared or sawed to the required
dimensions (ref. 4.2).
4.25 Sheet is usually produced from plate by cold rolling to final sheet
thickness, followed by trimming, annealing, heat treating, stretching,
and ether finishing operations.
4.26 Wire is produced by drawing rod through a series of progressi-ely
smaller dies to obtain the desired dimensions.
4.27 Extrusions are produced by subjecting reheated cast billets to enough
pressure to force the metal to flow through a die orifice, forming a
product whose cross-section shape and size conforms to that of the
orifice. Speeds, pressures, and temperatures must be closely con-
trolled to insure uniform quality of extruded products.
4.28 Tube is produced by extruding or by welding. Extruded tube is made
by forcing cast billets through an orifice as described in 4. 27; a die
and mandrel are used. Welded tube is produced by slitting coil stock
into strips and passing the strips through a series of rolls to form
tube; the longitudinal seam is welded as the tube leaves the last roll-
forming station.
4.29 Forgings are made by pressing (press forging) or hammering (drop
forging). Relatively heavy equipment is required since aluminum is
not as plastic at its forging temperature as steel. Aluminum forgings
compare favorably with structural steel in unit strength at about one-
third the weight. With comparable strength and with a lower elastic
modulus, aluminum alloys have a much higher impact-energy-absorb-
ing capacity than mild steel.
4.3 Casting of Alloy Ingots
4.31 Metal for wrought products is alloyed in large 10- to 25.-ton double
hearth furnaces, carefully controlled and instrumented. The direct
chill (DC) method is generally used for casting these ingots. Molten
metal is poured into a mold and a hydraulic piston descends slowly
as the metal solidifies. Water is sprayed on the outside of the mold
to promote apid solidification. Additional processing may include
scalping (machining of outside surfaces) or homogenizing (refs. 4.2
and 4. 3) .
16

.tt"
4.1 Ka. r Aluminum and Chemical Sales, Inc., "Kaiser Aluminum

Sheet. and Plate Product Information," Second Edition, January
1958.
4.2 Reynolds Metals Co., "The Aluminum Data Book, Aluminum
Alloys and Mill Products," 1958.
1962.
f -
1 1,
_;
17

PRECMING PAGE BLANK NOT PITM1',,.
Chapter 5
MANUFACTURING METHODS
5.1 General. This heat-treatable alloy is available bare and in the

Alclad condition. Although the alloy was originally developed for
forged parts to be used up to 600 0 F (3150 C), it is now available
in many forms as shown in table 5. 1.
5.2 Forming
5.21 Sheet and Plate. The alloy 2219 exhibits equal or superior form-
= ability characteristics to 2024 and 7075 for comparable tempers
(ref. 5. 3). Results of Olsen cupping tests indicate that the 2219
alloy is slightly more formable than 2024. Both alloys were tested
clad and bare, in both "O" and "T6" conditions. Dimpling for rivet-
ing, on the basis of 3/16-inch dimples in 0.064-inch sheet, was
satisfactory when performed at room temperature. However,
2219-T6 exhibited slight edge cracking when dimpled at room temp-
erature. This was eliminated by hot-dimpling at 350 0 F (1770 C)
(ref. 5. 12).
5.211 Cold forming. The formability of alloy 2219 sheet and plate is
directly related to the temper strength and ductility. As with other
aluminum alloys, high elongation , as well as considerable spread
between yield and ultimate strength will be indicative of good form-
ability. The simplest and most widely used forming method is prob-
ably that of bending. Table 5.2111 indicates the ease of forrning in
terms of recommended minimum bend radii as a function of temper,
and sheet and plate thickness, using typical mechanical properties
for 0.100-inch (1:.254-cm) sheet.
Formability is al. a maximum in the annealed temper and is equal
to or slightly superior to that of other high strength aluminum alloys
such as 2024 and 7075 (ref. 5. 1). In general, severe forming and
drawing operations should be done with annealed stock, and the
tools must be clean and free of scratches. Less severe operations
may be performed on material in the T42, T31, and T37 tempers.
Although some mild .forming operations can be performed on arti-
ficially aged material, the more critical operations should be done
while the material is in the solution-treated or naturally-aged con-
dition. Forming; may be performed during the heat treatment cycle.
Table 5.2112 indicates the heat treatments which are used and the
resulting temper., for the alloy. The solution treatment for all
products consists of heating to 595 0 F f 100 F (5350 C f 5" C) and
quenching into cold water. The alloy is then artifically aged. Since
the alloy ages very slowly at room temperature, solution-treated
and naturally-agr.d material retains good formability for a
19
_ .4.1wo
considerable period of time. In comparison, alloys 2014 and 2024 age

rapidly enough at room temperature to develop high strength prop-
erties within four days. Artificial aging, upon completion of a form-
ing operation, leads to much higher strength in the final structure.
Aluminum sheets are normally formed using operations such as:
1. Bending 9. Stamping
2. Flanging 10. Spinning
3. Rolling 11. Contour Forming
4. Drawing 12. Bulging and Exr3anding
5. Pressing 13. Beading and Roll Flanging
6. Stretching 14. Necking
7. Embossing 15. Curling
8. Coining
The factors influencing bending of 2219 sheet as spelled out previously
also influence the 14 other forming operations in the same general
manner.
Because of the lower modulus of elasticity of aluiiinurn compared
with steel, a much greater "springback" is expected and indeed is
encountered. Over-forming is the common way of correcting the
tendency. All of the bending precautions described in the handbook
on alloy 2014 should be considered.
5. Z2 Shapes, Tubes, and Pipes. The use of aluminum shapes of the 2219
alloy have been limited but this is a reflection of the fact that the
manufacture of the alloy has only been from about 1960. However,
the alloy is amenable to the standard production techniques.
5.23 Forging. Forgings are made using either the open die or closed
die methods and by impact or pressure. Small runs are made using
the hand-forging, open-die techniques. Hand forgings over a ton
in weight can be made. As in all forgings, there is a grain flow in
2219 which is characteristic of the forging process. The resulting
grain pattern results in anisotropy of properties and this must be
considered for the property evaluations. The process for most pro-
duction forgings starts with the stock which can vary from 3/8 inch
to 8 inches diameter round stock; from 3/8 inch to 4 inches square
stock; and rectangles from 3/8 inch for the minimum dimension to
as much as 10 inches on the maximum dimension. Conditioning to
remove localized surface defects is permitted at this point. The stock
is carefully heated in the range of 650' to 875° F (362 0 to 4570 C).
After preheating, the stock can be forged to shape in one step or, in
the case of complicated parts, in several operations involving sev-
eral reheatings. Dies in the forging operation are .heated with aux-
iliary gas or electric heaters. The flash resulting from excess metal
overfilling in the mold is removed by hot or cold trimming, sawing,
or grinding. Holes in the forging are pressed to produce "punchouts"
in the forging. Sometimes the punchout is combined with the trim
operation. Very close tolerances can be met in the standard forging
20

-C11"
by die coining (cold) to precise dimensions, usually within a few

thousandths of an inch (70 ^tm). Straightening after heat treatment
is often a required operation. Templates combined with indicators
and other gages are used to determine the out-of-tolerances.
Straightening ranges from hand straightening to "cold restrike"
operations. ( Note: 1 inch = 25.4 mm. )
The forgings are inpsected for grain flow, mechanical properties,
dimensions, and ultrasonic soundness. A design manual for die
forgings is available from the Aluminum Association ( ref. 5.14).
5.3 Machining
5. 31 Conventional machining. This alloy has good machining qualities
in the annealed state (ref. 5. 2). Since most of the machining is
done in the .heat treated condition, lathe tools should be ground to
10-200 side rake, and 8- 100 clearance. Parting tools should have
a 15--200 top rake with a 4-5 0 side rake. Planer and shaper tools
for roughing cuts should have a 12-150 top rake, 32 - 380 side rake,
and a 8-100 front and side clearance. Finishing tools should have
a 45-500 top rake, 50-60 0 side rake, 8-100 front clearance, and
little or no side clearance. Twist drills should have larger spiral
angles than standard highly polished deep flutes, narrow bands,
and up to 180 lip clearance. Threading taps jhould have highly pol-
ished flutes and should be undercut; spiral fluted taps are usually
better than straight fluted. The rake angles should be increased
to 12-180 . Soluble oil emulsions, kerosene, and kerosene-lard oil
mixtures are recommended for most machining operations, but
high viscosity lubricants are recommended for tapping operations.
It is difficult to produce a precise tabulation of machining para-
meters for each of the different types of operations. However,
table 5. 31 is a compilation of typical factors for many common
machining operations ( ref. 5.8) and can be used as a guide. Grind-
ing typically uses awheel speed of 6000 ft/min and a table speed
of 60 ft / min. A down feed will produce a rough finish if it is kept
about 0. 001 inch per pass (25 Etm), and a fine finish if the down
feed is kept below 0.0005 inch per pass ( 12.5 I m). The cross feed
is approximately one-third of the wheel width.
5.32 Electrochemical and Chemical Machining
5. 321 General Remarks. Weight reductions are important for space
vehicle components, particularly large boosters, where the fuel and
oxidizer tanks are fabricated from precurved cylindrical and spher-
ical sections of high-strength aluminum alloys. The use of sections
which are " integrally stiffened" by ribs, which are left i ntact while
the bulk of the metal stock is removed, has been examined for both
electrochemical and chemical methods.
21
.1611"
5. 322 Electrochemical Milling. In the section on electrochemical nulling;

for the 7.014 alloy, the basic principles of the inethod are discussed.
In electrochemical metal removal, Faraday's 'Law of Electrolysis'
controls the rate of rnetal removal. Because this ECM is the reverse
of electrodeposition or elec +:roplating, the anode is the wort: piece.
The tool configuration depends upon the particular type of y»et.al re-
moval geometry desired. The shape of the tool cross-section can vary
froni simple squares, ovals, rounds and D-shapes to rather com-
plicated design shapes. A 5-10% NaCl solution is supplied under
pressure (: 100-250 psi) and escapes through the clearance between
the end of the tool and the work piece (ref. 5. 9). At 10, 000 amperes.
1.26 in3 (2 x 10"ni3 ) will be removed in one minute. Voltages of 10
to 15 voltsyield excellent results, The temperature of the electrolyte
is about 120"F (49"C) for good quality finishes.(P =--.07—.18 kg/mm')
5. 323 Chemical Milling. The removal of metal stock by chemical dissolu-
tion or "chemical milling," in general has many potential advantages
over conventional milling; methods. However, variations in etch rate,
undercutting, and surface finish arc a result of certain metallurgical
factors which interfere with the "normLal" electrochemical phenomena
(ref. 5. 10). Buffered caustic etc.hants with wetting and sequestering
agents plus complex f luorides to improve surface finish are employed.
When subjected to the chemical attack, the presence of high copper
intermetallic precipitate at random sites over the surface results in
small local cells (the copper areas become strongly cathodic). The
formation of smut (complex hydroxide, silicates, etc. ) adheres to the
surface providing an undesirable masking effect. In addition, differ-
ential quenching conditions in the heat treatment or differential effects
of mechanical working provide various amounts and dispersions of
CuAl,, particles. This leads to a difference in the physical form of
the smut produced during chem-milling. In 1-he "slow-attack" zones,
a well-cemented coherent, adherent "paste" is produced which does
not easily fall off the metal surface. In the "rapid-attach" zones, the
placement of C:uAI r particles is evidently such that no cohesion is
established as the matrix is dissolved away. Work at IITRI continued
to improve the method (ref. 5. 10). For Bomarc fuel tanks, between
20 and 45%'o of the original thickness (0. 16 and 0.25 inches, 0.42 and
0.64 cm) is chem-milled from selected shell areas for weight reduc-
tion (ref. 5. 6).
Studies at Martin-Denver (ref. 5. 11) have indicated that the 2219 alloy
can be successfully chem-milled by Martin Process DP 65043 in the
O temper and in fully heat-treated tempers. Solution-treated materials
incur a rough surface (up to 350 RMS) when chem-milled. The results
of chem-milling tests oil 2219 alloy sheet are given in table 5. 323.
The feasibility of chem-milling 9 11 0" panels without immersion has
been dcmonstrated at Lockheed Missiles & Space Co. (ref. 5.7). By
utilizing an acid spray technique, depths of 0. 500 inch (1. 27 cin) with
a variation of .10. 012 inch (0.3 mm) have been etched at an average
rate of 0. 0047 inch (0. 12 mm) per minute.
22

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23
TABLE 5. 2112. — Heat Treatments for Various Products
and Tempers
Source Ref. 5. 13
Alloy 2211)
Temper Product and Treatment
T4(a) Solution treated and quenched in cold water
T31 Solution treat and stretch
(Sheet)
T37 Solution treat and cold reduce by rolling;
(Sheet, plate, and forg;ings) I
T42 Material in any form or temper, resolution 1
treater] by the user 3
T6 Solution treated and artificially aged
(F org;ing;s )
T62 Material in any form or temper, resolution
treated and ag;ecl by the user
T81 Solution treated, stretched, and artificially aged
(Sheet)
T87 Solution treated, cold reduced by rolling, and s`
artificially aged
(Sheet, plate, and forg;ing;s)
(a) Forg;ing;s only
a
24
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TABLE 5. 323. —Results of Chemical Milling; 'Pest on 2219 Alloy Sheet

Source Ref. 5. 11
Alloy 2219 (0.088 and 0. 100 inch sheet)
Test Chemical Milling; (11 in x 12 in Test Panels) (a, d)
Temper Weightr Metal T'hickncss Weight Metal Thicknes
Loss, Removed, mils Loss, Removed, mile
0 118.1 19 to 21 215.3 47 to 69
T42 93.3 20 to 21 185.7 33 to 35
T31 96.8 13 to 15 163.4 33 to 41
T62 110.9 22 to 25 204.7 40 to 42
T81 113.7 23 to 24 215.1 41 to 43
T62+(b) 124.2 23 to 27 222.5 45 to 49
T81+(c) 124.8 24 to 26 196.6 44 to 46
T62 109.4 21 to 23 194.4 1 41 to 43
(a) Chem milled area was approximately 100 in2 (Martin Company,
Process DP65043).
(b) Aged to T62 from "SW" condition (solution treated and refrigerated).
(c) Aged from T31 to T81
(d) 1 inch = 2. 54 cm; 1 mil = 0.025 mm.
26

a.:^
,: '"-
r ^r
^^ .` .} ^.
Chapter 5 - Refers r
.^^ _^
>:
5. 1 J. A, rdoek, Jr. , M. Holt, and D.O. ^prcw^ ^ "A New High-

Strength Aluminum Alloy," Metal Fro ^ ,September 1961,
p. 87. ^"^' .
5.2 Allo Di *est, " Aluminum 2219," Engineering Alloys Digest, Inc. ,
Octo er 19 0.
5. 3 Kaiser Aluminum and Chemical Salea, ,j^c., 'Alloy Technical

Data," March 15, 1962. ,
5.4 Alumi :run^ Company of America, " A.1 cos Aluminum Handbook,"
1962.
5. 5 Metalworking News, August 20, 1962.

5.6 S.L. Sears and R.S. Crial, " Welding t^19 Aluminum for Bomarc..
Fuel Tanks," Me tal Progress, November 1961, p. 88.
5.7 G. Dufour, " Acid Spray Technique Mills -Aluminum Alloy Materials
without Immersion," NASA Tech Brief 67.10463, November 1967.
5.8 ORD P 40 - 1, "Machining Data," July 1961. .

5. 9 Armour Research Foundation, " Deep Pocket Milling of Aluminum
Alloy Using Electrochemical or Other ^'oCeBSes," Report No.
ARF-B235 - 14, June 21, 1963.
F
5.10 Armour Research Foundation, " Investigation of Random Thickness

Variations in Chem-Milled 2219 - T33 Alurîawn Alloy," Project
No. F36031 with NASA/MSFC.
5.11 Martin - I?enver, " Surrunary Informalioa Aegardisig Aluminum Alloy

2219," Evaluation Report N^^. 1, MI.61..4a. November 1961 .
5. I2 R . G. Mahorter, Jr, and W. F. Emmpt^p . "A Study of (:reep Resist-

ance, Formability and Heat H'reatmen! o^ Glad X2219 - T6 Alum-
inum Alloy," Report No. NAMC-AML•131110, Naval Air Mat-
erials Center, August 1959.
5. 13 L. W . Mayer, " Alcoa Aluminum Alloy+ ^^^j f! Alcoa Green LEtter,
Aluminum Company of America, Octdba^ 1'60; revised NovNm-
ber 1963. ,.,
5. 14 Aluminum Associaiton, Aluminum For iA Iêei n Manual, First

Edition 1967; second printing, 1 .r
-^_^'_
27
_^>„ __
_^;^: °:
tt^^
YP,EC;ÎNG PAGE I;LANK NUT FiLî^:^;
Chapter 6
SPACE ENVIRONMENT EFFECTS
6. 1 General. Aluminum alloys have been used in both structural and

irunatructural applications in launch vehicles and spacecraft with
excellent success since, in general, the aluminum alloys are rel-
atively insensitive to degradation in typical space environment
conditions. The vapor pressures of the structural aluminum alloys
are sufficiently high (table 6.1) so that the combined temperature—
vacuum effects generally are negligible. Structural alloys such as
2219 are sufficiently harc?ened so that nuclear and space indigenous
radiation induced defects do not significantly affect mechanical and
physical properties, at room ambient and elevated temperatures,
below accumulated doses of about l0as particles / cma . When irrad-
iated at cryogenic temperatures, the threshold may be lowered one
or two decades, but the probabilities of experiencing doses on this
order of magnitude are extremely remote except in the vicinity of
nuclear reactors.
Elevated temperatures, hard vacuums, high energy radiations, and
micrometeoroids car singularly and collectively influence surface
characteristics of 2219 by desorption processes and erosion. These
phenomena might be of great importance if optical properties, lub-
rication, certain electrical properties, etc., were critical design
parameter 5 .
Sputtering of the surface by atomic or molecular particles can de-
teriorate surface finishes in a relatively short period. A 300-^ coat-
ing of aluminum ( 10' s g/cm2) can be destroyed in one month during
a period of low intensity solar wind or in several hours during a solar
storm, for example. The threshold energies of particles required
to remove one or more atoms of the surface material they impinge
are quite low, of the order of 6, 11, and 12 eV fur O, N 2 and 02
particles, respectively. Estimates of surface e^rosior ► by sputtering
are given in table 6. 2 for aluminum alloys.
Micrometeoroids can produce surface erosion similar to sputtering,
although perhaps on a more macroscopic scale, as well as punc-
tures. Micrometeoroids vary widely in mass, composition, velocity,
and flux; generalizations about the rates of erosion and penetration,
therefore, must be used with care. The predicted and measured
frequency of impact as a function of meteoroid mass is given in
figure 6. 1, Data are given in figures 6.2 and 6.3 on the penetration
and cratering of aluminum alloy skins of various thicknesses. Cal-
culations of armor thickness required for protection of different
structures and orientations are given in table 6.3. The design of
bumper-hull meteoroid protection systems is discussed in reference
6.12.
29
_ ...^^
The surface erosion of aluminum alloys due to corpuscular radiation

is probably insignificant, amounting to something of the order of 254
nanometers per year. Indigenous space radiation, however, will
tend to accelerate the removal of surface films, which might result
in loss of lubricity and an increased propensity to "cold weld." The
interaction of indigenous radiation with desorption gases might cause
some spurious, transient electrical cwiditions when aluminum alloys
are used for electrical applications. 'l'he interaction of indigenous
radiation with the alloys may produce s^nne internal heating; that might
be significant for small items and may induce home ^•adioactivity.
30
._^►
TABLE 6. 1. -Evaporation Rates in Vacuum of Typical Elements

Used in Aerospace Alloys (a, b)
Source Ref. 6.14
Evaporation Rate, g /cm 2 /sec
Element -100° C 0° C 100 ° C 250° C 500°C
Aluminum 1.2 x 10 -e1 1. 1 x 10 -48
2.0 x 10 -33 1.7 x 10 -x1 b. 5 x 10-1 a
Titanium <10-ss 2.5 x 10 -B0
4. 1 x 10- 4a 7.4 x 10' ae 2.0 x 10-1s
Iron <10-99 2.4 x 10 -44
6.8 x 10 -64 4.8 x lU- a9 9. 1 x 10-1''
Nickel <10-88 5.7 x 10 -70
1.3 x 10 -48 6.7 x 10' 3a 1.7 x 10 -1 s
Copper 1,2 x 10 ' x4 1.4 x 10 -s6
6.2 x 10 -39 4.0 x 10- aB 4.7 x 10- 14
Chromium 9, 5 x ZO -9a 1.0 x 10 ' 64
1.4 x 10 -37 3.8 x 10 -a4 2.2 x 10'13
Vanadium QO-9s 1.9 x 10' 87
2. 1 x 10' 61 5.0 x 10 '41 1.2 x 10-a4
Manganese 2.2 x 10-7a 1. l x 10 -42 6.5 x 10-as 3.8 x 10- 16 1.6 x 10-s
Silicon < 10-88 1.9 x 10 - sa 3. b x 10 -43 4.3 x 10' x6 5. 5 x 10-1s
Magnesium 2.9 x 10 -56 5. 3 x 10 - aO 1.8 x 10 -12 1.3 x 10'6 b. 6 x 10 - a
Zii_^ 3 . 5 x 10' 30 5. 1 x 10 -1s 1.8 x 10-s 2.3 x 10'4 2.80
(a) The actual evaporation rate of each element in combination with
others will be lower. '^
(b) The values may be in error by several orders of magnitude as

they have been extrapolated from high-temperature data. The
rates at low ternpeatures will be considerably less than the
values given in the table.
31
l"
TABLE 6.2. -Estimated Rate of Removal and Time to Remove

1 x 10' 9 mm of Aluminum by Sputtering
Source Ref. 6.2

Orbiting Vehicle Escaping Vehicle
Height, Rate, Time, Rate, Time,

km atom cm- 2 sec - 1 sec/1x10' 7 mm atom cm- 2 sec-1 sec/lx10- 7 mm
100 3.1x1016 1.9x10' 3.4x1017 1.8x101
220 2.0x1013 30 2.0x1017 3.0x10 -3
700 2.2x109 2.7x106 3.4x1011 1.8x103
2500 4.3x106 1.4x109 1.6x108 3.8x106
TABLE 6. 3. -Computed Thicknesses of Armor Required for Protection

from Meteoroid Impact over a Period of 1000 Days
Source Ref. 6. 11
Av. No. of
Orientation Vulnerable Prob'y No Destructive
Critical
Structure Area Destructive Thickness
fta Impacts per
(a) cm Impact, 0/6 in cm
Mission
Plane i, leading 1000 92.9 99.5 0.005 0.209 0.530

500 46.5 99.75 0.0025 1 0.209 0.530 i
i, trailing 1000 92.9 99.5 0.005 0.109 0.278
500 46.5 99.75 0.0025 0.109 0.278
j, either 2000 185.8 99.0 0.01 0.232 0.590
side alone 1000 92.9 99.5 0.005 0.232 0.590
k, either 2000 185.8 99.0 0.01 0.197 0.500
side alone 1000 92.9 99.5 0.005 0.197 0.500
Cylinder i 2000 185.8 99.0 0.01 0.215 0.547

j 2000 185.8 99.0 0.01 0.190 0.481
k 2000 185.8 99.0 0.01 0.205 0.521
Sphere (random) 2000 185.8 99.0 0.01 0.198 0.502
(a) i = direction of the apex of earth's movement

j = direction within ecliptic plane, approximately away from sun,
exactly perpendicular to apex of earth motion
k = direction perpendicular to ecliptic plane, southward
y
32
4
3 ^MeCRACKEN, ALEXANDER.DU81N 1961

2
^
WHIPPLE 1963
V EXPLORER
E -2 Im a 1=
\`\
PEGMS ^ ` —VAN OF HULST 1948
_3
... -4 ELFO. (RADAR) NAUMANN 1966

Z \
TENTATIVE NASA
O -5
-j WATSON 1941---f^
° - 10 0 MAGNITUDE (PHOTOGRAPHIC)
-8 -7 -6 -5 -4 -3 -2 -1 0 1
LOG M Win)
FIGURE 6.1. 'Various estimates of meteoroid mass influx.

= (Ref. 6.3)
33

-410"
Crater Depth, mm
10- 4 10` a 100 102

a
104 10
102 100
100 10-1
ro A
A 10-2 10-3
N
n
10-4 10- 8
ao
m
y ..a
x 10-6 10-7
x
10-11 10-9
10-io 10-11
10- 5 10-4 10-2 100 102
Crater Depth, inch
FIGURE 6. 2. — Hit rate vs crater depth in the earth neighborhood
but without earth shielding.
(Ref. 6. e It
1 1
P(o)=0.9999
P(o)=0.9990
vE P(o)=0.9900
.S 100
H
U9
2
Y
U

10-1 P(o)=0.9500
P(0) =0.9000 . 4
. a
-2 ' 1W i 11111
iiil i Sul iîl t till uii
10
10 106 10^ 108 109 1010 ld, 1012
. a
Ar (m2-$00
FIGURE 6.3. —Sheet thickness of Al as a

function of the surface area4ifetime pro-
duct required for various probabilities of
no meteoroid puncture.
(Ref. 6.1)
34
_,Awl
6. 1 C. G. Goetzel, J. B. Rittenhouse, and J. B. Singletary, Eds. ,

Space Materials Handbook, Addison-Wesley Pres3, Palo Alto,
California, 1965.
6.2 J,,R. Redus, "Sputtering of a Vehicle Surface in a Space Envir-
onment," NASA TN D-1113, June 1962.
6.3 SAMPE, The Effects of the Space Environment on Materials,
Western PeriodicaIs Go., North Hollywood, a i ornia, 19-D.
6.4 L. E. K_aechele and A. E. Olshaker, "Meteoroids - implications
for the design of space structures," Aerospace Engineering, 19,
May 1960.
6.5 K. S. Clifton and P. J. Naumann, " Pegasus Satellite Measurements
of Meteoroid Penetration," NASA TM X-1316, 1966.
6.6 F. L. Wtipple, "On Meteoroids and Penetration," J. Geophys.
Res,, 4929 (1963).
6.7 H. C '.de Hulst, "Zodiacal Light in the Solar Corona,"
A strip J., 105, 471 (1947).
6.8 F. G ,W.^1►tson, Between the Planets, The Blakiston Co., Phila-
delph ,4 1941; revise , Harvar University Press, Cambridge,
Mass , -,'. 1956.
6.9 C.W. McCracken et al., " Direct Measurements of Interplanetary
Dust kticles in the Vicinity of the Earth," Nature, 192, 441
1961.'
6.10 R. J. ann, " The Near-Earth Meteoroid Environment,!'
NASA D-3717, November 1966.
6.11 C. D. er, " Meteoroid Hazard Evaluation for Simple Structures 3
with Varjous Orientations," NASA TN D-6056, October 1970.
6.12 C. R,. Nysmith, "A Discussion of the Modes of Failure of Bumper-
Hull Stuctures with Applications to the Meteoroid Hazard,"
NASA, TN D-6039, October 1970.
P
6.13 W. M. Àlexander et al., " Zodiacal Dust: Measurement by

Mariner IV," Science, 106, 1240 (1965).
6.14 S. Dushman, Vacuum T ec hniques, John Wiley & Sons,
New York, 197-
9.
35

PRI:CI^TR'G PAGE BLANK NOT r'I?.rfVJ,
Chapter 7
STATIC MECHANICAL PROPERTIES
7.1 Specified Properties

7.11 NASA Specified Properties
7.111 NASA specified mechanical properties for die forgings and sep-
aretly forged test bars, table 7. 111.
7.112 NASA specified mechanical properties for hand forgings,
table 7.112.
7.12 AMS Specified Properties
7.121 AMS specified tensile properties for sheet and plate, table 7.121.
7.122 AMS specified bend factors for sheet and plate, table 7. 122.
7.13 Military Specified Properties
7.14 Federal Specified Properties
7.15 ASTM Specified Properties
7.16 :aluminum Association Mechanical Property Limits
7.161 Aluminum Association tensile property limits for sheet and
plate, table 7. 161.
7.162 Aluminum Association tensile property limits for Alclad sheet
and plate, table 7. 162.
7.163 Aluminum Association tensile property limits for rolled or
cold-finished bar, rod and wire, table 7.163
7.164 Aluminum Association tensile property limits for extruded bar,
rod, shapes, and tubing, table 7.164
7.165 Aluminum Association tensile property and hardness' limits for
die forgings, table 7. 165.
7.166 Aluminum Association tensile property limits for hand forgings,
table 7.166.
7.2 Elastic Properties and Moduli
7.21 Poisson's ratio
7.22 Young's modulus of elasticity, E
7.221 Design value of E at room temperature for sheet and plate,
E = 10.5 x 10 3 ksi (ref. 7.1) 7. 5 x 10 3 kg/mm'
7.222 Effect of elevated temperatures on modulus of elasticity,
figure 7.222.
7.223 Effect of low temperatures on modulus of elasticity of T81 sheet,
figure 7.223.
7.231 Compression modulus, EC
7.231 Design value of E C at room temperature for sheet and plate,
E = 10.8 x 10 3 ksi (ref. 7. 1) = 7.6 x 103 kg/mma.
7.24 Modulus of rigidity (shear modulus), G
7.241 Design value of G at room temperature for sheet and plate,
G = 4.0 x 103 ksi (ref. 7. 1) = 2. 8 x 103 kg/mma.
7.25 Tangent modulus
7.251 Typical compressive tangent-modulus curves for T62 sheet and
plate at room temperature, figure 7.251.
7.252 Typical compressive tangent-modulus curves for T81 sheet and
37

...4"
7.253 ' Typical compressive tang ent- mod %ilus curves for T87 sheet and
7.26 Secant modulus
7. 3 Hardness
7.31 Brinell scale (500 kg, 10-nim ball)
T31, T351 96
T37 110
Condition T62 113
T81, T851 123
T87 128 (ref. 7.23)
7.4 Strength hroperties (see also 7. 1 )

7.41 Tension, see also figure 7.4612.
7.411 Design and typical tensile properties.
7.4111 Design mechanical properties for sheet and plate, table 7.4111
7.4112 Design mechanical properties in metric units, table 7.4112.
7.4113 Design properties for Alclad sheet and plate, table 7.4113.
7.4114 Typical mechanical properties for various tempers 6 f sheet
and plate, table 7.41 i4.
7.412 Stress-strain diagrams (tension).
7.4121 Stress - strain curves for alloy in T6 condition at room and elevated
temperatures, figure 7.4121.
7.4122 Stress-strain curves for T62 sheet at low temperatures, figure
7.4122.
7.4123 Stress-strain curves for T81 sheet at low temperatures, figure
7.4123.
7.4124 ^ Stress - strain curves for T87 sheet at low temperatures, figure
7.4124.
7.4125 Typical tensile stress-strain curves for T62 sheet at room temp-
erature, figure 7.4125 (see also figure 7.251).
7.126 Typical tensile stress - strain curves for '181 sheet at room temp-
erature, figure 7.4120 (see also figure 7. Z5L).
7.127 Typical tensile stress-strain curves for T87 sheet at room temp-
erature, figure 7.4127 ( see also figure 7.253).
7.413 Effect of test temperature and exposure on tensile properties.
7.4131 Effcc : t of temperature on the ultimate tensile strength (Ftu ) of T62
bare and clarl sheet and plate 0. 040-1. 000 inch thick, figure 7. 413 1 .
7.4132 Effect of temperature on the tensile yield strength ( Ft ) of T62 bare
and clad sheet and plate 0.040-1.000 inch thick, figur 7.4132.
7.4133 Effect: of h!niperaturc on the ultimate tensile strength ( Ftu ) of T81
bare and clad sheet and plate, figure 7.4133.
7.4134 Effect of temperature on the tensile yield strength (Fty ) of T81
bare and clad sheet and plate, figure 7.4134.
7.4135 Effect of temperature on the ultimate tensile strength (F tu ) of
T87 bare and clad sheet and plate, figure 7.4135.
7.4136 Effect of temperature on the tensile yield strength (Fty ) of T87
bare and clad sheet: and plate, figure 7.4136.
7.4137 Minimum tensile properties for 2219-T6 after 10, 000 hours
exposure, figure 7.4137.
38
!iw"
7.4138 Minimum tensile properties for 2219-T81 after 10, 000 hours
exposure, figure 7.4132.
7.4139 Minimum tensile elongation for 2219 alloy in T62 and T81
conditions after 10, 000 hours exposure, figure 7.4139.
7.414 Effect of test temperature on tensile properties.
7.4141 Typical tensile properties at low and elevated temperatures
for alloy in T6 and T6L conditions, figure 7.4141.
7.4142 Tensile property bands for T62 sheet at low temperatures,
figure 7.4142.
7.4143 Tensile properties of T6 extrusions at elevated temperatures,
figure 7.4143.
7.4144 Tensile property bands for T81 sheet at low temperatures,
figure 7.4144.
7.4145 Typical tensile properties of T81 sheet at elevated tempera-
tures, figure 7.4145.
7.4146 Natural aging response of solution treated alloy, figure 7.4146.
7.4147 Effect of irradiation at cryogenic temperatures on tensile
properties, table 7.4147.
7.42 Compression
7.421 Design compression properties
7.4211 Design compressive yield strength (F cy ) for sheet and plate,
see tables 7.4111 and 7.4113.
7.4212 Typical compressive yield strength for various tempers,
see table 7.414.
7.4213 Typical Fcy for T62 sheet and plate, figure 7.4213.
7.43 Bending
7.44 Shear and torsion
7.441 Design shear properties
7.4411 Design shear strength (F su ) for sheet and plate, see tables
7.4111 and 7.4113.
7.4412 Typical Fsu for alloy in various tempers, see table 7.4114.
7.4113 Effect of low temperature on shear strength of sheet, figure
7.4413.
7.4414 Typical Fsu curve for T62 sheet and plate, figure 7.4414.
7.45 Bearing
7.451 Design bearing properties
7.4511 Design bearing propertites for sheet and plate, see tables
7.4111 and 7.4113.
7.4512 Typical bearing properties for alloy in various tempers, see
table 7.4114,.
7.4513 Typical bearing strength of alloy in T31 and T81 conditions,
figure 7.4513.
7.46 Fracture
7.461 Notch strength
7.4611 Effect of stress concentration factor on notch strength of
T62 and T81 sheet, figure 7.4611.
7.4612 Effect of low test temperature on tensile and notch properties,
figure 7.4612.
7.4613 Effect of test temperature on net fracture strength of T81 sheet,
figure 7.4613.
7.462 Plane-strain fracture toughness
7.4621 Average plane-strain fracture toughness data, table 7.4621.
39
_ .00"
TABLE 7.' 1. - NASA Specified Wchanical Propertic•^

for Die. For s ings and Separately Forged Test Bars
Alloy 2219- T6 (b)
Specification NASA- MS FC-SPEC-144
Maximum section, thickness 4 inches (10. 16 cni)
Orientation A B
F tu (min), ksi (a, c) 58.0 56.0
Ft y , 0.2% offset (min), ksi (a, 38.0 36.0
e(2 in (5.08 cm) or 4D), rnin, % 8 4
A Test specimen parallel to forging flow lines
B Test specimen not parallel to forging; flow lines
(a) Tensile and yield strength test requirements may be
waived for material in any direction in which the dimen-
sion is less than 2 in because of the difficulty in obtain-
ing a tension test specimen suitable for routine control
testing.
(b) Die forgings in sonic configurations of this alloy can be
purchased in the heat treated and mechanically stress
relieved T652 Le nper conforming to the mechanical
properties requirements specified for the T6 temper.
(c) 1 ksi = 0.70307 kg/mm2
TABLE 7. 112. - NASA Specified Mechanical Properties for Hand F o rgings

Alloy 2219 -^
Specification NASA- MS FC-SPEC-144 B
Temper Thickness Axis of Test Ftu(inin), F ty(min), e(2 in (5.08 cm) or
p (b) Specimen ksi (c, (1) ksi (c, d) 4D), min, %
T6 x'4.000 in L 58.0 40.0 6
(10. 16 cm) LT 55.0 37.0 4
ST 53.0 35.0 2
T852 <4.000in L 62.0 50.0 6
(10. 16 cm) LT 62.0 49.0 4
ST 60.0 46.0 3
T352 -4. 000 in L 42.0 25.0 12
(1.0.16 :,m) LT 40.0 23.0 8
S1 1
39.0 20.0 1 7
(a) Maximum cross - sectional area is 256 in 2 (1 . 652 ma).
(b) Thickness is measured in the short transverse direction and applies to
the dimension "as forged," before machining;.
(c) Tensile property requirements may be waived for directions in which
the dimensioi. is less than 2 inch es.
(d) 1 ksi = 0 7037 kg /:ian° .
40
TABLE 7. 121. — AMS Specified Tensile Properties for Sheet and Plate
Alloy 2219
Specification AIRS 4031B
Condition 0 T4 or T42
0.040 to 0.500 to 0.040 to 1.000 to
Thickness, in (c) 0.499 2.000 1.000 2.000
Ftu (max), ksi (a, d) 32.0 32.0 54.0 56.0
Fty (max), ksi 16.0 - 36.0 36.0
e(2 in) min, %u (b) 12 - 6 6
(a) Test specimens shall conform to ASTM E8-57T except from
material less than 3/4 inch wide, and shall be cut across the
direction of rolling except from material less than 9 inches wide.
(b) a applies only to material 3/4 inch and over in width.
(c) 1 inch = 2. 54 cm.
(d) 1 ksi = 0.70307 kg/mma
TABLE 7. 122.— AMS Specified Bend Factors for Sheet and Plate I
Alloy 2219
Specification AMS 4031B
Condition 0 T4 and T42
<0.250 0.250 to 0.750 to 0.0625 to 0.250 to
Thickness, in (a) — 0.750 1.000 — .0625 0.250 0.500
Bend factor (b) 4t 6t 8t 8t 12t 16t
(a) 1 inch = 2. 54 cm.
(b) Axis of bend parallel to direction of rolling.
41
TABLE 7. 161 . - Aluminum Association Tensile Property Liiiiits
for Shect and Plate (a)
Source Ref. 7.4

Alloy 2219
Standards Aluminum Association Mill Products
Temper Thickness, Ftu, csi Fty, ksi 4(2 in or 4D),

inch Min Max Min Max
0 0.020-2.000 - 32.0 - 16.0 12
T31 (d, v) 0.020-0.039 46.0 - 29.0 - 8
0.040-0.249 46.0 - 28.0 - 10
T351 `d) 0.250-2.000 46.0 - 28.0 - 10
2.001-3.000 44.0 - 28.0 - 10
3.001-4.000 42.0 - 27.0 - 9
4.001-5.000 40.0 - 26.0 - 9
5.001-6.000 39.0 - 25.0 - 8
T37 0.020-0.039 49.0 - 38.0 - 6
0.040-2.000 49.0 - 37.0 - 6
2.001-2.500 49.0 - 37.0 - 6
2.501-3.000 47.0 - 36.0 - 6
3.001-4.000 45.0 - 35.0 - 5
4.001-5.000 43.0 - 34.0 - 4
T62 (b, w) 0.020-0 039 54.0 - 36.0 - 6
0.040-0.249 54.0 - 36.0 - 7
0.250-1.000 54.0 - 36.0 - 8
1.001-2.000 54.0 - 36.0 - 7
T81 0.020-0.039 59.0 - 44.0 - 6
0.040-0.249 62.0 - 46.0 - 7
T851 (d) 0.250-1.000 62.0 - 46.0 8
1.001-6.000 62.0 - 46.0 - 7
2.001-3.000 62.0 - 45.0 - 6
3.0 r :-4.000 60.0 - 44.0 - 5
4.0':' 5.000 59.0 - 43.0 - 5
5.001-6.000 57.0 - 42.0 - 4
T87 0.020-0.039 64.0 - 52.0 - 5
0.040-0.249 64.0 - 52.0 - 6
0.250-1.000 64.0 - 51.0 - 7
1.001-3.000 64.0 - 51.0 - 6
3.001-4.000 62.0 - 50.0 - 4
4.001-5.000 61.0 - 49.0 - 3
Footnotes: s-! ,-- page 46.

Note: 1 inch = 25.4 mm; 1 k s i = 0. 7.' .:g/mm2.
42
- -s m"
TABLE 7. 162. - Aluminum Association Tensile Property Limits

for Alclad Sheet and Plate (a)
Source Ref. 7.4
Alloy 2219
Temper Thickness, Ftu, ksi Fty, ksi e(2, in or 4r),
inch Min Max Min Max min,
0 0.020-2.000 - 32.0 - 16.0 12
T31 (v) 0.040-0.099 42.0 - 25.0 - 10
0.100-0.249 44.0 - 26.0 - 10
T351 (d, v) 0.250-0.499 44.0 - 26.0 - 10
T37 (v) 0.040-0.099 45.0 - 34.0 - 6
0.100-0.249 47.0 - 35.0 - 6
0.250-0.499 47.0 - 35.0 - 6
T62 (b, w) 0.020-0.039 44.0 - 29.0 - b
0.040-0.099 49.0 - 32.0 - 7
0.100-0.249 51.0 - 34.0 - 7
0.250-0.499 51.0 - 34.0 - 8
0.500-1.000 54.0 - 36.0 - 8
1.001-2.000 54.0 - 36.0 - 7
T81 0.020-0.039 49.0 - 37.0 - 6
0.040-0.099 55.0 - 41.0 - 7
0.100-0.249 58.0 - 43.0 - 7
T851 (d) 0.250-0.499 58.0 - 42.0 - 8
T87 0.040-0.099 57.0 - 46.0 - 6
0.100-0.249 60.0 - 48.0 - 6
0.250-0.499 160.0 1 - 1 48.0 - 7
Footnotes; see page 46.
Note: 1 inch = 25.4 mm; 1 ksi = 0.70307 kg/mma.
43
!L-1"
TABLE 7. 163. — Aluminum Association Tonsils Property Linnirs

for Rolled or Cold-Finished Bar, Rod, and Wire (f)
Source I'Vef. 7. 4
Alloy 2219
Diameter, RILL, ksi n i or 4D)
Ft k , si e(2
Temper inch Min Max Min y Max min, ",u
T851 0.500-2.000 58.0 - 40.0 - 4

2.001-4.000 57.0 _ 39.0 - 4
3
Footnotes: see page, 46.
i
Note: 1 inch = 25.4 mm; 1 ksi = 0.70307 kg /.nni
2
TABLE 7. 164. — Aluminum Association Tensile Property Limits for

Extruded Rod, Bar, Shapes, and Tubing (f)
Source Ref. 7.4
Alloy 2219
,standards Aluminum Association Mill Pi-oducts
Temper Thickness, Area Ftu, ksi Ft y , ksi e(2 in or
inch in` Min Max Min y Max 41)), min,
+) (c) Al l All - 32.0 - 18.0 12
T31, T351 ;^, '0.49y X25 42.0 - 26.0 - 14
T3511 (d, x) 0. 500-2.999 _25 45.0 - 27.0 - 14
T62 (b) <.0.999 <25 54.0 - 36.0 - 6

;1.000 ,32 54.0 - 36.0 - 6
T81, T8510, ---2. 999 X32 58.0 - 42.0 - 6
T8511 (d, w, y)
Footnotes: see page 46.
Note: 1 inch = 25.4 mm; 1 ksi = 0.70307 kg jmm 2 .
44
_ ..N"
TABLE 7. 165. — Aluminum Association Tensile Property and

Hardness Limits for Die Forgings
Source Ref. 7.4
Alloy 2219
Temper Brinell
Grain Hardness Ftu, ksi Fty, ksi e(2 in or 4D)
' Min Max 'vlin Max min o
T6 A (n) 100 58.0 38.0 - 10
T6 B (;:) 100 5 .0 - 36.0 - 4
* 500-kg load, 10-mm ball
A Parallel to grain flow Footnotes: see page 46.
B Not parallel to grain flow
Note: 1 inch = 25.4 mm; 1 ksi = 0. 70307 kg/mm a .
TABLE 7.166. — Aluminum Association Tensile Property Limits

for Hand Forgings (p, q)
Source Ref. 7.4
Alloy 2219
Thickness, F.tu, ksi Ft , ksi e(2 in or 4D)
Temper inch r L LT ST L yLT I ST LILT I ST
T6 54.000 58.0 55.0 53.0 40.0 37.0 35.0 6 4 2
T852 54.000 62.0 62.0 60.0 50.0 49.0 46.0 6 4 3
L - Longitudinal (m)
LT - Long transverse Footnotes: see page 46.
ST - Short transverse
Note: 1 inch = 25.4 mm; 1 ksi = 0. 70307 kg/mma
45
,f.%►
Footnotes for Aluminum Association Standards
(a) Test specimens taken transverse to rolling direction for widths > 9
inches and parallel to rolling direction for widths O inches.
(b) Material heat treated from any temper by the user shoui,' attain the
properties applicable to this temper.
(c) O temper material shall be capable of developing properties for T6
temper after heat treatment.
(d) For stress relieved tempers, properties other than those specified
may differ from the corresponding properties of the basic temper.
(e) For plate 0.500 inches or over in thickness, the listed properties
apply to cure material only. Strengths of composite (core plus clad)
are slightly lower depending on thickness of cladding.
(f) Specimens taken parallel to di.recti.on of extrusion, rolling, or drawing.;.
(g) O temper material within the size limitations specified for T4 temper,
shall upon heat treatment be capable of developing properties applic-
able to T4 temper.
(h) Fo:• rounds (rod) maximum diameter is 8000 inches; for square, rec-
tangular, hexagonal, or octagonal bar maximum thickness is 4 inches
and 36 square inches cross-section area.
(;) Round tuLc 2 in-hes or less in diameter, and square tube 1.5 inches
or less on a side are tested in full-section.
(k) Fur round tube over 2 inches diameter, for square tube over 1.5 inches
on a side, for all sizes other than round or square or when full sec-
tion cannot be used, a cutout specimen is employed.
(m) Tensile tests are performed and properties guaranteed only when
specifically r( ,glii.red by purchase order or contract.
(n) These values apply to standard 0.5-inch diameter test specimens
machined from separately forged c o-upons representative of the forg-
ings. For spccir-oens machined from forgings up to 4 inches in thickness
or diameter with specimen axis substantially parallel to direction of
grain flow, requirements apply except minimuwn e shall he 70 percent
of values in the table.
(p) Maximuru cross-sectional area is 256 square inches.
(q) These properties are not applicable to upset biscuit forgings or to
rolled or forged :ing forgings.
46
-rio41
(r) Thickness measured in short transverse direction.

(s) Applies to all available widths of sheet and plate.
(t) The measurement of a and F ty is not required for wire less than
0.125 inch in thickness.
(u) These values apply to standard specimens machined from forgings
up to 4 inches with the specimen axis not parallel to the direction
of grain flow.
(v) Upon artificial aging, T3 and T31, T37, T351, T361, and T451
temper material shall be capable of developing the mechanical
properties applicable to the T81,. T87, T851, T861, and T651
tempers, respectively.
(w) This temper is not available from the material producer.
(x) Upon artificial aging, T31, T3510, T3511, T4, T4510, and T4511
temper material shall be capable of developing the mechanical
properties applicable to the T81, T8510, T6, T6510, and T6511
tempers, respectively.
(y) These properties can usually be obtained by the user when the
material is properly solution heat treated or solution and precip-
itation heat treated from the O (annealed) or F (as fabricated)
temper.
Note: 1 inch = 25.4 mm; 1 ksi = 0.70307 kg/mma.
i
47
- f.1"
04 V
La Cq
to La
cc IV It w
to LO
N N UI A O ^0 -
D 0 0 t -
W .4 14 qw 00 M to CO La w
oo in Lei U15 LO C* M C4 00 ab
-W N eq C4 kaaD 14 00 10 t-
0. to ha Go Ob
d0
M 0
P4 MM to M a N
^q
N Q .4 .4 q* tD 2 &a t-
20 3 ka -0 -0 La ft C4 Ch
td
I * co C4 CO) W 00 go to ab
oa LO ba ka ka C* 0 Cq 00 ab
do,
V
w M 04 C4 to " 0) w t- to 41
oo MM ka LO C* OWN (A
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to &*I* La CID 0
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tY V' V' M M M M N -lD oo u11D
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1 .Yi U1 rO < N O
M
N
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A M M r
°
MO ^ ^ N 1 1 C
co N V M
r O Y
Iri r < Mi .+ `D w, O
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MM r IR u1 N O 1419 10 fA
MO cQ
v MM d' Ln co Ln to 1
F dr co d' V' MM MM N 'o Go u1 ^D
u1 O .p ^D O M r M M GR u1
N u1 1 < M M n N M u1 lD V' d'In r u N
V^ V' M M M M N ^D ^ u1 ^D
M M P
r 0 171 N M N u1 00 0p P
MM O m
u1 O ^'' d' Y^ of u1 ^D V' ID 1
M MM N ,o co u1 to O C
O M rM10v! .. .. v.
ON < MM MN In 'D Ln wN oo N u
C V' MM MM N lD Oo u1 .D O ^
MM r 1n N M N V! mm O ^
MM
VN u1 ao • D ^D I
N
NM MM N 10 V NO
F °^ Do c! In 11: Ll
eo '
O O ^' M M M N M It In u1
aw MM MM N .D oo 1n .D v 'O
r 11: ° o v, v, n In 0 o
11: 1%
N r' O oo
MM
ao 1010 r r N O op u1 r 1 N N
utco NN NN N .Dr d'u1
F F
•D
H
o
O
0
1n <
In o!
%n A
r r
'DO
1n
N
^. Ô
P •O
n In
♦M
Go co NN NN N In v N
N 171 O N In O F
u NEaH N aH EaH N a
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ld Y
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49
II
--jsv"
rAIIL.L: 7.4111. - Design Propurlicti for AM ad tihcrl. and. l']At"
Soul-cc
All„ 2-21"
['.:^,^ e r P62 _ 1'81 1'8 1 1 "i
0, 040- ^. 00_ 0. 040- 0. 100- 0.25 - ('. - -
Thickness, inch (a:) (1.009 1 .000 0.099 0.249 2.000 t). 09 1 ) 2.000•
V tu , ksi (b) -1_ . 49 32 55 57 57 57 59
-1 1 4O 'i2 1>() 58 58 58 u0
V' L , ksi -11 32 34 4(` 42 42 45 47
1
- 1' 34 41 41 -45 47
i2 39
F ey , ksi -11 34 36 40 42 42 45 47
-T 34 36 41 43 43 48 50
Fsu, ksi 29 31 32 33 33 , ' 34
Fbru (c/D J." 1, 1- 1 79 81 94 F4 84 87
(c/1)- 2. 0). ksi O8 104 106 110 10 110 1 14
Fh ry (c/D=1 .5), k i 51 54 58 61 61. 6 66
(c 1) 2.01, k> ;i 61 65 6(. 70 70 72 75
c(2 in ur 41)), !0 -"1 6 6 t, 6 5 5
(a) I inch 54 crn hri u`
(b) 1 1:si - 0.70307 ki-,
TABLE 7.411 . 4. - 'I ypical .Mechanical Properties for -Various

Tempers of Bare Sheet and Plate
S(nirce Ref. 7.23
Alloy -^ Z-^ 1 ` i
rc!, ►r;,. r -- U T42 T351 r37 T02 '8511 T87
F ttt , ksi (a; L - - 52 56 56 66 62^
! 25 50 52 56 58 66 68
Fty , ks !. - - 36 45 40 5C 56
11 25 34 44 40 50 56
s(2 - - 20 12 10 10 10
-'r 1F' 20 16 10 10 10 10
FC.. Nr f ksi -L - - - - 44 53 57
-'r - - - - 44 54 60
F .. ^, - - - - 36 38 40
F bM ' / I). 5 ► , .... - - - - 90 96 100
(E /D-2.0 ► , ksi - - - - 20 125 131
Fhry ( e /D- 1.51ksi ( _ .. _ _ 67 76 80
(c,/}) "1..0), ksi - - - - 80 87 91
Hardness, Brittelt
^ 9(, 110 113 1L3 128
(500 g, 10-nt.t, ball) _
(a) I ksi -- 0. 10 )6 7 xg
50
I
_SW"
t~
0 00 M N ^D %0 00 H'
u ^+
N cd H 00 O ^D N ^D ^D u1 M .-+
O U
(-4
1~ i+ ty -4 4 O %0 %0 M M O`
y
N O^ O^ N 1-N N O
O
O ►
7
LL
x
ul
t` ... d: rn 1n d^ r+ N eN M !^
N N Ln N M .-i 00 N u1 N r-
U U u1 ON 00 r • O cr, N
O H y^ ~
O
O Z7
LU k tn u1 u1 NN Ln o M
Q U ,
. . . . .
u F". t` t- ^D 00 co u1 M M N
zU) .^ .o Ln oD Oo ti O` ^ N
w
y .^ O N d' r- 'd' u1 u1 r-
3 N
a x ,^ Ln oo o C^ r, o o r+
U N r- ti to 00 r- %0 00 OD %D
0 w
^
Ic W
+' .-^ .-^ r- M M . q 00 00 00
I A ir,^ MM c NNN
y N N
N N[- ul Nt-Ô N NCO
td
i.7
C
dl
ca'd a w ^
.-+ X u1 O ô N M u1 00
b
0
H r-
y i+ ~ No Ln r- Ln c}+ Ln
J
t;. .0
,,
C F n to
w c NNO o%OM NNM
G"
U .4 X4 4 urv Ln v u1Ln v
w to
v.
.!G
U ... ..
O rd t`
I
J.d
.
(d
v v v 0M
N À C. ^D 'D N .0 ,0 r- Ô Ô r- O
O O,O%N TO, N OÔ*N N
d^
H
0C O
N G It
00
O
O be
Q
71
.a O •4
U
14
>. ^' +^ ^pp U W rd U A w
î
O O O ed ..î
O w .40" •^ ed ^
to [^ LEI rd b sa b v v
51
-;l!
t,t
0 w)
Oa N Tr ^}^ M o0 er N N
H
V' u In .O .D O O O .O .p
u bf)
t~
r^
a • o U
x x
Ln
1
r- M rn to N to N m I.n
N
^ t Al
a, o
a rn q O
V U (A O O O O O O
I I ^, N
C, W
C
can
t 00 M N N .-^ f` M a`
a tV c n !1 d' M en N N co
^' c? n O cn O O O C
x
i
u ^ ^ M
rd
x v
i In M o M M to o a-
y ^. M
3 ^"..^ to M .D 00 C^
N N M M M M M M M M ^
.^ (D 11
..a ^/
O
I fd y
V .^ O O
"Cy .^. C'. N
1 rA
a; N U S N N 1 1 1 1 1 1
^ N Â H A. .-r ^,
a` N U) 3 ., i
0. N b
u
rn 'U) on "}' c1' c+1 M O O

A 3u
^s~^ 1 to
î Q: i^ •x
y I 1 M M ^ ^ t N N
r+ U)
')
f^ N f^ f^ N f^ û.+
Q. N
lq4I O 11
0 U .z
41 41 U
11
r bl. , _, G a0 M M dt dl O^ N M
d O 9
m ...
N V 'A I m
>41 ., o rn rn Co 0o •
t an PQ d o
'dry.
..^
to to to to In to to to
Z > 03
x r.0
(A
u k
a •..^44.0
.J 41
O
U
^r. aaHH aH ^
n s~
41 Qn
x
f•a U ' t4 O O H y ti
V] 0 ti .1
C!. O
td
.Ui b b -4
UrU y j M t
..a ,..1 .+
O dO
13. r+ ^ ^ +^ W ^ W ^ W W
fa
n .4
u a^ Z p, U
u,, y, a 1 H ..
fnâx a^
NHHHNH co H ^ ^ô
:1 n to to to to to f^ I-
o 00
Id .n u
52
—Wr i
I
100 200 300 400°C =_
12 r
7. t 8.0
O Ref. 7.5:
i' O Ref, 7,7'
10 7.0
=t. i }
E, t ! t , '} tell
nii î i 103
;— i
10 3 ksi kg / mm2
i r ^ ^! qtr yt# 4!-}! i ;: { ( t :t
6.0
{ I Exposure, ' =f i::
8 ±i
f` 1 C O hours }
5.0
I
1r 1 i tS i (Y
r ^' I ^ ^ {f1 '
}}
^ (!:
7^-^^
i, ,.r
6 r
.rrr} '^^
200 0 400 600 8000 F

Test Temperature
FIGURE 7.'222.—Effect of elevated temperatures on
modulus of elasticity of 2219-T6 forgings.
(Refs. 7. 5, 7. 7)
-240 -200 -150 -100 -50 0 °C

13
x I
0 1--i -$ -
L 12
U
r {
W {- ! - {
! 4 'I
; i
----0.100 in --
0 10
0. 063 i n :_,_ l.;
, j 1 f
I -r f j
0
- 6.6
_ ;^, ^, F- 1 I^- L {r- fi t+
-400 -300 -200 -100 0 100OF

Test Temperature
FIGURE 7.223.— Effect of low temperature on modulus of elasticity
of 2219-T81 sheet. (1 inch = 25.4 mm)
(Refs. 7.15, 7.' )
53
50
30
40
30
20",
m
x
xbo
a^ 20
y14
10
10
0 2 4 6 8 10
Strain, 0.001 length /length
Tangent Modulus, 10 3 ksi (703 kg/mm')
FIGURE 7.251. — Typical tensile and compressive stress-strain
and compressive tang ent-rnodulus curves for 2219-T62 sheet
and plate at room temperature; thickness, 0. 125-2.00 inches
(3.175-50.8 mm).
(Ref. 7. 1)
54
C_ __ Z.
60 : i ij
r ,. T Compre a ion
VA 40
4"
L Co ress Lon
50
L and T Tension'
4f
30
I
it
40 L Compression
T7
vi
30
20
4 4
T
20
( :t 1 :11` j'
E 1+ ^ .I ,^. rl ,,^! ' { + . ii
-T' iT 10
+
10
1 417 ;1
0 0
0 2 4 6 8 10
Strain, 0 . 001 length / length
Tangent Modulus, 10' ksi ( 703 kg /MM2)
FIGURE 7 . 252. — Typical tensile and compressive stress - strain

and compressive tangent-modulus curves for 2219-T81 sheet
and plate at room temperature; thickness, 0. 125 - 2. 00 inches,
(3.175-50.8 mm).
(Ref. 7. 1)
55
--..-6-0m
70
60
40
50
30
tv
40
m x0o
30
m 20
v
is
L^
20
10
10
1
0 0
0 2 4 6 8 10 12
Strain, 0.001 length/length
Tangent Modulus, 10 3 ksi (703 kg/mm2 )
FIGURE 7.253. — Typical tensile and compressive stress-strain t
and compressive tangent-modulus curves for 2219-T87 sheet
and plate at room temperature; thickness, 0. 125-2.00 inches
(3.175-50.8 mm).
(Ref. 7. 1)
56
40
Z5
FIGURE 7.4121.—Stress-strain 30
curves for 2219-T6 at room ZO
and elevated temperatures.
m
(Ref. 7.7) .^ 15
20 kg/
a^ mm2
r..
10
10
5
01
0 0.002 0.004 0.006 0.008
Strain, length/length
100 70
f ,,- I^
1 :. 60
!4 t_ r - f l .^.., 1
L.__ i i ► '. 1 --423
1 0 F(-253 0 C) , +i i
80 IfT
f i - 11 ti ^ {^ + 50
x E —320°F(-- 196° C)
6C
;i
—110 F (-7 8.9°0 C) . 40
U) kg/mm 2
-Y RT , i _ ,.
30
4C
J-- T
f
+-+-t }tom-
..
-
ZO
I
SSj4F
20
0 0.040 0.080 0.120 0.160 0.200
FIGURE 7.4122.— Stress-strain curves for 2219-T6 sheet (0. 100 inch,
2. 54 mm) at low temperatures.
(Ref. 7.15)
57
120
80
i
1
100
70
. j
' t i
;^ I -4230 F(-253 0 C). 60

/,
MIZZ:7z:^^
80
i
50
-320° F(-196°C)
kg /mm`
60 -110 F(_ 7 8. 9 C
RT. 1 40 -
î
m
a^
30 t
40
T 20
L !,.!
20 (
10
I ,
0 0
0 0.040 0.080 0.120 0.160 0.200
Strain, length/length 3
FIGURE 7.4123. — Tensile stress-strain curves for 2219-T81 sheet S
(0. 100 in, 2.54 mm) at low temperatures. s

(Ref. 7. 15)
58

I
120
^^
I
r.t 0
1
100 I, - 7
` 142 3°F -253°C)+-I^
71 T4:
., F ( k - -^ , -3200F(-196°C)-"
! r
^► i i a 4— r t i
x I , ; i 1100 F( -79 ° C)
60
w I — }
I + r 1 T 1 i I I, 4 1,
{ "m} m
z
t
30
40
T1
.f. ^ ^^'• t i I. I_ ..^ .... } .
20 i__
I +_ } , +
I`
i
0 } —, } i } a -h+ r ^.
0
0 0.040 0.080 0.120 0.160 0.200
FIGURE 7.4124. — Tensile stress-strain curves for 2219-T87 sheet
(0.100 in, 2.54 mm) at low temperatures.
(Ref. 7. 15)
59
-- of - lim
60
40
50
30
14 40
ro
-'d 30
20
bo
14
U)
20
10
10
0 0
0 0. oz 0.04 0.06 0.08 0.10
FIGURE 7.4125. — Typical tensile stress-strain curve (full-
range) for 2219-T62 sheet and plate at room temperature;
thickness, 0. 125-2.00 inches (3. 175-50.8 ma-L).
(Ref. 7. 1.)
60

70 ;I
! ( New
Transverse J.
60
( Longitudinal^t!! , I t l' ' + t 4C
50 i ^! !
t! I Ilia;
.(
^..! t ?:. 1>r

( I f ( ^ ^ ''I,I'
it
+' I I ^^' i11
i
, 1^^ 1 +a' I H 1 ' 30
.I ,
i 1 1 'ills ( („ (i I. ^ I 1+ ;I, .'
40 f. I I I ^ I
i^ i
+^
Î
Ii i f
N I ij (•'(;rf ' t I ^ î
x .I.
- i ^'^-
^
(^ , 1. '; =, '^ -1'
I
' i i
f
^; F ^+-1.
'^ ' .i
ai ''^
'1
y ^ ^. ' ' i •` i
m TP 0
30
20
1 {
I! l ^ t 1 t i ,
T7 7
i1i ;1 r i t' 1
if
20
j-, ► , t --j1 r l ^.
10
+ }r • r .n 7
10
0 t it h ,)' I "l l I w ,.
0.
0 0.02 0.04 0.06 0.08 0.10 0.12
Strain, length / length
FIGURE 7.4126. — Typical tensile stress - strain curve (full-

thickness, 0. 125-2 . 00 inches (3.175 - 50.8 mm).
(Ref. 7.1)
61
f
i`
,f
E
70
60
40
50
30
40
C9
CA
a, E
U) 30 x
20
20
10
10
0 0
0 0.02 0.04 0.06 0.08 0.10 0112
FIGURE 7.4127. — Typical tensile stress-strain curve (full -
thickness, 0. 125-2.00 inches (3.175-50.8 mm).
(Ref. 7. 1)
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00 —100 0 100 200 300 4000 C
80
` I
70 I i 50
',
60
Ftu 40
m
x
kg / mma
50
j., _ tt I I y
-
N 1 t
NA
i 30
40
F
a^ ty ':" I 1 i
30
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:^ 10
10
. v
11-j 1.1 .' 1
0 ' 0
-400 -200 0 200 400 600 800°F
Test Temperature
FIGURE 7.4137. —Minimum tensile properties for 2219-T62 after
10, 000 hours exposure at temperature indicated under no load.
Strain rate: 5 kei (3.5 kg mm2 )/min to Ft /
0.050 length / length / min to faLre.

(Ref. 7.6)
69
200 —100 0 100 200 300 400°C
90
80
50
70
60
40
x
50 kg /mm2
a^
m
30
a^
40
a^
30
20
20
10
10
-400 -200 0 200 400 600 800°F

Test Temperature
FIGURE 7 . 4138. — Minimum tensile properties for 2219-T81 after
10, 000 hours exposure at temperature indicated under no load.
Strain rate: 5 ksi (3.5 kg / mm2 )/min to Ft ,
0.050 length / length / min to €a ure.
(Ref. 7.6)
70
.400 .100 0 too 200 too 40VIC
y 11111
10
U 41) . ......... ....

T6A
oeo 'rot
30
. .. .... .... ...
to . .... ......... .
t t-
it)
-00 .2no zoo 400 a 600 oWr

Test Temperature
FICIURF 7.4119. — Minimum tersile elongation for 2219 alloy in TU
and 'r8i conditions after 10.000 hours exposure, at tomporaturo
indicatu'l undur no load. (Ref. 7.6)
.200 -100 a 100 zoo 30 40000
80
Ptu - T62
60
4
kel Vim T& —3. -
40
F
I T"
y
r -T&
W,
. . .... ....
40
I
L
so
a T42 q . .. .... .... .... ..... .
I I
IM
-400 Moo o 100 400 600 so r

Tsai Temperature
rIGURZ 7,4141, - Typical tonsils ptoperliss, 0 low and alwaked
temperatures for 1219 allay to T&I and T6 conditions,
(Rot. 1.11)
71
50 -200 -150 -100 -50 0 °C
100 70
65
90
60
80
55
ksi k8 / mm2
50
70
45
60
40
50 35
15
10
v
c.
-400 -300 -200 -100 0 100 "F

Test Temperature
FIGURE 7 4142. — Tensile property bands for 2219-T62 sheet
at low temperatures; thicknesses, 9.090 to 0. 125 inch
(2.29 to 3.18 )nm). (Refs. 7.15, 7.17, 7.18, 7.19)
72
0 50 100 150 200 ;0
80
45
G0 tv
ksi i5
k t l m.zi^"
40 Ftu
25
20 15
20 e(1 in)
percent
0 100 200 AO 4)0 r•G0 )F

Test Temperalure
FIGURE. 7 4143. —Tensile properties or 2218-'I'6 extrusions
alter 100-hour exposures at. clovated 1.emperatures.
(Ref, 7.8)
'N
-200 -150 -100 -50 0 `'C
100 70
65
90
60
80
55
.^c
kg /mm`
50
70
45
60
40
15
d
v
a^
CL
10
-400 -300 -200 -100 0 100 "1'

Test Temperature
FIGURE 7 . 4144. —Tensile property bands for 2219 - T81 sheet at low temperatures;
sheet thicknesses, 0.063 to 0. 100 inch ( 0.596 to 0. 540 mm).
(Refs. 7.15, 7.16, 7.18, and 7.20)
74

60
40
FIGURE 7.4145, —Typical tensile

properties of ZZ19-T8I sheet at
elevated temperatures; thick- W
neelit , 0. 100 inch (2. $4 mm).
40 ... ........ IV
(Ref. 7. 14)
30
.L.
.... ...
20
1 7
if
e
v to
0
0 100 400
Gt
40
lit
S
Fes,
In
4i
kg/mma
It
-7 Ft ZA
: , ! ^ . I . I I
20 - I t : f I I
0.1 1 to 10 too lot

Natural aging time, houre
FIGURE 7.4146. — Natural aging response of solution treated 2119 alloy

(solution treated at 1000*F ( 51180 C) plus cold water quench).
(Re(. 7.23)
75

•200 .100 0 1 I 200 wo it,t, C

i
611
tU
{
hti
in
40 kc/nunx
y,
hxi
i11
t I i to
211
In
In
i
.4111) .2f10 n 200 400 600 Ron ^F
Test Teniperalure
1•I(MIO: '7.4211... Typical compressive yield strength (F•y)
for 221'1-T62 sheet and plate..
(Ref. 7.51
SO -200 •150 400 -SO 0 sC

711
Co
40
kg/ntms
SU
Fsu.
kei
In
40
if)
211
20
-400 .Inn -200 .100 n inn a}'
Test Temperature
FI .URC 7.4411. — FJfect of low temput*ture OR *hear etrenttth (Fs*)
of 2219 sheet; thickness. 0. 100 inch (2. S4 n,mi.
(RRf. 7. IS)
76
-ZT) ton jwl Alltl Ion tun'c:
n
.. ........
hll
40
su
.. . ...... .
kmi
so .. ... .. .. .... .... .... ......... ....

zi
.... .........
An
.4 . . .... .... .....
In
-400 -2nn J 'inc

T.• %t I.-wperature
ZnO
7. ♦414. — Typical 4 AII'VC fur ahear st rvaigt If IF
221 1 1 pill, • I and plats.
0 so LOO iso too z1vo ion ^r.
I ZO
KO
ton
80
vb1v
(n
ii
40
a ri I .m
Y
20 . ..... ... .... ..
n 100 200 300 400 Soo AM) III
, rc-si rumparaturn
I
7.4511. — * rypivai f • aring etrength of 121 1 1 shma rl 'I"! I
ard I MI LfIndition (a/D 2.01; LhIckness, 0.100 Inch (.. -',I will)
(FIV, 7, 14)
77
100
60
80
50
60
40
m
x
100 kg /mm2
y
v
m
s~ 60
v
F' 80
u
y
O
z 50
60
40
40 . 1
0 5 10 15 20 25
St-ress Concentration Factor, Kt s
FIGURE 7.4611 . — L.ifect of stress c.oncentrat ion- factor on nutch strength

of 2210-T62 and -T81 shot; sheet thicknesses, 0. 063 to 0. 125 inch . 1
(1.600 to 3. 175 mm).
(Refs. 7.15, 7.16, 7.17, 7.48, and 7.20)
78
Ito
]on
j. +
4p)
St rem a,
60
Notth (Kt.6.3)
kg/mm'
80
I.
F
70 ^..y _.
i
60 n
. . . ....... -
15
5to
-400 10n -ton -too 0 too O F

I'vat Temperature
PIMME, 7.4612. — Effect of low test tvniprrp.Aores tin tensile

and not ch properf io•s ell' 221 '1- 1 ti
-100 o
LA 0 1 f) 200 00
40
Fracture
Strength,
ksi 35
kg I mni2
,n
FIGURE 7. 461 3. — Effect of test temperature on net fracture strength of

2219- ,1'87 shoot; thickness 0.060 inch ( 1. 524 ASTM specimen.
3- inch (7. 64-cm) wido, K. based on initial crack length.
(Ref-
79

7.1 Military Handbook-5A, "Metallic Materials and Elements for Flight

Vehicle Structures,"Department of Defense, FSC: 1500, February 8,
1966,' through Change Notice 4, January 5, 1970.
7.2 NASA/Marshall Space Flight Center, "Effects of Low Temperatures
on Structural Metals," NASA S1'-5012, December 1904.
7.3 Aluminum Company of America. "Aluminum Sheet and Plate - General
Information, Mechanical Properties, Physical Properties," Section
AC2A Product Data, Deccniber 1961.
7.4 Aluminum Standards and Data, Second Edition, Aluminum Association,
New York, December 1969, second printing, August 1970.
7.5 Aerojet-General Corp., "Materials Properties Data Book," Report
No. 2275 to AEC-NASA, NERVA Program, revised July 1964.
7.6 Aluminum Company of America, "Alcoa Aluminum Handbook," 1962.
7.7 W. P. Achback, R. J. Favor and W. S. Hyler, "Materials- Property-
Design Criteria for Metals," WADC TR-55-150, Part VI, October
1955.
7.8 P. L. Hendricks, "Metallurgical Investigation of Aluminum Alloy
X2219-T6," WADC TR-58-57, ,Tune 1958.
7.9 J. E. Campbell, "Plain-Strain Fracture-Toughness Data for Selected
Metals and Alloys," DMIC Report S-28, June 1969.
7.10 Alloy Digest, "Aluminum 2219," (Filing Code: Al-96), Aluminum
Alloy, Enguaeering Alloys Digest, Jnc. , October 1960.
7.11 J. Viglione and W. F. Worden, "Fracture Toughness Properties of
Some Alloy Steals and Aluminum and Titanium Alloys," Report No.
NAEC-AML-2111, Naval Aix Engineering Center, March 1965.
7.12 C. N. Freed(:, et al., "Comparison of Fracture Toughness Test Pro-
cedures for Aluminum Alloys," NRL Report 6853, Naval Research
Laboratory, Washington, D.C. , February 17, 1969.
7.13 Reynolds Metals Company, 'The Aluminum Data Book," 1965.
7.14 Martin-Denver, "Summary Information Regarding Aluminum Alloy
2219," Evaluation Report No. 1, MI-61-44, November 1961.
80
7. 1 5 F. V. Scliwartr.berg anu S. H. Osg(jocl, Grvni,;onic MaLoria's

i:andboolc, Air t , r , • e Reporl. No. MT. - 'l D -- 1,-I-Zt.J andSil l ) !.)] ii c
7. 16 J.L. Christian and .,1. liurlic li, "Phyr;ical ar,.i Mlec • haaical 1^r >-
ertces of Pressure Vessel Materials for Apidicration in Cry r.tî
Environincnt," ASD-'VDR.-62-2 1i V, Par`. IT- ,^.1!? ;, 196",
7.17 M. Y. Hanson, et: al., "Sharp-Notch Behavior of Somi. , lliglt
St.rrngth Aluminum Alloys and Welded Joints at 75, — iZn, and
—423 F," ASTM-STP ; "T, 1960.
7.18 i, . R. Schwartzberg and R. D. Keys, "Mechanical Properties cal
2000 Series Aluminum Alloys at Cryci .turos,"
cnic Terttperzz
Martin-Denver Co. Report R-61-32, October 1961.
7, 19 C.V. Lovoy, "Low Temperature Mechanical Properties X 2171'ri-

T6 and 2219 - T6 Aluninum Sheet Alloys," IN-Y& V F.-M-62- 3,
Marshall Space Flight Canter, May 1962.
7.20 J.L. Christian, "Mechanical Properties of Aluminivii Alloys at.
Cryogenic Temperatures," MRG-190, Gonvair/Ast.ronai.tics,
December 1962.
7.21 J.L. Christian, .I. E. C:hafcy, A. Hurlich, .T. F. Watson, and
W. E. Witzell, "Structural Alloys for Cry-gvnic Service,
Metals Progress , 83, (3), March 1 ,141,.
7.22 F.R. Schwartzberb et al., "Detc: rmi.na.tion of Low Tempe ratttre
Fatigue Properties of Aluminum and Titanium Alloys," Annual
Summary Report under NASA Contract NAS8-2631, Martin-
Denver, July 1963.
7.23 L. W. Mayer., "Alcoa Aluminumn Alloy 2219," Alcoa Credit LOA er,
OcLober 1960, latest revision Nuvc!niber 19 63.
7.24 M. Kangilaski, " Radiation Effects Design Handbook: Sec. 7,

Structural Alloys," NASA CR - 1873, October 1971.
7.25 J. J. Lombardo, et al., "Cryogenic: Radiation Effects on NERVA
Structural Materials," Paper presented at 69th Ann. Mtg., ASTNI,
Atlantic City, New Jersey, ,Tune 27-July 1, 1966.
81
"I"
PRIXEUINU PAUE' BLANK NUT FILMb,.
Chapter 8
DYNAMIC AND TIME DF:T'F,NDENT YR':11'!:;RTIES
8.1 General. Aluminum alloy 2219 exhibits ,;caul iali t-mo and •
e t c c p-
riwltire properlirx up to Iemprraturrs of ihmit (,09`F
8.2 S ,c cifird i'roperties
8.3 Impact
F
8. 31 Impact strom!th of T87 plate at low 1r:rrpc • rao-rcs, fi }-m ,•
8.4 Creep
8.41 Creep - rupture • curves for extrusions io+ 'u. et-rutition at 40 0 ' aii(i
C), fiycuro 8.41.
600') F (Z04' and 315"C),
8.42 Creep and crr e-rupt.urr• curvr•^ for a.V,) y in T(, co ndilloll frr,rr
300' to 700')F (149" to 37.1°C), figure V.42
8.43 Creep data for clad sheet in T6 condil ion at 400 F (7.04 C).
` figure 8.43.
8. 44 Creep data for clad sheet in T6 condition at Soo', F' ( i,(Y' C;),
figure 8.44.
[ 8.45 Creep data for clad sheet in TO condit.ic,n at (oOO Y ( 31 S' C.),
figure 8.45.
8.5 Sta bil it y
R. 51 Effect of exposure temperature on room temporat.ure t rL„+sversf,
tcnsil(- properties of plate, figure 8.51.
( 8.52 Effort of exposurc temperature on room temperature tensile prop-
ert.,es of 221`)-T(, forged rod, figure 8.52.
8. 5 3, Effc;c.t of , , xposv:• e and lest tcmperati!re on tensile properties o
furged rcrc!, figure 8.53.
8.54 Effect of cxpi,snre a,irl lest !-cmperatrrrc wi trairsverse tensile
ti. properties of plate, figure 8.54.
8.6 Fatigue
8.61 Fatigue limit in rotating beam tests at 5 k 10^ cycles, tahlr 8. hl .
8.62 Fatigue strength of forged rod at. elexaterl temperatures, table 8.62.
8.63 Fatigue strength of extrusions at elevated temperatures, table 8.63.
8.64 5-N curves for fur(;int s at 400 and 600° F (204° and 315'' C),
figure 8.64.
8.65 Fatigue strcn!rth of shrel. in T87 condilion at room temperature,
and low temperabire, iip ,,ure 8.65.
a
i
,
i
- 33
- __a"
TABLE 8.61. - Fatigue Limit in Rotating 13cam Tests

Source Ref. 8.4
Alloy 2219
Test R ot ating Beam Fatipw (5 x 10" cycles)
Condition T6 T86
Fatigue limit' 15 (10.5) 15 (10.5)
ksi (kg/mm )
TABLE 8. 62. - Fatigue Strength of Forged Rod at Elevated Temperatures

Source Ref. 8. 2
Alloy 2219- T6
Te st Rotating Beam Fatigue (R = -1)
Temperature Fatigue Strength (at cycles shown), ksi (lcg /nini 2 )
F 0C 106 1013 107 108 5 x 106
R 30 (21.1) 25 (17.6) 21 (14.8) 18.5 (13.0) 17.5 (12.3)
300 149 27 (19.0) 22 (15.5) 17.5 (12.3) 14.5 (9.4) 13.5 (8.7)
400 204 25 (17.6) 22 (15.5) 15 (10.5) 12 (8.4) 11 (7.7)
500 260 22 (15.5) 17 (12.0) 12 (8.4) 9 (6. 3) 8 (5.6)
600 315 18 (12.7) 13 (9.1) 9 (6. I) 7 (4.9) 6.5 (4.5)
TABLE 8.63. - Fatigue Strength of Extrusions at Elevated T e mperatures

Source Ref. 8. 1 v -_._
Alloy 2219-T6
Test Direct Stress Fatigue 'r,;sts (R = 0) 1
Temperature Thickness Fatigue Strength (at cycles), ksi (kg /mm2 )

() F °C inch cm 106 10`' 107
3
400 20.1 1.5 3.81 36 (25.3) 28 (19.7) 22 (15.5)
600 315 1.5 3.81 25 (17.6) 20 (14. 1) 14 (9.8)
600 315 0.12') 0.32 25 (17.6) 20 (14.0) 16 0.1.2)
84 =�
1^ -201) -150 -100 0
5
).(1
6
kg-ni
LO L I
I ^
F .
T
I I
s.
1 I T
O ' I i
M 1
i~ 2
1~ F
I ^ F
-400 -300 -200 -100 0 100' F

Tempe raLure
FIGliRE S. 31 . — Impact strength of T87-221 c) plate at Iow Iumperat.ilreS;
thickness, 0.500 inch (1.27 cni). (Ref. 8.6)
30 O L
O T C 20
In
x 20 4000 F (20 . 1 0 (') 15
n; kg/mm`
i 15
A 10
O
6000 F j3l.6 G;

i0 7
0.1 1 10 100 1000

Time. hours
FIGURE 8.41 . — Creep rupture curves (I,. T) for 2210-T6
extrusion at elevated temperatures.
(Reef. 8. 1 )
85
t1
;t
F
4
3poD 4 90 C)
25
3
20
2 15
4
25
31 400uP C1
r (204. 20 . I
21 + 15
1' kg /mm2
31
+ 1 Sp0o 16
60oC,
21 - ` +s+
12
1`
8
t4 !3160
i(
1 \•^^ - ^^^ 1. 9
f 6
a^
5
^ f
4
4 3
3
2
2
Rupture •♦ "I
— — — 1%
Creep
—^— 0.5` %0
0.2% ♦ '
1
I.1 1 10 too 1000
Time, hours
FIGURE 8 . 42. — Creep and creep rupture curves for 2219-T6
forted bar at elevated temperatures.
(Ref. 8.2)
86
29
15
z \,-TT.
\î
11AT.
W;
10
0
,lip I
I Ti ;I
I
II
II!
i kg /mm'
ICI
C "'.1
0 0. 1 I !l ! A
0.1 1 10 100 1000

Time, hours
FIGURE 8. 43. — Creep data for clad 2219 - T6 sheet at 400°F

(204 0 C); thickness, 0. 064 in (1.626 mm).
(Ref. 8.7)
2")
15
20
I
10
kg / mms
U) 10
N
^j I JIM., L- S
_
Creep ( Plastic) 11 X A1,
5
• 0.1%
0 012%
O.S%
0%
1.0%
i 0
0.1 1 10 100 1000
Time, hours
FIGURE R. 44. — Creep data for clad 2219 - T6 t4hect At S00° F
(260°C); thickness. 0. 064 inch (1.626 mm).
(Ref. A 7)
87

1.
r
0 44
1 c - co .
O i T 00
4j
O
O yl 01 C,
4-1
--T 40 'd
O
2, 1'4' 1
al o 6,0 1
00
0 n C- 0
I
E
O
o.
C.
—Iu
^1
SOO. 0.
{^^ CL
^^
i^, u L b.^
^ !^Î III I l
Î^ i I
0 CD
^^ l ij'^ am
I^ t'i.t ` I ^ ^^ ii I
4)
d)
9.
u 0
ÎI ^^ lil I' Ir^ I:
OD
t t
i
I
^^'^ ill( ^ ► Î (j ^ ^ i ^.
U,
2
1231 '22a.1 1S
98

r
rr
C
U,
m In In In Y O O C W ^
(^ 'r M fV .+ M N ..
^ v
O " _
0 0 pa
G 0o C 0
M
A
00
d »
a a+ v
O » ^ a
O O
0 .o u a n.
M w
Y a
A w
o v
O
0
N E v av
u 0 0
H W y ►•
S
a i v
0 V eo
I 0 O d
N F+ LA 7 w
a o,
O
O V0N
O O O
'p
cc O C O O W
CID N ID y' N d' N
Al
A auaniod • (uiZ) a
a
E
E
11 u
w
U
Ln to M 0 0 o G. o
n d to N M N •r o " 0
A M
0 O w
0 CIO 4 v
ac
-a
Ew wu
u u
a c4
O ..... .O y a
0 a d
M I I
A
I
V x in
a V a
0 0 oy
O —{ V
N F
i I y^ ' ^ y I I »^ V V y O
^"' W A 4
......... j_ ......:..... .--- -- - . x _ .. ^_........... 1
O
i
x x c
O I I o^nOOO i • E °^'
r ^^ »•000 N K
t .{. .. ... I ^G ...I .r .^.^ . W N V.0
} 60000 ^n
0o E'
C
0 W o0
c 0 O O O 0 0 O RCN
00 .^ •r •r N t J (^
ni Al
89
--- —61 0: 0
Cl
f 1
iz
^^^ j,; !;^ ^

TII
T I
1 I^ 1. i _
F.
Ii l i II I -r i i ^ I mil ( ^
`` I
fl!^11 ^î of
ill
II^
^^^ ^j! Ij
I Il iij!,^ ^ j'^
;j^^^;, l^;î "Oo

I I ^; I î
i,;
E 0-
00
^ I^ Ilj ;^ ► !^
rt W
L+.
o.
r
0
11A •
boa
0 ll- L4
Ai .,
'
! s m , - j u a:) .iad '(u ! 7)
4.
90
.&V"
G
O O O ^ O O
^n d' cn N .^.
r y ^
O H co
i 00
td
H,
^ w
v
L /^
N
^ C
O ^
H ^
^ N
^ U
N W
O 000
U C° x n
O
pH N of
fA
Rai
C U 04
m C 'O O
^ 4j It ^
1 H ^'
r.
coro
W^
r
O w
O O O O O O O O
[^ ^D to M N .--t
T8^( ` SSa.i3S ,
91

._ Ril"
Chapter 8 - Roferences
8.1 P. L. Hendricks, "Metallurgical Investigation of Aluminum Alloy

X2219-T6," WADC-TN-58-57, ,Tune 1958.
8.2 Aluminum Company of America, Data Sheets, May 24 and July 25,
1957.
8. 3 "The Elevated Temperature Properties of Aluminum and Magnesiuni
Alloys," ASTM STP-291, 1960.
8.4 G. W. Stickley and J. 0. Lyst, "Aluminum in Fatigue," Product
Engineering, November 1954.
8.5 E. H. Dix, Jr., "Aluminum Alloys for Elevatcd Temperature
Applications," ASME Paper No. 56-AV-8, 1956.
8.6 F. Schwartz enberg, et al. , Cryogenic Materials Data Handbook,
ML-TDR-64-230, August 1964, and supplements.
8.7 R. G. Mahorter, Jr. and W. F. Emmons, "A Study of Creep
Resistance, Formability and Heat Treatment of Clad X2219-T6
Aluminum Alloy," Report No. NAMC-AML-AE 1100, Naval Air
Material Center, August 1959.
92
._ -Awo
ChapLe r 9
PHYSICAL PROPERTIES
9. 1 Density (p)
In figure 9. 1 the density (p) of Al-2219 is given as a function of
temperature. Values were calculated from room temperature
data (p = 0.102 lb/in'), and Lhr average thermal expansion co-
efficient, cr av , using the relation;
p(t) = p(68°F) [l-3;yav (t-68°F)] (ref. 9.1, p. 36, 39).
9.11 Specific }gravity, 2.84 g/cm` (ref. 9. 3). -`
9.2 Thermal Properties
9.21 Thermal conductivity (K), table: 9.21.
9.211 Critical appraisal of data
The thermal conductivity of 2219 aluminum is, at room temper-
ature, much lower than that of electrical conductor grade. There-
fore, the heat transfer depends markedly on temper and compo-
sition. The allowed composition range for secondary elements
is rather large (ref. 9. 1 ). This should produce a corresponding
variation in the thermal conductivity. Data of K can be regarded —_
only as nominal.
9.22 Thermal expansion (cy), figure 9.22.
9.221 Thermal expansion of plate at low temperatures, figure 9.221.
9.23 Specific heat (cp ) at 212° F, 0. 23 Btu/lb/° F (ref. 9. 5), or
0.23 gram calories/gram/°C._
9.24 Thermal diffusivity
No data found.
9.25 Melting range, 1010° to 11900 F (5430 to 643( C), reference 9. 3.
9. 3 Electrical Properties
9.31 Electrical resistivity, table 9.31. 'm
9.311 Critical appraisal of data
The electrical resistivity depends markedly on impurity concen-
tration and distribution. The allowed composition change for
secondary elements is rather large. The y ofore, the electrical
resistance will change noticeably from heat to heat of material,
even with identical heat treatments.
9.32 Electrical conductivity, table 9.32.
9.4 Magnetic Proper ics
9.41 Permeability. The alloy is not ferromagnetic.
93 -

9.42 Susceptibility. The susceptibility changes strongly with heat t reat-

ment. Reversible and irreversible microstructural changes can be
determined from susceptibility measurc cents. This makes it
possible to use these nicasurement.s for studies in thc• kinetics of
precipitation processes in M-Cu alloy systems.
9.5 Nuclear Properties
No data found.
9.6 Other Physical Propprtics
9.61 Emissivity. No data foiuld.
9.62 Dainping capacity. No data found.
9.63 Crystal structure, fcc.
94
Eg
TABLE 9.21. — Thermal Conductivity
Source
AlCondi Ref. ' ) . 3
loy tion cal/c► n/cm` C/sec 2219T,-)C K, btu/in/ft` F/hr T, "F
/° /"
OT31, T37 0.0.4217 2525 190

780 7777
T62, T81, T87 0.30 25 870 77
TABLE 9. 31. — Electrical Resistivity
Source
AlCondi Ref.
loy tion Microhin-in at 2219 9. 3
68° F Microhni-cin at 20'C
OT31, T37 1.4544
2. 3.29
6.
T62, T81, T87 2.24 5.7
TABLE 9. 32. — Electrical(Percent vity at 200 C (68° F),

ConductiIACS) t
Source
AlCondi
loy tion Ref. 9. 3
2219
Equal Volume Equal Weight
FT 31, T37 4428 13888
30 qzE
95

-"200 -100 0 100 200 300 400 500 ", C
3.4
. I i 3.2
o^
4 A-
0.11 3. 0
0.10 2. 8
2.6 c
y 0. 01)
2.4
y
Q 0. 08 V 2
^ ^ 1
-400 -200 0 200 400 600 800 1000 OF

Temperature
FIGURE 9. 1 — Density of 2219 allay versus temperature. (Ref. 9. 1)
-200 -100 0 100 200 300 400 500°C
Pr
26
14
24
4,
22 Û
12
i. .. 20
^Q U
10 18
O
2
C5
16
8 14
- I i ^ I I I I 1,.. i. i
t.
-400 -200 0 200 400 600 800 1000 "r

Temperature
FIGURE 9. 22. — Linear coefficient of thermal expansion from room
temperature to temperature indicated. (Refs. 9. 1. 9.5)
96

-200 -100 0 "C
I ^ II '1 I ^ ^ y tI
^ ^ I, ^ ^
, I I ' 'i ,.:' . l i. ' _ _ ri^. ,t,l

_
iiT$rl:^ •'I i^. il ^^';} î:.
W
o -100 i l I O
k
G4 U
C) U
NO w _200
^00
^N nO
',r.
ii^ ( ' + ^ ^lj^^.l: ii• !' " t '^ I. Î ,_ .,.
HI , i
jt 14 v
p' -300 _: `' '_ I '' "rte

^. •1
0N II
,.
t t jl i
ji
-400
n'
, ^. IiL'I I I
-500
-400 -300 -200 -100 0 100°F
Temperature
FIGURE 9. 221. — Thermal expansion of , 219-T87 plate (L);
thickness. 0. 500 inch (1.27 cm)
(Ref. 9. 2)
97
Ks"
[ 9.1 Aluminum Company of America, "Alcoa Aluminum Handbook,"

{ 1962.
9.2 F.R. Schwartzberg et al., "Cryogenic Materials Data Handbook,"
ML-TDR-64-280, August 1964.
f 9.3 Aluminum Association, Aluminum Standards & Data, 1970-71,
2nd Edition, December 1969, second printing August 1970.
9.4 Martin-Denver, "Summary Information Regarding Aluminum
Alloy 2219," Evaluation Report No. 1, MI-61-44, November 1961.
9.5 L. W. Mayer, Alcoa Green Letter, "Aluminum Alloy 2219,"
November 1963.
It
98
_ -60"
-- _ --- -- -- --- - --- -
Chapto r 10
CORROSION RESISTANCE AND PROTECTION
10.1 General. Despite its high chemical reactivity and affinity for
oxygen, aluminum exhibits excellent corrosion resistancV in
most common environments because it passivates spontaneously
and very rapidly under normal oxidizing conditions. The passive
film is a hard strongly adhering layer of aluminum oxide, estim-
ated as 200-300 k thick on aluminum exposed to air (ref. 10. 1),
which protects the metal fro ►n direct attack. Thus, the corrosion
€ rate of aluminum generally decreases with time, except under
severe. or specific exposure conditions which tend to disrupt the
i passive filin. Outdoors, aluminum and its alloys weather to a
pleasant. gray color, with some initial superficial pitting which
gradually ceases (ref. 10.2). Industrial soot, sulfur dioxide,
sulfur trioxide, and marine spray tend to increase atmospheric
corrosion, but hydrogen sulfide and carbon dioxide do not (ref.
10.3). Twenty-year tests at several marine, industrial, and
rural sites have shown that atmospheric attack on aluminum takes
place principally in the first year and progresses very slowly
beyond the second year (ref. 10.41. Even at hit,h temperatures
in dry atmospheres, aluminum is highly resistant to niost co ► rn-
mon gases, except the halogens (ref. 10.2).
In aqueous environments, corrosion resistance of aluminum is
greatest under neutral or slightly acid conditions, where the pro-
tective oxide filin is most stable (pH 5. 5-8. 5 at room tempera-
ture, 4.5-7 at 95°C) (refs. 10.1 and 10.5). Strong alkalies and
strong nonoxidizing acids destroy the oxide and greatly acceler-
ate corrosion. Pitting attack occurs in waters containing chloride
or other halogen ions, particularly at crevices or stagnant areas
where passivity breakdown is accelerated by differential aerative
effects. Trac(-s of copper, iron, and mercury ions are also effec-
tive in promoting localized attack via galvanic cells formed be-
tween aluminum and metal deposited by replacement reactions
(ref. 10. 1). Since aluminum is strongly anodic to most other
common metals, galvanic coupling with them generally produces
severe attack on the aluminum, especially in sea water (ref. 10. 2).
Aluminum and its alloys are rather resistant to most molten salts.
However, molten metals generally attack aluminum, particularly
zinc and tin, which form alloys (ref. 10.2) Even a small amount
of mercury is especially harmful since it breaks down passivity
and amalgamates, causing rapid perforation of aluminum piping
02• sheet (ref. 10. 1). Aluminum exhibits very pour resistance to
uninhibited chlorinated solvents and may even react explosively
with them (ref. 10.6).
Aluminum purity significantly affects its corrosion resistance.
High purity metal is more resistant than commercially pure al ien-
inum which, in turn, is generally more resistant than most
99
_mss►
f
alloys (ref. 10.1). ..irrosion resistance of specific alloys is affected
by composition, heat treatment, and stress conditions, as discussed
further below.
10.2 Aluminum—Copper Alloys. For maximum resistance to corrosion,
the compo's t on of an -alroy should be kept as homogeneous as possible
since nonhomogeneities frequently initiate localized attack. This
principle applies to the Al—Cu alloys, of which 2219 is a typical ex-
ample. Copper generally depresses the electrode potential of alum- i
inum in the cathodic (noble) direction, but the copper concentration
and distribution are significant. For optimum corrosion resistance
of Al—Cu alloys, copper should be. maintained in solution by rapid
quenching from above the homogeniz;ng temperature (about 900 0 F,
4820 C). If the cooling rate is not rapid enough, the compound CuAl2
forms preferentially along the grain boundaries. This can result in
copper depletion adjacent to the intermetallic compound, making the
grain boundaries anodic to the grains and susceptible to intergranular
corrosion (refs. 10.1 and 10.7). 3
Tensile stresR in the presence of moisture may lead to intergranular
stress corrosion cracking. Susceptibility toward this type of attack
is heightened by the presence of grain boundary precipitates, although
authorities disagree on the details of the mechanism involved (refs.
10. 1, 10. 7, 10.9). Attack is particularly severe in the presence of
chloride ions which weaken the protective oxide films.
10.3 Resistance of Aluminum Alloy 2219. The 2219 alloy has somewhat less
resistance to atmospheric corrosion than other Al—Cu alloys such as
2014 and 2024. This is less than the lower strength alloys such as
6061 (ref. 10.10). General surface corrosion characteristics of nat-
urally aged tempers, T31 and T37, are similar to those of 2024-T3. a.,.
The corrosion resistance of the artificially aged tempers, particularly
T81 and T87, appears to vary consider: bly from lot to lot and has led 1
to some disagreement in the literature when the resistance of the nat-
urally aged tempers is compared with the artificially aged tempers.
One source reports that the corrosion resistance of the artificially aged
tempers is superior to that of the naturally aged tempers. Data sup-
porting this contention are presented in table 10.1 (ref. 10. 11). Another
investigation compared the difference in corrosion behavior between
2219-T37 and 2219-T87. Weight loss and type and depth of attack were
obtained, with and without an Iridite coating after 1, 3, 5, and 7 days
in 5-percent continuous salt spray. These data are shown in table 10.2. I
A greater weight loss with the T87 temper and the beneficial effect of
the Iridite coating in reducing attack of both tempers was noted. Depth
of attack values were greater with the T37 temper since corrosion was
intergranular as opposed to a pitting attack with the T87 temper; al-
though the depth of attack was less for the T87 temper, the total amount
of corrosion was greater (ref. 10.14).
100
5tudivs havo indicated that the stress-corrosion resistance of
221()-T87 is equal to 7075-1`73 alloy in the short transverse
grain direction (ref. 10. 15). The stress corrosion resistance
of the T62, T81, and T87 tempers is reported as excellent pro-
vidrd that no deviation is made from the recommended heat
treatment methods (ref. 10. 10); also sre table 10.3 (ref. 10.11).
Th( , artificially aged tenipers (T81 and T87) have shown a high
resistance to exfoliation in 3. 5% NaC1 (intermittent spray) and
Miami tidewater exposure tests. Tests on forgings, in the T6
and T852 terYipers, and T62 and T81 extrusions have also indic-
ated high resistance to exfoliation and stress corrosion crack-
ing (ref. 10. 11 ).
The salt spray corrosion resistance of anodized bare 2219-F
sheet was evaluated after 24 hours of exposure at 600° F (316° C).
It was found that bare 2219- F with Type I or Type II anodized
coatings (applied por MIL-A-8625A) exhibited no corrosion after
a 24-hour heat soak at 6000 F followed by 250 hours of salt spray
exposure. The sane alloy with 0.001-inch (0.025 mm) Hardas
coating showed an average of 2.6 pits/in' (0.2/cm`) of exposed
surface (ref. 10. 12). M: tallographic examinations were made
of parent ntelai t.:st panels of 2219 sheet in various tempers after
20-percent salt spray exposure for different expo::urc times
(ref. 10. 13). The results on this particular lot of material showed
that the solution heat treat condition was the most resistant and
the annealed condition the least resistant to salt spray attack.
The effect of salt-spray corrosion on the t..t,sile properties of
sheet in various tempers is shown in figure 10. 1. Studies have
also indicated that 2219 - TS1 alloy is resistant to corrosion by
dry nitrogen tetroxide and Acrozine-50 in lung term applications.
The alloy is compatible with liquid oxygen ^.nd liquid hydrogen.
An investigation at the Boeing Company (refs. 10. 17, 10.18)
demonstrated th it no significant evidence is present in precracked
specimens of alley 2219-T6F.46 exposed to hydrogen gas at press-
ures tip to 10, 000 psi ( 7. 0307 kg/nun ` ), and that this material is
superior to Allay 718 and titanium 6Al-4V for high-pressure A
hydrogen-gas tankage.
It is reported that no ad4erse effect on corrosion resistance is

encountered on reheating of any properly artificially aged temper
of 2219. The recommended maximum reheating tithes are given
in table 1 0.4.
10.4 Protective Measures. Anodic coating_ are v 3iaely used for the
corrosion protection of aluminum all( . • s. These oxide cca'ingR
are hard and are resistant to abrasio„ anu curi , ction. Cathodic
protection has also proved effective in retarding Loth general
dissolution and localir.ed attack, altki)ugh overprotection by this
method should bu avoided to insure "r -inst har;riful accumulation
of alkali at the cathode: surface (ref. 10. 1).
101
_.;WM
)
)
E
E Paints and inorganic inhibitors have also been applied successfully

in specific cases ( ref. 10.2).
I
The 2219 alloy is available as Alclad sheet and plate, which is bare
2219 with a thin coating of 7072 on both sides. The clad material
is chosen to provide a surface havin g a high resistance to cr.rro-
sion and sufficiently anodic to the 22.19 core to afford electrochem-
ical protection.
It• is also important that careful heat treatment and proper fabric-
ation techniques be used with this alloy to avoid localized tensile
stresses and structural crevices so as to minimize localized attack
and stress corrosion cracking. Surface treatments arc discussed
in more detail in Chapter 11.
10.5 F^,lution Potential and Electrical Conductivity Measurements.
'Sol ution potential an c-lectrical conductivity measurements were
obtained on 2219 alloy samples, with and without an Iridite coating,
to determine the effect of temper on the response of the alloy. These_
data are shown in table 10. 5. The sinnilarity of the potential values
of the bare and Iridite coated samples indicates that the Iridite coat-
ing does not provide a complete barrier against the corrosive media.
It was postulated that the primary protective properties are a result:
of the hexavalent chromium content serving as an anodic inhibitor.
The difficulty in forming an impervious chemical conversion coating
of any type on high copper alloys was noted ( ref. 10. 14).
g The protection afforded by conversion coatings is often seriously
reduced when the alloy is welded or otherwise heated. It has been
F found at Marshall Spacc Flight Center ( ref. 10. 16) that damaged
Iridite 14-2 or Aludine 1200 on alloy 2219-T87 can be replaced with
initial protective; value if an area within 6 inches of the weld is stripped
manually and then rccoated by sponge or spray application with a
solution two or three times stronger than that used originally. Addi-
tionally, spray applications of the conventional solution improve worn
or abraded coatings.
i
101
TABLE 10. 1 — Corrosion Resistance of Heat Treaiod Sheet
Source Ref. 10. 11
Alloy 2219
Type Loss in Tensile Strength, percent b, c
of 41i-Lr Al, Na('.l—l-l.,0.. 12-wk Al, 3.5) ",0 NaGlro
Temper Attack Not Stressed 75 ,'n Not Stressed 75%/u
(a) Stressed of Ft , (d) Stressed of F, v (e)
O P+I 8 - 14 -
'T31 I 16 23 25 3.1
T37 I 18 30 32 43
T02 I 14 17 25 38
T81 P 11 14 17 24
T87 P 11 1.1 1-' 26
(a) P = pitting; I = intergranular (MIL-fl-6088E)
(b) Exposed as cross-grain machined tension specimens,
0.064-inch (1.625-mm) thick.
(c) AI = alternate immersion
(d) Stressed as simple beam with dead weight load
(c) Stressed by bending in consf.anl- deflection fixtures.
TABLE 10. 2 — Corrosion of Alloy in 5% Continuous Salt Spray

Source Ref. 10. 14
Alloy 2219
Condition and Exposure, Weight Loss, Av. Depth,
Temper days rr:g /in2 (a, b) Type mils
Uncoated, T37 1 5.1 4.6
5
7
12.0
16.1
Intergranular
4.4
5.2
Uncoated, T87 1 6.9 1.6
3 10.3 Pitt; ng 1.8
5 13.6 1.4
7 18.2 1.5
Iridite Coated, 1 0.19 -
T37 3 0.25 -
5 0.48 -
7 0.68 Not -
Iridite Coated, 1 0.26 Determined -
T87 3 0.42 -
5 0.58 -
7 0.98 -
(a) Corrosion product was rum(-ved by immersion in concentrated HNOs
(b) 1 in2 = 6. 4516 x l 0 4 n i ` ; 1 mil = 0.025 mm.
s
103
i
^l
t
t
F TABLE 10. 3 —Stress Corrosion Cracking
Source Ref. 10. i 1
Alloy 2219
Form 0. 064-in (I. 625-mm) Sheet
12 weeks AT (c) 1 year sea coast
Temper 2. 5° NaCl a1 nios here.
F/N (b) Days to Fail F/N Days to Fail
O 2/2 7, 12 2/2 82, 82
T31 212 5, 7 2/2 82, 82
T37 0/2 OK 84 012 OK 365
T62 0/2 OK 84 0/2 OK 365
T81 0/2 OK 84 0/2 OK 365
T87 0/2 OK 84 n/2 OTr e,5
(a) Plastically deformed tension specimen blanks,
stressed in constant bend deflection fixtures
(b) FIN dern,tes ratio of numher of failures to
number exposed
(c) Al - alternate immersion

TABLE 10.4 — Recommended TABLE 10. 5 — Potential and Conductivity
Maximum Reheating Times Measurements
Source Ref. 10.10 Source Ref. 10. 14
Alloy 2219 Alloy 2219
Temper All
Condition Temper Potential
(a)
Conductivity,
Tem ;o IACS )
1
F 'C Timp., hr a) Uncoated F 802 my 42.6
500 260 to temperature T37 643 m y 28.7 I
450 232 1/2

T87 797 my 32.2
425 213 1 Iridite F 801 my -
400 204 5 Coated T37 632 my -
375 189 50 T87 796 my -
350 176 100
325 156 1000 (a) Against. a 0. 1 N calomel electrode in
300 1 149 1 10, 000 plus 53 g/l NaCl, 9 ml/l 30% 11202
(a) Thesu times and tertiperatures
are based on a 5% ma-irnurn
decrease in mechanical
properties.
104
O T84
(bT82
6 T62
O T42 50
70 T31
j 1:4 1 m
60 1
i
x j I
40
;.
kg /mm'
Wy
50
I I ^^.
30
40
17 1
v 20
U
i+
N
a
10
N
0 40 80 120 160 200

r
Exposure Time, hours
FIGURE 10. 1 . — Effect of salt-spray (20% NaGI) corrosion on
tensile properties of 2219 sheet in variou.3 tempers;
thicknesses, 0.088-0. 100 inch (2.235-Z. ti4 cm).
(Ref. 10. 13)
105
_ K>1f
10. l I1.II. IJhlig, Corrosion and Corrosion Control, John Wiley & Sons.
New York, 1963, Ch. 28.
10.2 L.L. Shreir, Corrosion, John Wiley & Sons, New York, 1963,
Vol. I., Sec.
10.3 P. N1. Arir. and H. P. Goddard, Corrosion, 15, 529t (I 95(l).
10.4 Symposium on Atmospheric Corrosion of Non-Ferrous Metals, 3
ASTM srl'- 1 75, 19s t).
10.5 J. Draley and W. Rut.her, Corrosion, 12, 441t. 4801 (1 ^^551.
10.6 A. Hamstead, G. Elder, and J. Canterbury, Corrosion, 14, 18 0 1 (10ii';
10.7 K. F. Thornton, "Alcoa Aluminum-Magnesium Alloys Suitable for
Structural Welding Applications," Alcoa Green Letter, November 1957: l 3
revised by R. L. Flucker, August 1962.
10.8 Materials in Design Engineering, Materials Selector Issue, Mid-
October 19 ,4. i
10.9 Metals Handbook, "Properties and Selection of Metals," 8th Edition. i
3
American Society for Metal s, 1961, Vol. I.

10.10 L. W. Mayer, "Alcoa Aluminum Alloy 2219," Alcoa Green Latter,
October 1960; latest. revision November 1963.
10.11 J. A. Nock, Jr., et al., "A New High Strength Aluminum Alloy,"
Metal Prog-ess, 80, September 1961.
T
10.12 J. L. Co •r.2_r1, "Determination of Corrosion Protective Surface Treat-
ment for Bare 2219-F Alloy at Elevated Temperature," Convair/
Fort Worlh Report No. FTDM-2222, August 1962.
10.13 Martin/Denver, "Summary Inforniation Regarding Aluminum Alloy r
2219," Evaluation Report Nu. 1, Mi-61-44, November ] 96] .
10.14 W.G. %cllcy, "Development of Improved Conversion Coating fOr
Aluminum Al.](-ys," Contract NAS8-11226, Alcoa Research Labs,
May 191)5.
10.15 B. W. Lifka, et al., "Investigation of the Stress-Corrosion Cracking
of Ifigh Strength Alumnium Alloys," Contract NAS8-5430, Tenth
Quarterly Report, October 1965.
10.16 R. 11. Higgins, "Renewal of Corrosion Protection of Coated Aluminum
after Welding," NASA Tech Brief 69-10150, May 1961).
10.17 P. M. Lorene. "Effects of Pressurized Ilydrogen upon Inconel 718
and 221' Aluminum," Paper W9-1 3. 2, WESTEC Conference (ASM),
Los Angrl,.s. California, March 10-13, 1969.
10.18 J.E. Campbell, "Effects of Hydrogen Gas on Metals at Ambient
Temperature," DMIC Report 5-31, April 1970.
106
__ KIT
Chaptc r 1 1
SURFACE TREATMENTS
11.1 General. A wide variety of surface treatments can be applied to

t e 2219 alloy (and other aluminum alloys) to protect and improve
the appearance of the surface. These include mechanical, chem-
ical, and electrochemical finishes and organic, porcelain, and
paint coatings. Alclad forms of aluminum alloys have a verN high
inherent resistance to corrosion and may be used without bone-
; fit of protective coatings for some applications (ref. 11. 1).
11.2 Alclad Products. The 2219 alloy is available as Alclad sheet and
plate which consists of bare: 2219 core material clad with a thin
coating of 7072 alloy on both sides. The clad material is metal-
lurgically bonded to the core material. It is chosen to provide a =
surface having a high resistance to corrosion and sufficiently
anodic to the 2219 core to afford electrochemical protection to
it in corrosive environments. Consequently, any spot of attack
can penetrate only as deep as the core alloy where further prog-
ress is stopped by cathodic protection. Corrosion is thus confined
to the clad material only. The life of the cladding is a function of
its thickness and severity of the environment. Alclad products,
therefore, limit corrosion to a relatively thin clad surface layer
(refs. 11.2, 11.8).
11.3 Mechanical finishes. Mechanical finishes are used to alter the
texture of the alloy surface to provide a more decorative appear-
ance or as a treatment prior to other finishing such as painting.
Grinding, polishing, and buffing result in smoother reflective
surfaces. Abrasive blasting (sand or grit) gives a rough matte
finish which is often used as a base for organic coatings. Scratch
finishing, satin finishing, Butler finishing, and skin finishes are
scratched-line finishes which remove minor surface defects and =
provide a decorative effect. Mechanical methods remove the i
original 1wavy oxide film. For this reason, mechanically finished
parts are often given a protective coating by anodizing or lacquer-
ing. The possibility of generating an explosive miYtore of fine
powder and air durin g; mechanical finish operations should be
recognized (ref, 11.3).
f
11.4 Anodizing. Anodic coatings are hard, abrasion- and corrosion-
resistant oxide coatings. The alloys can he anodically coated in
a number of electrolytes, but most commercial anodizing is done
by either the sulfuric acid or chromic acid pz uc.:i::;i;. The thick-
ness of the coating is dependent upon the Enodizing time. Coatings
produced by the sulfuric acid process vary ir thickness from
0.0001 to 0.001 inch (2.54 to 25.4 [1m). Coatings produced in
107

.L1s"
F
4
chromic acid vary front 0.00001 to 0.00009 inch (0.254 to 2.29,µn1).

Anodic coatings provide good protection against corrosion and ai--'
excellent bases for paint coatings (ref. 11.1). However, the chro ►>î,
acid process does not. provide as corrosion-resistant a coating as
does the sulfuric acid process (ref. 11.11).
11.41 In recent years, a number of now methods have been developed for
producing heavier anodic coatings of from 0.001 to 0.010 inch (25.4
to 254 juil). These methods require electrolytes which enable the
oxide growth process to continue until the desired coating thickness
is obtained.
Another recent development: in coatings is that of hard anodizing,
designated as "hardcoating." Processes most suitable for a wide,
range of applications are Alumilit-e 226 (oxide coatings, 0.002 hich or
50.8 I^ ►n thick) and Martin Hardcoat (coating thicknesses up to 0.004
inch or 101 lLm). A flash hardcoat of a very thin film can also be
applied by those methods by shortening the normal time cycle. The
operating conditions for the baths employed in these processes are
given in table 11. 1. The Martin process should be specified where
maximum hardness and corrosion resistance are required along with
thickness buildups to 0. 004 inch. Alumilite 226 is selected where
hardness and corrosion resistance are required and 0.002 inch is
the acceptable maximum buildup. Further details of these processes
are presented in reference 11 .9.
11.42 A white anodize has been developed by the Reynolds Co, for alloy
2219 to provide a gopd reflectance value and excellent resistance to
corrosion (ref. 11.4). The technique consists of 4 steps: (1) surface
preparation by mechanical and chemical pretreatment; (2) anodizing =
in a 26-percent sulfuric acid electrolyte containing glycerol, lactic
acid, and titanium ammonium lactate; (3) pit4mentation with lead
sulfate in a complex acetate solution; (4) sealing with a polyorgano- €
siloxane after boiling-water scaling.
11.5 Chemical Finishes. Chemical finishes are of three main types. Fin-
ishes used for ecorative effects include caustic etching, acid etching,
and clicmical polishing. Etched surfaces have a matte appearance 1
while chemically polished surfaces are highly reflective and require
protection by anodizing or lacquering. Conversion coatings can be
F oxide, phosphate, or chromate types and are used primarily as base
coatings prior to application of organic coatings. Miscellaneous
special-purpose finishes include those produced by the Alrok process,
modified Bauer-Vogel process, and processes for staining aluminum
alloys.
11.6 Electra olishing. This process produces a highly reflective surface
and is often used for surface preparation prior to microscopic ex-
amination of meta.11grgical structure.
108

_— so"
11.7 Electroplating of aluminum alloys has trained increased com-

mercial use in recent years. A commonly used finish consists
of successive deposits of copper, nickel, and chromium. Other
metals may be applied over the copper. A satisfactory base
surface for electroplating is provided by immersing the alum-
inum part in a solution of sodium zincate of controlled compo-
sition. Brass, iron, silver, or chromium can be applied directly
over this zinc immersion coating (ref. 11.4).
11.8 Painting. When severe conditions of exposure are to be encount-
ered, it is frequently desirable to protect aluminum alloy sur-
faces with paint. Prior to painting, the surface should be prop-
erly prepared before priming. Dirt may be removed by brushing
and grease or oil may be removed by means of solvent or de-
greasing techniques. The parts are then immersed in (or swabbed
with) a solution of phosphoric acid and organic grease solvents
diluted with water. A number of proprietary solutions of this
type are available commercially. Solution temperature should
be between 500 and 90° F (10" and 32") C) and contact with the
metal part should not be for less than 5 mbiutes.
The part is then rinsed with water and driod thoroughly. Where
chemical treatment is impractical, mild sandblasting methods
may be employed. A chemical conversion coating per MII_.-C-
5541 or an anodize coating is necessary prior to priming with
zinc chromate primer per MIL-P-8585. For severe conditions
of exposure, both primer and joint compound should be used
at joints .
All surfaces except contacting surfaces may be given a second 6
coat of paint consisting of two pounds of aluminum paste pig-
ment (ASTM Spec. D962, Type II, Class B) per gallon (239. 6
g/1) of varnish which insets Federal Spec. TT-V-86b, Type II
or equivalent. The final assembled structure may be finished
with one coat of aluminum paint. One or more coats of alkyd
base enamel (pi, rented to desired color) may be substituted
for aluminum paint (ref. 11 .5).
11.81 To minimize stress- corrosion cracking when the alloy is sub-
jected to sust:aine surface stresses anc corrosive environ-
ments, certain surface treatments and _,_ot:;:Live coatings are
effective. The most effective protection is obtained by applying
a topcoat of epoxy-polyamide paint to shot_ ,uz;.ed or metallized
surfaces of the alloy. Satisfactory temporary protection is
outained by an electroplated galvanic coating (3 to 4 mils thick),
or a topcoat of paint containing epoxy- polyamide or polyurethane
resins. The former is preferred and ca;. be ubed on unprimed
surfaces. Care is necessary to prevent l.ruc:kin t; or scratching
the paint film. Shat peening alone will provide good surface
protection (if all surfaces are treated) when corrosive environ-
ment is not severe. Anodic films and zinc-rich paints are the
least effective coatings for preventing stress-corrosion crack-
ing (rcf. 11.6).
109
__ .61*
11.9 Porcelain Enameling. The principal diffr.renco between o(lrcrlaii)

cnamc inti of aluminum alloys and other metals is the use of por-
celain frits which melt at lower temperatures. High lead fries are
cottun"nly used and they can be formulated in a wide variety of
colors and surface lini g hc s. I'he enamel slip is sprayed onto chem-
I ically c • Ir.am , d and treated surfaces and then fired at temperatures
()t' 950" to 1050"F (510" to 717"C) for a period of 4 to 8 mimites
0-cf. 11.7).
l
1
lE
110
_*Sign
)
I
i
^ t
TABLE 11 . 1 — Baths for Hard Anodized Coatings

Source Ref. 11.9
Alloy Aluminumn Wrought Alloys
Process
Parameters Martin (a) Alumilite (b)
Composition 15% H 2 SO4 12'',o H2SO4,
1'Ao H. Cr2O4
Electrolyte Temp. , F 25 to 32 413 to 52

C —4to0 atoll
Current Density 25 asf 36 asf t _ ji

It
(a) Developed by the Martin Conipany

(b) Developed by the Aluminum Company of America
111
SEE -
Chapter I - References
1 1 .1 1971 SAE. Handbook, Sociel y of Automotive Engineers, Now York

11.2 MrLals Handbook, Vol. 1, '' p roperties and Selection of Metals,"
8Lh Edition. American SocieLy for Metals, 1901.
11.3 Reynolds Metals Co., "The Aluminum Data Book, Aluminum
Alleys and Mill Products,'' 1958.
11.4 K.II. Dale, "Advances in Aluminum Anodizing," NASA 'Poch liriof
B69-10144, May 1961.
11.5 Aluminum Company of America, "Alcoa Structural Handbook,"

1960.
11.6 Alcoa Research Labs, "Aluminum Alloys Protected Against
Stress-Corrosion Cracking," NASA Tech Brief 65-10172.
.Tune 1965.
11.7 J. Vaccari, "Wrought Aluminum and Its Alloys," Materials and

Processes Manual Nu. 231, Materials in Design Engineering,
,Tune 1 `165.
1962.
1 1 . 9 C. R. K1 iemann, "Bard Anodizing of Aluminum Components,"
Metal Progress, July 1965, p. 63.
11.10 J. L. Cozart, "Material: Bare 2219-F Aluminumi Alloy: Elevated

Temperature Corrosion Protective Treatment," Repot No.
FTDM-2222, C;cncral Dynamics/Fort Worth, August 1062.
1 1 . 11 George C. Marshall Space Flight Center, Marshall Space Flight,
Center, Alabarrna, Unpublished Data, 1965.
1
112

_ .:s"
Chapter 12
..IOINING TECHNIQUES
12.1 General. The 2219 aluminum alloy can be joined satisfactorily

l yTia ion and resistance welding techniques and by riveting.
Brazing, gas welding, and soldering are not recommended,
since satisfactory materials and methods have not been devel-
oped for this alloy. Specifications for welding of aluminumn
alloys are presented in Lablo 12.1
12.2 e
Weldin^. Reliable, sound, high quality welds have been made
in aluminum alloys for many years. Although aluminum is one
of the most readily weldable of all metals, it has individual char-
acteristics which must be well understood for successful welding
of the metal or its alloys. Four important factors that must be
considered are the low melting point., the presence of an oxide
film, low strength at elevated temperatures, and the fact that
aluminum exhibits no characteristic color changus even at temp-
eratures up to the melting point. The welding of aluminum alloys
requires care to prevent excessive nieltLig of the material. The
oxide film must be removed and prevented from reforming by
some inhibiting technique before a good bond can be obtained.
Parts should be well supported during welding to prevent dis-
tortion (ref. 12.2).
12.21 Fusion Welding;. The 2219 alloy exhibits the best weldability of
the 2xKx series of aluminum alloys. In particular, its suscepti-
bility to weld cracking is less than that of 2014. This is due to
the absence of magnesium and silicon as alloying elements.
These elements form ternary and quaternary eutectics of low
melting points and thus increase the melting range of the alloy. t
Both the wide range of melting; temperature and the presence of
phases with a low melting temperature are Known to cause weld
cracking as discusycd in references 12.3 and 12.4
The filler rod used to fusion weld 2219 has the as:ne composition
as 2219 plus titanium and is designated as 2.319.
Frequently th(! alloy, when fusion welded, is used in the "as

welded" condition. To compensate for the low strength in this
condition, designers usually arrange to have the welded joint
thicker than the parent metal. For highest strength, ductility,
toughness, and corrosion resistance, a full heat treatment after
welding; is recommended (ref. 12.5).
12.211 Fusion Welding Methods. One of the most important advances

î aluminum welding has been the development of inert-gas-
shielded methods that do not require a flux. The "tungsten- inert-
gas" (TIG) method and the "metal-arc-consumable electrode"
113
1"
(MT(;) method have both contribuled mignificant.ly to the advancement

of the "state of the art" of aluminumr. welding. TIC', and NUG tech-
niques each have inherent advantages and disadvantages and are dis-
cussed in detail in reference 12.6. The niain problem wiLh these
fusion welding processes is the occurrence of porosity in the weld
which adversely affects the mechanical properties. Invest igations of
the factors that can cause porosity are reviewed in detail in refer-
ence 12. 37. Il has been indicated Lhat gases (notably hydrogen) t rapped
in weld zones are the principal cause of porosity in 221 11 alloy weld-
ments (ref. 12.7). Hydrogen is soluble in liquid aluminum bttl is
nearly insoluble in solid aluminum. Thrts, any hydrogen present at
solidification is rejected in the form of porosity as the alloy solidifies.
At Lemperatures above 920"F' (493"C). aluminum reacts with water
to produce "nascent" hydrogen plus oxygen. 'f he hydrogen dissolves
in molten aluminum and the oxygen combines to form aluminumt oxide
(ref. 12. h). The' solubility of hydrogen in aluminum is shown in figure
12.1. Control of humidity and cleaning of filler wire Lo remove Lhe
oxide surface layer have helped to reduce porosity in 2219 alloy welds.
However, hydrogen in the interior of the base metal or filler wire: is
more di;Eicult to eliminate (ref. 12.4). It has also been found that por-
osity is more prevalent in multipams welds than in single pass welds.
Apparently, successive beads pick up gas contaniinaLion from preceding
beit r Is to cause a cuseeulative effect (ref. 12.9). TIG welding results in
slightly lower porosity levels in the weld than MIG welding. The speed
of welding has a siicable influence on the porosity level for both
methods as indicated in figure 1Z. 2. The effect of increasing levels
of porosity on mechanical properties is shown in figure 12.3.
Another strength reducing factor is mismatch of the pieces to be joined,
as is shown in figure 12.4.
The mechanical properties of welded 2219 also depend upon the follow-
ing factors: Sheet or plate Lhickness, heat-treatment condition before
and after welding, welding niel.hod (i.e., manual or autoniatic), type
of back-up bar used, and Lhe lotting temperature.
The effect of original temper and post-weld treatment on the strength
and elongation of TIG and MIG welded sheets and plates of various
thicknesses is shown in table 12.2. The results indicate tha t: Lhe best
properties are obtained by welding parts in the solution treated or
"as fabricat,-l' s condition, which are subsequently solution treated and
reaged to the T6 condition. Material in the T81, T87, T31, or T37
condition, which is aged after welding or left in the as-welded condition,
shows that some increase in strength can be obtained by post-weld aging.
Typical Lensilc properties of 0. 75-inch (1.90-mm) 221 9-T87 welded
and unwelded plate are tiveti in Lable 12. 3,
The effect of cryogenic temperatures on the tensile strength and elonl^-
ation of 2219 welded sheet in the T81 or T87 condition is shown in
figures 12. 5 and 12, F,. Similar data for the T62 condition is given in
figure 12.7.
114
Both the base metal and the weld strength increase with de-
creasing; elongation. The joint efficiency is about 70 percent
and the elongation only about 2 percent. Both values are nearly
constant at all testing temperatures. Failure occurs in the
wold heat-affected zone before any significant. amount of elong-
ation occurs in the parent metal (ref. 12.13). The "A" and "B"
values shown in figure 12.5 are lower bounds on the weld
strengths, as defined in MIL-Handbook 5A. It should be noted
that they are relatively low at —423" F (-253 0 C) which indicates
a greater scatter of the tensile data than at higher temperatures.
The effect of high temperatures, welding procedure, elimin-
ation of the weld bead, and post-weld heat treatment on the
tensile strength and the "A" and "B" values (MIL-Handbook 5a)
is shown in figure 12.8.
The tensile strength of 2210 in all conditions is lowered by in-
creasing the testing temperatures. The "as-welded" tensile
strength at room temperature is decreased more with respect
to the parent material than at 400') F (204' ) C) and higher temp-
eratures. Furthermore, the scatter of the experimental results
is higher at room temperature than at elevated temperatures,
particularly for the manually welded pan; ls.
The strength and ductility of panels with reheat treatment after
welding closely approximates that of the parent material.
Machine welded panels have slightly higher strength and ductility
than manually welded panels. The tension and elongation values
of the panels which are reaged after welding are quite similar
to the values of the panels in the "as welded" condition. There
is no significant difference between machine and manually
welded properties.
The room temperature strength of the "as welded" and reaged
panels is markedly reduced when the weld beads are ground
flush. At elevated temperatures, however, the effect- of weld
bead reinforcements is generally negligible. Except where weld
defects are present, the grinding of weld bead reinforcements
does not materially affect the strength of the reheat treated panels.
The strength of a weld in general will he highuc when less heat
is seeded to fusion weld. Thus, the wctd „ieL 1 zone and heat
affected zone should be as small as pc,ssiblG. ihis can be
achieved by using suitable welding spc(sds and back-up bars.
The effect of these two variables on th , ^ limit ,,f the tempera-
ture zones above 500 0 F (260 0 C) is shown ).,i f. ures 12. 9 and
12.10. The temperature gradient cau-ed by tt,e welding pro-
cess will result in a gradual decrease in -strength from the base
metal to the weld. This is shown in figure 12. 11 where the
Rockwell "ti ll hardness across the weld is plotted as a function
of welding speed and back-up material. The change in mechani_A
115
Son
i
properties across the weld can also be shown h teriu3 of stross-
strain data as indicated in figure 12. 12. This f igture , in which only
the initial part of the stress- strain curves is ploLted, shows that
the strength of Lhe material increases with the distance from the
weld. The effect of weld procedures and post-weld heat treatment
on bulge properties of 2210 sheet is illustrated in table 12.4 and
figure 12.13. These results indicate that 2219 is the most easily
welded and the lca^C sensitive Lo variations in weld procedures of
all the high strength, heat-treatable aluminum alloys. When reheat
treated after welding, the alloy consistently develops bulge strengths
equal to the tensile strength of the base metal. 'rho T81 and P87
tempers are recommended for assemblies to be left in Lhe " as welded"
condition. For assemblies to be post-weld heat treated, the F Lemper
(as-fabricated) is recommended because of its lower cost. Other
tempers, however, are also satisfactory. 'The recommended post-
weld treatment practice is T62 for maximum bulge strength.
The fatigue properties of butt welded 2219-T87 aluminum are excel-
lent, particularly at —423 7 F (-253° C) where the endurance limit is sub-
sLanLially higher than at room teTnperal . ure as shown in figure 12. 14.
The low-cycle fatigue data of figure 12. 15 indicate that specimens
can be cycled up to 2000 cycles at 75, 85, or 95 percent of the static
joint strength without. failure. The low temperature stren--ths are
higher than those at roc.m temperature.. S-N curves for the T87 sheet
are given in figure 12. 16.
The range of angles to which 2219 in the T6E46 condition can be bent
over a ram of radius 5T is given in table 12.5.
12.212 Gas Metal Arc: Spot Welding (or inert - gas spot welding) is used to
make high strength localized welds with light equipment and from one
side only. It is a quick and reliable method to join sheet, extrusions,
and tubing. The localized welding is accomplished by using very high
automatically controlled welding currents for a short period of time
with the. addition of a small quantity of filler metal (ref. 12.26). Filler
metals recommended are 2319 and 4043. The tensile shear breaking
loads of 0.064-inch ( 1.6-mm) thick 2219 - T6 alwninum overlap joints,
welded with 2319 filler of an experimental investigation, are 695
pounds ( 313 kg) for a nonpenctrating and 1300 pounds ( 585 kg) for a
penetrating weld spot (ref. 12. 34).
12.22 Electrical Resistance WtAding. Resistance welding ( spot welding and
seam welding) is a most rnseful, practical, and economic method of
joining aluminum alloys. The welding process is almost entirely
automatic and standard welding machines are capable of handling a
wide variety of operations. Resistance welding heats only a small
area of metal. Thus, there is only a minimum of metallurgical dis-
turbance for a minimum length of time,w•hich is important in the
welding of aluminum alloys. _—
116 = — ==

cl"
Mechanical or chemical cleaning of the contact surfaces is

necessary to obtain good spot welds in aluminum as no fluxes
are used during; spotwelding. In aircraft construction, it is
recommended that the contact resistance of the elements to
be joined be continually checked to ensure surface cleanliness.
Surface contact resistance should not exceed 90 microhms for
best results. Details on surface cleaning are given in reference
12.25, page 48.
12.221 Mechanical Properties of Spot Welds. Very little information
on spot welding of 2219 is available. The effect of cryogenic
temperatures on the cross-tension and tensile shear strength
of single spot welds of 2219-T81 sheet is shown in figure 12.17.
The data indicate that spotwelded 2219-T81 sheet has sufficient
strength at cryogenic and room temperatures. The tensile shear
curves, however, show a tremendous scatter, as can be seen
from the low "A" and "B" strength values. Furthermore, between
—3200 and —423" F(-196 0 and -2530 C), the cross tension strength
drops rather sharply, indicating some loss in toughness in this
temperature range. The suggested minimum joint overlap and
spacing of spot welds is presented in table 12.6 and the minimum
allowable edge distance for spotwelded joints is shown in table
12.7. Spot weld maximum shear strength standards are given in
table 12.8.
12.3 Brazing. Brazing of the 2219 alloy is not recommended. The
melting; point of 2219 is lower than that of the commercially
available brazing alloys (ref. 12. 30).
12.4 Riveting. Riveting is a commonly used method for joining alum-
inu particularly the heat-treatable alloys. It is reliable because
m,
riveting is a method that is well understood and highly developed.
Also, modern riveting methods are largely independent of the
operator's skill and thus uniformity of riveted joints can be
readily attained (rcl. 12.2). Specifications fer aluminum riveting
are presented in table 12.9.
12.41 Alun.inum alley rivets are preferred for the fabrication of alum-
inum alloy si.ruckares, although cold-driven annealed steel rivets
have been used successfully for some applications. To determine
the strengTtl, of riveted joints, it is necessary to know the strength
of the individual rivet. The average shear strength for driven
rivets of various aluminum alloys is given in table 12. 10. In
most cases, such joints fracture by shearing, by bearing or
tearing failure of the sheet or plate. It is customary to use a
slightly larger factor of safety for the shear strength of rivets
than is employed for other parts of an assembly. The design of
joints where rivets are subjected to tensile loads should be avoided.
Bolted connections may be used where high Lensile stresses pre-
clude the use of riveting. Information in detail on the riveting
117

of aluininnrn alloys is given in references 12.31 and 1:;.32. Design

data on rnec.hanical joints using rivets or bolts may be found in
MIL-Handbook 5A (ref. 12. 11).
12.5 Electron Beam Welding. Electron beam welding is not yet a nnaior
process for joining aluminum in production, but has sufficient
promise to be mentioned (ref. 12. 37). hi this process, fusion is
accomplished by bombarding the worlcpiece with a dense stream
of high-velocity electrons in an evacuated chamber. The j oint de-
sign is a square.-butt joint with no gap; a filler metal is not reetuii-od.
12.51 Impressive welding speeds have been cited for 2219 in tlhicl<rresses
of 0.5 to 6 inches (1.27 to 15.24 cm) (refs. 12. 38, 12.39): strength
and joint efficiency developed in plate gages haves been superior to
those formed by gas tungsten-arc or gas metal-arc (ref. 12.39).
In an improved technique developed at Westinghouse Electric Corp.
(ref. 12.40), the power density of the bearn relative to the speed
of the workpiece is such that the material is melted but not vapor-
ized as it is in the usual technique; an inclined weld front is pro-
duced. Several hundred welds of the bead-through-plate variety
were made with 2219-T87.
118
TABLE 12. 1. — Welding Specifications
Source Refs. 12.1, 12.21, 12.22, 12.23
Alloy 2219
Product or Process Federal ASTM Military AMS
Weldments (aluminum and MIL-W-22248
aluminum alloys)
Welding of aluminum alloys MIL-W -8604
Welding (aluminum alloy MIL-W-45206
armor)
TIG welding, aluminum
alloy for structures MIL-W-45205
Welding; resistance, M1L- W- 45210A
aluminum alloys
Welding; spot, seam, or N_1L-W -6858B
stitch(Al, steel, Mg, Ti)
Welding rods (aluminum- QQ-R-566-2 B285 4190A
2319) 4191A
Welding electrodes 5597C
(flux coated)
B184 MIL-E-1
Welding electrode wire B285 MIL-E- 16053J

Flash welds (rings, 7488C
flanges)
119 -
--. -![v
TA13I.E 12.2. - Effect of Original Temper and Past-Weld Heat

Treatmerlt on Elongation of Welded 2210 (Al-121U9 Filler)
Source Ref. 12. 5

Form Sheet and Plate
Original temper
n h Th;ckness, No. of Ftu Fty C
trand
n heatt inch (a) samples ksi (a) ksi (a) (b)
T81 or T87 AW 0.064 22 47 32 3

T81 or T87 AW 0.125 23 4^, 10 3
T81 or T87 AW 0.250 10 40 - 1
T81 or T87 AW 0.500 4 40 - 1
T31 age - T87 0.064 22 49 43 2
or T37 age - T87 0.12r) 23 44 38 2
T37 age T87 0.250 10 46 - 0.6
T37 age T87 0.500 4 41 - 1
O or F age IITAT62 0.0:')4 9 59 40 8
O or F age IITA'T02 0.125 12 57 8
O or F age HTAT62 0.250 5 60 43 4
O or F age IITAT621 0.500 1 2 52 - 3
(a) 1 inch = 2. 54 cm; 1 ksi - 0.70307 kg/nini2
(b) Gage length, 2 in for 0.004 and 0.125 sheet
Gage length, :; iu for thickness :-0. 1L5 sheet
TABLE 12. 3. - Typical Tensile Properties of Welded and

Unwelded Plate
Source R(-f. 12. 12
Alloy ?.219-T87, 0.75-inch (1.9-cm) plate
Weld Method Condition Test temp, Ftu , 1«i Ft , ksi e - all)

of weld ° F (b) (a) y(a) (2 ill)
- Base metal 72 68.2 56.3 13
t TIG As welded 72 43.1 26.7 4.3
F MIG As xveI(Ie(1 72 41.5 26.1 3.6
- Base metal -320 84.6 68.2 16.
TIC; As welded -320 50.8 10.8 4.()
MIG As w(4dod 1 -320 55.7 31.9 4.(1
(a) 1 ksi = 0.70307 kg /film`
(b) 72" F 22. 2`' C; -320' F = -196° C.
120
TABLE 12.4. Tensile and Bulge Tests of Fusion Welds in Sheet (a)
Source Ref. 12.20
Alloy 2219
Thickness 0.064 in (1.625 mm) 10.125 in (6.35 mm)
Weld Method SA (b) D SP (c)
6
Temper T87 T37
(d)
T31 T87 T37 T31
(e) (d) (e) T87 T37
(d)
F
tu, ksi (f) 46 53 52 47 53 53 45 50
Fty, ksi M 37 49 48 34 47 45 29 41
c (2 in), % 1.9 1.3 1.5 1.5 1.6 1.2 2.2 1.8
S (g ) 0.5 1.6 2.4 1.2 1.4 0.4 1.0 1.0
1
Bulge Tests
Tensile, ksi 47 54 55 50 44 42 48 47
Height, in 0.37 0.47 0.54 0.42 0.48 0.44 0.45 0.43
S (g) 2.1 1.8 1.4 1.5 0.4 11.4 1 1.6 t.1
(a) All welds made in flat position by completely a-tomatic procedures
(b) SA - MIG welds, "short arc" with 0. 030 electrode, 1 He/lAr gas
mixture
(c) DCSP - TIG welds, straight polarity, He gas mixture, 1 16 inch
cold wire feed
(d) Aged to T87
► (c) Aged to T81
(f) 1 ksi = 0. 70307 kg/mm. 2
(g) S standard deviation
121
I
I
TABLE 12.5. — Fiend Angle of TIO Welded (2319 Filler) 2219-0 Plate J
with T6E46 Pont Wuid Heat Treatment Bend over a Ram with a Bend
)
Radium ()f 5T
(
Source Rel'. 12.3
Alloy 2219-,r6E46 = 0.25 inch (6.35 mm) thick (T) plate
Total No, of Repai r Fiend an g le dr reds
Type of weld
S ecinwns filler wire max min avi
18 Plate to Nona 60 40 58
18 plate 2319 60 16 26
32 Plate to None 60 19 34
16 forging; 2319 47 15 23
TABLE 12. 6. — Suggested Minimum ,Joint O-, c!rlap

and Spacing; of Spot Welds
Source Ref. 12.25

Allay Aluminum Alloys i
Thinnest sheet Minimum joint Minimum weld
in 'oint inch a overlap, inch spacing, inch
0.016 5/16 3/8
0.020 3/8 3/8
0.025 318 3/8
0.032 112 1/2
0.04n 9/16 1/2
0.051 5/8 5/8
0.064 3/4 5/8
0.072 13/16 3/4
0.081 7/8 3/4
0.091 15/16 7/8
0.102 1 1
0.125 1-1/8 1-1/4
(a) 1 inch = 2. 54 cin
12;
TABLE 12. 7. — Minimum Allowable Edge Distances for
Spotwelded Joints (a, b, c)
Source Ref. 12.33
Alloy Aluminum Alloys
Nominal thickness of the Edge distance, E, in
thinner sheet, inch (d)
0.016 3/16
0.020 3/16
0.025 7/32
0.032 1/4
0.036 1/4
0.040 9/32
0.045 5/16
0.050 5/16
0.063 3/8
0.071 3/8
0.080 13/32
0.090 7/16
0.100 7/16
0.125 9/16
0.160 5/8
(a) Intermediate gages will conform to the requirement
for the neat thinner gage shown
(b) Edge distances less than those specified above may
be used provided there in no expulsion of weld metal
or bulging of the edge of the sheet or damage to bend
radii by electrode
(c) Values may be reduced for nonstructural applications
or applications not depended on to develop full weld
strength
(d) 1 inch = 2. 54 cm
123
TABLE U. 8. --• Spot Weld Maximum Design Shear Strength
in Panels for Bare and Clad Aluminum Alloys:
We](] SPEC MIL-NV-6858 (a, h, c)
Source Ref. Ill . .33
Alloy Aluminum alloys, bare and clad
Nominal thickness Material ultimate tensile strength
of thinner sheet, > 50 20 to 56 1' ► . 5 to 28 9. 5
inch (d) ksi (e) ksi (c) Icsi (e) ksi (e)
0.010 48 40 - -
0.012 60 5^) 24 16
0.016 88 80 56 40
0.1,?0 112 10ii 80 64
0.02- 148 140 116 88
0,032 200 188 168 132
0.0 .10 276 248 2.10 180
0.050 372 3.14 3;!0 236
0.063 536 488 456 316
0.071 660 576 516 31":0
0.080 820 684 612 420
0.090 1004 800 696 476
0.100 1192 936 752 540
0.112 1474 1072 b00 588
0.125 1696 1300 840 628
0.160 2496 1952 - -
0.190 3228 2592 - -
0.250 5880 5120 - -
(a) The reduction in strength of spotwelds due to cumulative

effects of time -temperature-stress factors is not greater
than the roduc:tion in strength of the parent metal
(b) Strength based on 80 percent of minimum values specified
in MIL-W-6858
(c) The allowable tensile strength of spotwelds is 25 percent
of the shear strength
(d) 1 inch - Z. 54 cm
(e) 1 ksi = 0.70307 kg/mms
124
TABLE 12. 9. —Specifications for Aluminum Rivets
Source Ref. 12. 1
Products Federal Military AMS
Rivets F F-R-556a MIL-R-11 50A-1 7220C
- MIL-R-56748-1 7222C
- MIL-R-12221 R 7223
Rivets, blind - MIL-R-7885A-1 -
- MIL-R-8814-1 -
- MIL-R-27384 -
Rivet, wire QQ-A-430-1 - _
TABLE 12. 10. — F su (Average) for Driven Rivets (a)
Source Ref. 12. 31

Alloy and Alloy and Fs
Temper before Driving Procedure Temper after (Av^,
Driving; (b) Driving ksi
1100-H14 Cold, as received 1100-F 11(c )
2017-T4 Cold, as received 2017-T3 39
2017-T4 Cold, immediately after quenching 2017-T31 34(d)
5056-H32 Cold, is received 5056-H321 30
6061-T4 Hot, 990 0 to 1050° F (532''-566 ) C) 6061- T43 24(d)
7277-T4 Hot, 850 0 to 975 0 1F (454"--524"C) 7277-1'41 38
(a) These values are for rivets driven with core point heads. Riv• to
driven with heads requiring more pressure may be expected co
develop slightly higher strengths
(t, : ese designations should be used when ordering rivets
(c) 1 ksi - 0.70307 kg/mm2
(d) Immediately after driving, the Ghcar strengths of these rivets arc,
about 75% of the values shown. On standing at ambient temperaûres,
they age harden to develop full shear strength. This action takers about
4 days for 2017-T31 and 2024-T31 rivets. Values shown for 6001-T31
and 6061-T43 rivets are attained in about 2 weeks. Values of 26 ksi
(18. 3 kg/mm 2 ) are attained by 6061-T3 rivets about 4 months after
driving. Values shown for 7277-T41 rivets are attained in about
one week.
125 ==
i
F
I F
t
500 600 700 800 °C

. ;
!
1.0
OD
O
O
0.10
v
0
H
V
x
I ?^
0.01
800 1000 1200 1400 1600 OF
Temperature
FIGURE 12. 1.— Solubility of hydrogen in aluminum.
(Ref. 12. 9)
12b`
- --a"
1.0 2.0 3.0 mn-i

50
! ^ I. I ' ! tl j '^ ^
L!t
^!
^; ' :r
ri I I! ' ! .I:l. ' ^ I'
a
40
J'
—4—
9 A. IT -MIG One Pass Horizontal Weld
025 ipm 4%
30
Q) 0 30 ipm 1% Repair
035 ipm 0%
114
0 I I
U ^ ` .—: ^. t.:.l :-.L . 1.
U 20 rd ' J ! .. ^...:^.. ^
0
1+4
0
1A
j;
U
r. 10
(U
0
> 30
4J
T^ T4
j
4-
20 TIG One Pass Horizontal Weld'
020 ipm 2. 7%
025 ipm 2.75% Repair
6 30 ipm 1.0%
7.
10
0 0.02 0.04 0.06 0.08 0.10 0.12 0. 14 inch

Size
FIGURE 12. 2. — Effect of welding speed on the occurrence and size

of porosity in a 2219-T87 cylinder joined by TIC, and MUG butt
welding; cylinder, 132-inch diameter (3. 35 mm). 0. 224-inch
thick (5. 69-mm).
(Ref. 12.10)
127
SEE
.7
30
n 40
L
P
C 35 25
N a
Y C4
N 30
H
20
O
v -Y
0 25 . a
v
4
r 15
20
. a
15
10
c
Y
10
C
O
O 5
P
C
O
W
0
0 1 2 3 4 >4
Porosity level
FIGURE 12. 3. — Tensile properties of 2219-T87

sheet containing increasing levels of porosity
(as graded by radiography); thickness, 1/4-inch
(6.35 nim).
(Ref. 12.38)
0.5 1.0 1.5 mm
35
Base Metal ♦
4G
it!I I ^ l Thickness
3 J4 inch 30
1.91 cm)
I , I 1/2 inch
W- 3e 1 (1.27 cm)-
1/4 inch 25
(0.64 cm)
30
0 0.02 0.04 0,06 0.08 inch

Misalignment
YIGURE l2.4. — Effect of weld joint misalignment on the
tensile strength of TI(: welded 2219 - T87 joints.
(Ref. 12.11)
__ K11"
-250 -200 -150 -100 -50 0 °C
100 TIG Butt Weld: 2319 Al Filler; 70

6 ipm speed; Cu backup bar;
AC machine
N
80
50 x
^y
60
! 30
40
a C3 Avg of 5 I
_ V 0 "An^Values
. O O "B", MIL-HDBK-5A
, Base Metal
c Weld .
a^
20
a
AR- i
a u
N_ c
N 0 80 .0 q
wV
W^
a ^
60 'o
ti
-400 -300 -200 -100 0 100°F
Test Temperature
i FIGURE 12. 5. — Effect of test temperature on tensile properties

of base metal and butt-welded 2219-T81 sheet; thickness
0.003 inch (1. 600 cm).
129
(Ref. 12. 13)
- -sign
.A g o -200 _i5o -100 .100 n °c

IN
100
80
go
. a
60

40 in
20
0
KO
60 "
0 &
-400 -300 -200 -100 0 100°F
T,!mt ' remperature
FIGURE ILC. — Effect of test trnipt-rature on tensile properties
of base metal and butt-welded 2219 sheet; thickness,
0 Of. I inch (I 600 an,)
(Ref. 12.14)
-M -150 -100 -50 0 Oc

90
60 .f n
Automatic TIC Welded;

80 2319 Al Filler
so
70
Reh q at Treated
E
E
(10
^\ L
T
40
50
An Welded
30
0 1 1 1
1 1 ' - 3
-400 -300 .200 -100 0 100 OF
Teat Ternperattu-s-
FIGURE 12.7. — Effect of low temperature an Tfrj welded 2219-T62

sheet; thickness, 0. 1 25 inch (3.175 rnm).
(Ref. 111.191
130

0 100 200 300 0 100 200 300 °C
MIL-HDBK-5A Av "Alr Irglr I: ^^ - ^}};

i< Base metal 0 t
As welded O m e
Welded and ; I 11 ^.:,.,.' ...•
reheat treat
Welded and reaged 0 r^
i I: +1 ~ ' ^~ I
Automatic TIG Butt Welds 2319 Filler Wire
60
.1 111 I ^'' $ +, i. .I:'': 40
1 1
Q
.I. .I•
,
I l
u ll III 1 •, 1, , .fjl
+
I
11`1' ^
;^t^, 1 ^ t ^! t^l:i.^n
',i , •; ,^ Î
I
,.
30
. 40 .I ^.
li ,!•,
.._
a^ I t
x IT 1
h
-
.^,il' t
{ t
,1
" • +. 1. i ,III: •`Ìj!I: ^+ !
1 .^_ 1, ,.,^ g' :t. 1 î 7:^ II ^ r ' ! I J! .a' L • 1. _ ' 'I;

20 x
G4^' ^ i : i , i l 1. .I,I•:, ,
20
1} }: ;;:} I I 'i' ' i
10
Weld Bead Intact ;, !:
Y' `Weld Beads Ground Flush u ^'-
14.
J tI I ,.
0
0 r
tit
20
N_ j
RD ,il 1
t: t I 1
60 ^.: : i.
1 +', ,1( i I I
I ' + ' 1...1:.: I
I j; ; I .:I .' ,^ I ,; 40
Manual TIG Butt Welds 2319 Filler Wire, 12 ipm ! ''
7. .{ T I 1 tali! , t1 ! 'f i;l•
30 È
.^ 40
m V ti
x
20 x
^y
i ; II ;",., '11
20 T
i .` 4
rlyt. t} .
11 jIr ±1-
ll:!:,1
r."''•^-
I I
. {!
III
10
^'^.'
' '• it ^•. Î'i
a^
+ il.
I
1 ^t î I1^'I Î.
Weld Bead Intact ì -i Weld Beads Ground Flush,

0 I!iiit'^^ { tl v , ] ''i 1 • `r", ^ I I ' îi ! i!' • }' ^' ^) + ^1i 11•'.
b' {
20 1 1". t!:' ^'+
{{
it
i ll A
N_ j
AN I .. 1{• i1•
..
v 0 1 :I t 'I
0 200 400 600 0 200 400 600 °F

Test Temperature
FIGURE 12. 8. — Effect W — temperature and welding procedure on tensile
strength and elongation of butt - welded 2219-T6 sheet; thickness,
0.071 inch (1.803 -nun ). _ ( Ref. 12. 15)
_=_-- 131

0.5 1.0 1.5 cn•

2.0
'7T
Lt
49 0 C)
40
0 i: : 300OF A?, ^.^'
1. 5
'I T M 1 I 30
1:J! !4
0
" : 5000 F (2 0 C
1.0
20
U
0
0.5 8 iprn (20.32 cm/min)
0 4 ipm (10 . 16 cm/min) 10
3/8 in bar width jl ^^ ,.; ''
3/8 in bar spacing
(3/8 in n 9.52 mm)
0 0.375 0.750 Inch

Backing Bar Width 6 10 14 18 22 cm
1 400
FIGURE 1 2. 9. — Effect of welding speed t iliJ

and backup bar gap and width on weld-
Ing temperature limit for 2219.
ff W
300
(Ref. 12.16)
J
All fl,
200
2.0
it j , 500 F .4260*
16 Cu ,;. ^T.' iiii
L 40
1.5 Cram J1 , i
None

'r IV
iii, I 30
1.0
20
FIGURE 12.10e- Effect of welding speed
and backup bar material and width on
-fi ---
welding temperature limit for 2219. M
Bar width,
3/
3
4 "a
inches
(Ref. 12.16)
0' A"WA-

1. 0 2. 0 3. 0 0 1. 0 2.0 3.0 4.0 cni
I ^ I• i I ^ I^ i
! ^ I i I ^ ^ I
i J:.: I' ^ I t i I
80
I ' I Î 1.1 '

I: I 1• ^
1
70
o 60
(d
U t
U)
M If
0; 50
m
U
r I i i 4 iprri welding speed
f (10. 16 cm/ruin)
x 40
a^
I is I I, I t^.i ^. _r ^ i
xU
0
a 30
8 ipm welding speed I ^y I ^Î ' t i^
(20.32 cm/min) i if
20 } ! ^. :^:_ 4!_ .-L.O Cres

' backing '!
1 ; I OF'I` 1 f • 6 Copper backing
^.^ 'I --i- - O No backing ^.
10
0
0 0.5 1.0 0 0. 5 1.0 1.5 2.0 inches
Distance from Weld Centerline
FIGURE 12. 11. — Effect of weld backing and welding speed.
on hardness values of TIG butt - welded 2219 - T87 plate;
thickness, 3/8 inch ( 9.52 cm )-_ ( Ref, 12.16)

50
Strain
Gage
F, 7 I -7
4
1 7 71 ' - 1 J_; F-f]'" ! 111 1

1
30
40 Automatic Welding: 2319 Filler
Wire; 7 ipm (17.78 cm/min) T
25
t it
ti V
4.1
30
run) 20
0
I L bo
14
20 -41 t
15
if
• Heat affected base metal; V /Z 11
Inch (1.27 cm) from weld fusion

line), Ef a 0.97% 10
f - . 0 2 inch (5.08 cm) gage length,
r I'! Ef a 5. 9%
10
j 0 Transition zone. E f = 8.7%
(D Weld deposit. E 19.6% i 1 t
5
t
7 -J1
0 0.5 1.0 1.5 2.0 2.5
Strain, percent
FIGURE 12. 12. — Stress-strain curves of TIG butt-welded 2219-T87
for various locations across the weld as derived from miniature
strain gage data; thickness. 0.250 inch (6.35 nun).
(Ref. 12. 36)
1-34V
•
(b
T81
T87
As Welded
70
0 T31 Post - Weld Aged to T81
0 0 Post - Weld Aged to T62
0 F Post - Weld Aged to T62
9
45
60 —
50 35
ri)
er 40—
Sqtwre 15th Weida' ; ZiI4 i ►ii0i' mi" 25
2.
AIA
46
jb
- tl
94 e weided SWsf k e
a l bcs
T flC11
, Ar,
eta
.0 10 Lj
A ^^l
.
*bid pk6blcdu^d
h6b i0i It i j io lmdttf O^dtWum
k" am 1 11 kowit
In Dr., - V,

io -200 -150 -100 .50 0 0C

60
Endurance Limit Represents No
Failure in 10" to 10'? Cycles
Rate z 1800 Cycles/min 40
40 Minimum Stress /Maximum Stress
IV
E
0 Base Metal 20
(P Welded Metal
r 20
10
W r
-400 -300 -ZOO -100 0 100 'F

Temperature
FIGURE IZ. 14. — Effect of temperature on endurance limit

of base metal and butt-welded 2219-T87 sheet; thickness.
0.063 inch (1.600 mm).
(Ref. 12. 17)
80
.}ili 50
7 7 1 '; A jt; -gl
-7- it
60
If+ 40
40 30
1.11 !A T ..I . ... ... I-

it 20
20 '1: 1
80
3 T Temp.
.: i j, 0 0 -423° F (-253°C) 50
;0 (P -37,Oa F 1 -196°C)
' 0 • 78°-- Z
60
440
i v TOON
4--i -
. 40 :4--
TIG Butt Weld: 2319 Fjl; qF WLrai
4 ipm (10.16 cm min)'
20
" ^kup Bar
f q
f I id tj E
0 ff" 800' 1200 00 2660i
Number of Cycles
FIGURE
12. 15. – S- N curves for TIC; 66U-welded 2219-T87 sheet
at room and cryogenic tempos!atusteol thickness, -4. 125 inch
(3-.75 mm). MAL 12. 13)
IWO
— "I"
l
al
40
30 _A22 0 N' W53 a M i L
20
3200 F 140611 ;
10 TIG Welded: 2319 Filler Wire
R^ 5
Axial Load Fatigue. R n —1
0
I
104 lol
W. 103 101, 1011
Number of Cycles
FIGURE 12. 16. Fatigue strength of as-welded 2219-T87 sheet at
at room and cryogenic temperatures; thickness. 0. 125 inch
(?.175 mm).
(Ref. 12. 18)
_zSO -ZOO -ISO -100 -so 0 °C

1800
800
Thomson Tri-Mono Welder;
90 KVA transformer; electrode
tip radii 5/8 inch (I .588 cm) top.
1600 4 inch (10. 16 cm) bottom
700
1400
600
1290
Soo
1000
V
400
0
800 I.. . . ..... ... ....
300
600
200
k. Cross Tension
0 Mean) ( Avg 20 tests) F,u

0 A^
fl Value ( MIL-HDBK. SA)
0 200 100
-400 -300 -200 -100 0 100° F
Test Temperature
FIGURE 12. 17. — Effect of test temperature on Cross tension
and tensile shear strength of single spot welds (one heat)
on 221 9-T81 sheet; thickness, 0.063 inch (1. 600 mm).
(Ref. 12.25)
137
!L1^ "
Aft
12.1 Aluminum Company of America, Alcoa Product Data "Specifications,"

Section Al2A, July 1, 1963.
12.2 Reynolds Metals Company, "The Aluminum Data Book - Aluminum
Alloys and Mill Itoducts," 1958.
12.3 C. H. Crane and W. G. Smith, "Application of 2219 Aluminum Alloy
to Missile Pressure-Vessel Fabrication," Welding Journal, 40 (1),
33-s (1961).
12.4 P.J. Rieppel, "Weld Defects in Aluminum versus Base-Plate and

Filler Wire Composition," Battelle Memorial Institute, Minutes -
Aluminum Welding Symposium, July 1964, NASA/George C. Marshall
Space Flight Center, October 1964, p. 63.
12.5 I. B. Robinson, F. R. Collins, and J. D. Dowd, "Welding High Strength
Aluminum Alloys," Welding J . , 41, 221-s (1962).
12.6 Aluminum Company of America, "Alcoa Structural Handbook," Eighth
Printing, 1960.
12.7 Z. P. Saperstein and D. D. Pollack, "Porosity Formation and Solidifi-
cation Phenomena in Aluminum Welds," Douglas Aircraft Co., Mir-utes-
Aluminum Welding Symposium, July 1964, NASA/George C. Marshall
Space Flight Center, October 1964, p. 96.
12.8 H. Brown, "Aluminum Fabrication versus Environmental Humidity,"
TRW, Inc./ Electromechanical Division, Minutes - Aluminum Welding s.
Symposium, July 1964, NASA/George C. Marshall Space Flight Center,
October 1964, p. 55.
12.9 F. R. Baysinger, "Observations on Porosity in Aluminum Weldments,"

Kaiser Aluminum and Chemical Co., Minutes - Aluminum Welding Sym-
posium, July 1964, NASA/George G. Marshall Space Flight Center,
October 1964, p. 55.
12.10 G. Case, "Time-Temperature Effects on Welds in 2219-T87 Aluminum
Alloy," NASA/MSFC, Minutes - Aluminum Welding Symposium, July
1964, NASA/George C. Marshall Space Flight Center, October 1964,
p. 151.
12. 11 H. B. Farner and T. R. Rutkay, "Fabricating the S-1C Space Booster,"
Welding J., 44, 29 (1965).
12.12 D. M. Daley and D . C. Jeff erys, " Development of Weld Fabrication
Techniques for the S-1C Saturn V Vehicle," Welding J., 43 (1), 34 (1964).
12. 13 J. L. Christian, "Physical and Mechanical Properties satire Vessel
Materials for Application in a 6ryogente Enviro nies ASD-TDR-62-258,
;General Dynamics / Astronautics*
Paz# = cars
_Von
12.14 J. L. Christian and J. F. Watson, "Mechanical Properties of Sev-

eral 2000 and 6000 Se-its Aluminum Alloys at Cryogenic Temp-
eratures," General Dynamics, Contract AF 33(616)-7984, 2nd
QuartOrly Progress Report, December 1962.
12.15 L. Yates, R. Peck, and J. Gilmore, "Evaluation of the Mech-
anical Properties and the Weldability of 0.071-in X-2219-T6
Aluminum Alloy Sheet," North American Aviation, Inc. /Missile
Division, Report MDL-229, January 1960.
12.16 C. L. Cline, "An Analysis of Heat Transfer During the Welding of
2219-T87 Aluminum Alloy Plate," Lockheed Missiles & Space Com-
pany, Minutes = Aluminum Welding Symposium, July 1964, NASA/,
George C. Marshall Space Flight Center, October 1964, p. 165.
12.17 J. E. Campbell, "Evaluation of Special Metal Properties," DMIC.
Review of Recent Developments, December 20, 1963.
12.18 F.R. Schwart •rbc; rg et al., "Determination of Low Temperature
Fatigue Properties of Aluminum and Titanium Alloys," Annual
Summary Report, Martin Co., Denver, July 1963.
12. 19 M. P. Hanson et al., "Sharp Notch Behavior of Some High Strength
Aluminum Alloys and Welded Joints at 75, —320, and —423 F,
ASTM STP-287, 1960.
12.20 F.R. Collins, "Investigation Toward Obtaining Significantly Higher
Mechanical Properties of As-Welded. Joints in High Strength Heat-
Treatable Aluminum Alloys," Report No. 2-6-44, Aluminum Co.
of America, September 1961.
12.21 Index of Specifications and Standards, Department of Defense,

i Part I, Alphabetical Listing, Supplement, May 1971.
12.22 ASTM Standards, Part 6, "Light Metals and Alloys," 1971.
Si
12.23 SAE Aerospace Material Specifications, Society of Automotive
Eng=ineers, May 1971.
12.24 G. Cooper, F. Palermo, and J.A. Browning, "Recent Deveop-
ments in Plasma Welding," Welding J. , 44 (4), 268 (1965).
12.25 Aluminum Co. of America, "Welding Alcoa Aluminum," Third
• Printing, 1958.
12.26 Welding Handbook, Sec. 2, American Welding Society, N.Y., 1967.
12.27 "Flash Welded Combat Vehicles," Govt. Research Report, AD-
602 874, U.S. Dept, of Commerce, Washington, D.C.
12.28 W. Groth, "Trends in Welding Aluminum,' t Lockheed Missiles &
Space Co., Metal Progress, 83 (6), 76 (1963).
139 - _ -
KW"
2{
12. 29 Welding Handbook, Sec. 3, Ch. 3, American Welding Society, New

York, 19 7.
12.30 Aluminum Co. of America, "Brazing Alcoa Aluminum," 1959.
12.31 Aluminum Go. of America, "Alcoa Structural Handbook," 1960.
,,
12.32 Aluminum Co. of America, "Riveting Alcoa Aluminum," 1960.

12.33 Military Handbook 5A, "Metallic Materials and Elements for Flight
Vehicle Structures," Department of Defense, Washington, D.C. ,
February 1966, latest change order, January 1970.
12.34 R.A. Stocker, "Gas Metal-Arc Spot Welding of Aluminum," Welding
J. , 41 (9), 815 (1962).
12.35 E. F. Deesing, "A Study of the Resistance and Fusion Welding Char-
acteristics of X-2219 Aluminum Alloy," Report No. NAMC-AML-A_E-
1109, Naval Air 'Material Center, February 1960.
12.36 N.G. Lenamond, J. McDonald, Jr., and K.K. Speirs, "Strain Dis-
tribution and Failure Mechanisms in 2219-T87 Aluminurn Weldments,"
Southwest Research Institute, Mintes - Aluminum Welding Symposium,
July 1964, NASA/George C. Marshall Space Flight Center, October
1964, p. 185.
1
12. 37 R. P. Meister and D.C. Martin, "Welding of Aluminum and Aluminum
Alloys," DMIC Report 236, April 1, 1967.
12. 38 Martin Co., "Analytical and Statistical Study of the Effects of Porosity
on Weld Joint Performance, Contract NAS8__11335, March 1966,
NASA document No. N66-24588.
12. 39 H. James,.'! Electron BeareWelding," -Paper: No. 6, Session No.2j
Aluminum Welding Seminar, Chicago, Illinois, February 23-25, 1966.
12.40 M. W, Brennecke, 11 E1ectton- BeAm- W e13kI -wavy-Gage--Aluminum Alloy
2219," Welding J., 44 (1), 27s (1965).
12.41 B. Schumacher., !'Improved. Electron -Beam Wel ing Technirlue," NASA i
Tech Brief 70- 10127, June "70.
E•E
• I40

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Produced by the NASA Center for Aerospace Information (CASI)

MATERIALS DATA HANDBOOK

Contract No. NAS8 - 26644 ^`À^

WESTERN APPLIED RESEARCH & DEVELOPMENT, INC.

The revised edition of the Materials Data Handbook on the aluminum

The second edition of "Materials Data Handbook: Aluminum Alloy

Aluminum Alloy 2219

TYPICAL PHYSICAL PROPERTIES:

TYPICAL MECHANICAL PROPERTIES:

a One-half notch section dimension

fcc Face centered cubic

CONV ERSIUN FACTORS

Temperature in "C = ('F — 32) (5/9) p

1 . 1 Aluminum alloy 2219 is a heat-treatable wrought alloy developed

1.1 L. W. Mayer, "Aluminum Alloy 2219, " Alcoa Green Letter,

1.2 Alloy Digest, "Aluminum 2219," (Filing Code Al-96, Aluminum

1.3 Aluminum Standards and Data, 2nd Edition, The Aluminum

2.1 General. Aluminum 2219 alloy is available as sheet, plate,

Suurce Ref. 2.3, 2.4, 2.5, 2.6

(a) Specifications as of June 1971

TABLE 2.41. —Commercial Sires and Tempers Available for Sheet,

Source Ref. 2.1 (a)

(a) Consult producers of alloy for further information.

2.1 Aluminum Company of America, "Alcoa Aluminum Handbook,"

2.2 Aluminum Standards and Data, 1970-71,Second Edition, Aluminum

3.1 Chemical Composition

These composition limits are normally checked by spectrochemical

3.22 Heat Treatment.

Aging Treatment (T6 Condition): Heat T4 or T42 condition to 1800

3.5 Microstructure. References 3. 10 and 3. 11 are recommended as

TABLE 3.6. — Itching Soltuti,>rns I ' m- R , %caling Macrostructure

So diuin Hydroxide. Na0I1 10 , Fm cleaning surfaces, revealing;

TUCkor's IICI. (cone.) 4 r nil For revealing structure of

Modified IHC1 (cone.) 10 n,l_ For revealing structure of all

Flick's IICI (cone.) 1 5 nil For revealing grain structure of i

Atomic Percentage Copper

300 (A0 t (AI-Cu 800

FIGURE 3.13. — Binary phase diagram of the

3.1 Aluioimim Standards and Data, Second Edition, The Alumin un

;. 2 1971 SAC l tanclliook, Society of Auto>i„o,tive En^oinecrs, Inc.

;. ; ASTNI Standards, Part 6, 13209-71, American Sc>cioty for

3.4 Martin-Denver Go., "Summary Information Regarding; Aluniinurn

3. 5 Metals Ilanclbook, Eighth Edition, Vol. I, American Society for

3.6 1. A. Nock, ,I r., et al . , "A New High Strength Aluminum Alloy,"

3. 7 R. G. Mahorter, Jr. and W. 1 , '. Emmons, "A Study of Creep

4.1 Ka. r Aluminum and Chemical Sales, Inc., "Kaiser Aluminum

PRECMING PAGE BLANK NOT PITM1',,.

5.1 General. This heat-treatable alloy is available bare and in the

considerable period of time. In comparison, alloys 2014 and 2024 age

by die coining (cold) to precise dimensions, usually within a few

5. 322 Electrochemical Milling. In the section on electrochemical nulling;

' '1 m'db•(D

(a) Forg;ing;s only

to u1 O u1 O O -4 to O u1 .4 u1 u1 ••^ •• ••^ ••+ U '^ U U aN

TABLE 5. 323. —Results of Chemical Milling; 'Pest on 2219 Alloy Sheet

5. 1 J. A, rdoek, Jr. , M. Holt, and D.O. ^prcw^ ^ "A New High-