Browse Topic: Aluminum alloys

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Rings, Flash-Welded, Aluminum and Aluminum AlloysAMS7488H (Current)8/14/2026
This specification covers flash-welded rings made of aluminum and aluminum alloys (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Alclad Sheet (6156-T4) 1.0Si - 0.90Cu - 0.60Mn - 0.90Mg Solution Heat Treated and Naturally AgedAMS4405D (Current)8/14/2026
This specification covers an aluminum alloy procured in the form of sheet 0.078 to 0.197 inch (2.00 to 5.00 mm), inclusive, in nominal thickness, Alclad on both sides (see 8.5).
AMS D Nonferrous Alloys Committee
Finite Element Analysis of New Energy Vehicle Chassis Using ANSYS2026-99-03438/14/2026
Amid the rapid development of the new energy vehicle industry, the vehicle frame, as the core load-bearing component of the entire vehicle, plays a direct role in the vehicle’s safety, lightweight design, and power performance through its design and performance. Although research on new energy vehicle frames has matured, issues related to the lightweighting of drive shaft-associated structures and the balance between weight reduction and strength/stiffness still require in-depth exploration. This study focuses on the chassis of new energy vehicles, utilizing Q295 low-alloy high-strength steel. Based on the vehicle’s dimensions and mass parameters, a simplified 3D model was constructed using SolidWorks. Static analysis under bending and torsion conditions, along with a 6th-order modal analysis, was conducted using ANSYS software. Based on the analysis results, optimizations were implemented at both structural and material levels: structurally, the central crossbeam was widened, holes were opened on the crossbeam’s vertical plane to reduce weight, and the longitudinal beam welding process was optimized; materially, Q295 steel was retained in high-stress zones, while aluminum alloy replaced it in low-stress zones. The optimized frame achieved a 15% reduction in torsional stress, a 16% decrease in bending stress, a 2% reduction in torsional deformation, and a 3% decrease in bending deformation. Total mass decreased by 12.7 kg, with both strength and stiffness meeting design requirements. This approach synergistically enhances frame lightweighting and performance, providing technical support for optimizing the overall performance of new energy vehicles.
Guo, Lihong, Wang, Yiyou, Yang, Zihao
Molecular Dynamics Simulation of Temperature Effects on the Hot Deformation and Microstructural Evolution of Al-Mg-Si Aluminum Alloy2026-99-10108/7/2026
In this work, molecular dynamics simulations are applied to systematically examine the influence of varying temperatures (300 K, 500 K, and 700 K) on the Elevated-temperature compression behavior and micromechanical characteristics of polycrystalline Al-Mg-Si aluminum alloy. A nanopolycrystalline model was established to analyze the stress–strain response, dislocation evolution, and crystal structure changes occurring during the deformation process. The simulation results show that the yield strength and elastic modulus both decline as temperature increases, indicating a pronounced thermal softening effect. During the early stage of plastic deformation, dislocations mainly have their nucleation sites at grain boundaries and then propagate into the grain interiors, where they form interconnected networks along with stacking faults and twin structures. This work reveals the thermal deformation mechanisms of Al-Mg-Si aluminum alloy at the atomic scale and provides theoretical guidance for the optimization of its hot-working processes.
Sun, Ruifeng, Liu, Shoukui, Wang, Rui, Sun, Xuemei, Ding, Shuli, Ma, Xiaofei
Finite Element-Based Structural Optimization for UAV Storage-Launch Container2026-99-01647/31/2026
To fulfill the multi-tube launch requirements for a specific folding-wing UAV, this study improves the structure of the existing storage-launch container. Based on the finite element method, a parametric model of the container is established, and a multi-condition mechanical analysis is carried out for various storage, transportation, and launch conditions. The difference between the first six natural frequencies of the free mode and the prestressed mode is compared and analyzed. The modal analysis model considering prestress is used to identify the optimization area of the container. The variable density method (SIMP) is used to optimize the topology of the container, with the volume of the container as the constraint condition and the minimum strain energy as the optimization goal. The optimization results show that the first-order modal natural frequency of the container is increased by 108%, and the first six natural frequencies are increased to a safe range, which effectively avoids the resonance risk. At the same time, the quality is reduced by 29%, and good optimization results are achieved.
Yuan, Weiyang, Ji, Yuguo, Liu, Zhipeng, Yu, Wenxin
Weld Formation, Microstructure, and Mechanical Properties of High-Speed Friction Stir-Welded 6061-T6 Aluminum Alloys2026-99-01267/31/2026
In this paper, 6061-T6 aluminum alloys were subjected to high-speed friction stir welding. The associated weld formation, microstructure, and mechanical properties were systematically examined via combined experimental observation and numerical simulation approaches. At a welding speed of 3000 mm/min and a rotation rate of 3800 rpm, the defect-free weld was simply achieved due to the simultaneous intense thermal input and enhanced material flow. Microstructural analysis further demonstrated a fine equiaxed grain structure featuring a predominant simple shear texture with A/A components. The resultant joint exhibited an ultimate tensile strength equivalent to 80% of the base material, accompanied by excellent fracture elongation. This research provides experimental evidence for designing high-efficiency and high-quality bonding processes for aluminum alloys.
Guan, Yuankai, Wang, Ruiyang, Zhang, Kexin, Lin, Zhicheng, Deng, Jun, Liu, Zhe, Ganushchak, Oleg, Voitenko, Oleksandr, Zhao, Yunqiang, Gao, Shiyi
Finite Element Analysis and Structural Optimization of Aluminum Alloy Fuel Tanks2026-99-01937/31/2026
To address the failures observed in aluminum-alloy fuel tanks, specifically, cracking of the dual-chamber sealing partition, end cover, and drain boss, finite element analysis was employed for comprehensive calculation and structural optimization. Stress, strain, and displacement under varying load conditions were evaluated, revealing that failures of the sealing partition and end cover were due to stress concentration. At the same time, the cracks in the drain boss were caused by weaknesses in the weld heat-affected zone. Three optimization measures were proposed: adding an R5 chamfer to sealing baffles, incorporating R5 transitional fillets on the reinforcing ribs of the end caps, and designing the drain boss as an asymmetrical elliptical shape with a central transitional fillet. Following these optimizations, the maximum stress on the components was significantly reduced, and the safety factor markedly increased. Results from sealing, pressure, and vibration tests confirmed that these measures effectively enhance the structural strength of aluminum-alloy fuel tanks and extend their service life. This study provides robust support for the design and analysis of aluminumalloy fuel tanks.
Chi, Hong, Lei, Haisen, Sun, Liying, Zhang, Zhitong, Wu, Xiaoci
Discussion on Methods for Studying Material Fatigue Life: Taking Aluminum Alloy as An Example2026-99-01217/31/2026
Fatigue design is a key common quality technology for improving the quality control capability of China’s automotive products. The fatigue of materials is a multi-scale damage evolution process. Characterizing and processing the large number of three-dimensional defects inside the material, which have different shapes and distributions, and predicting the material’s lifespan based on the cross-scale damage evolution mechanism, is one of the key technologies for fatigue optimization design. This paper discusses the research methods for the fatigue life of aluminum alloy materials. Firstly, based on the staged fatigue damage experiments, the three-dimensional defect features are obtained through CT scanning and reconstruction, and a defect characterization and processing method based on k-d tree and multi-scale feature pyramid is established to accurately represent the topological and geometric relationships of non-uniformly distributed three-dimensional defects. Secondly, a mathematical model for the evolution of micro-damage and macro-cracks is constructed, and the cross-scale transformation of defects is achieved through hierarchical and recursive methods, revealing the cross-scale evolution mechanism of fatigue damage in aluminum alloy materials. Finally, a remaining life prediction model based on defect information and feature weights is established through the support vector regression algorithm (SVR). This research method can provide technical support for the fatigue life optimization design application of lightweight materials such as aluminum alloys.
Zhang, Liangxia, Niu, Zhijun, Cheng, Fangfang, Chen, Hao, Yang, Yali
Enhanced Vibration Damping Properties of Novel Mn-Cu Alloy for Ship Structural Applications2026-99-02367/31/2026
Low-frequency vibrations in ships have detrimental effects on the lifespan of onboard equipment and the comfort of crew members, thereby highlighting the importance of developing efficient vibration-damping materials as a critical research area. This study investigates the application of Mn-Cu damping alloys for mitigating vibrations within the 0–1000 Hz frequency range, which is typical of ship environments. The vibration-damping characteristics of the material were examined through a combination of experimental and numerical simulations. A numerical simulation framework was developed to predict the vibration response of manganese-copper damping alloys, incorporating a frequency-dependent damping ratio model derived from experimental characterization. Comparative analyses validated the accuracy of vibration simulations that incorporate frequency-dependent damping ratios and demonstrated the superior vibration attenuation performance of the Mn-Cu damping alloy across the 0-1000 Hz frequency band. Deck application analysis revealed that manganese-copper damping devices reduced the root mean square (RMS) vibration acceleration of the ship deck by up to 17.5% in the 0-1000 Hz frequency range compared to aluminum alloy counterparts. The damping effect was particularly significant in the 400–1000 Hz range, where vibration energy dissipation was most effective due to the material's intrinsic damping mechanisms. Additional engineering evaluation confirmed that the Mn-Cu alloy components maintain structural integrity while providing enhanced damping performance under typical marine environmental conditions. This study establishes a theoretical foundation for the design of ship vibration-damping materials, expands the potential applications of damping alloys in marine engineering, and provides valuable reference data for material selection and vibration control design in shipbuilding and offshore engineering applications.
Yao, Sitong, Tian, Ali, Zhao, Xianghua
A Data-Driven Model for Predicting Casting Solidification Time and Mold Thermal Stress2026-01-50557/31/2026
This study proposes a data-driven surrogate modeling framework for predicting solidification time and mold thermal stress during low-pressure die casting (LPDC) of aluminum alloy wheels. The methodology employed an optimal Latin hypercube design (OLHD) to sample key parameters including cooling channel geometry and process conditions. A sequential simulation methodology combining ProCAST and Abaqus was implemented to generate a comprehensive dataset of solidification times and thermal stress distributions. Based on this dataset, surrogate models were developed using Support Vector Regression, Kriging, and Polynomial Response Surface Methodology, with their hyperparameters automatically tuned through Bayesian Optimization (BO). The optimized models were rigorously evaluated using four statistical metrics: Coefficient of Determination (R2), Mean Squared Error (MSE), Mean Absolute Error (MAE), and Root Mean Squared Error (RMSE). The evaluation results show that the BO–SVR model demonstrated superior prediction accuracy for both output responses and exhibited exceptional nonlinear fitting capability. This work establishes an effective modeling approach for simultaneous quality and efficiency optimization in wheel manufacturing.
Fuhao, Fan, Zhan, Yunlang, Zhan, Zhenfei, Yang, Yutong, Xiao, Yong, Huang, Shiyao
Numerical Investigation on Semisolid Closed-Die Forging of 6061 Aluminum Alloy Scroll Plate Based on the Arrhenius Constitutive Model2026-99-08367/30/2026
As a key structural component of scroll compressors, the forming quality of the scroll plate directly affects overall performance. To address the issues of high forming load and poor rib filling in conventional processes, this study investigates the semisolid closed-die forging of 6061 aluminum alloy through numerical simulation. Semisolid rheological data were obtained from high-temperature compression tests. We also formulated an Arrhenius-type constitutive model to predict material behavior. This model proved highly reliable, achieving a correlation coefficient of 0.99547 and keeping the average absolute relative error down to 3.67%. By employing both orthogonal experiments and simulations, we evaluated how different process parameters impacted the outcome. This analysis ultimately yielded an optimal parameter combination: a die temperature of 350°C, a billet temperature of 600°C, and a punch velocity of 10mm/s. Under these conditions, the forming load, flow behavior, stress–strain distribution, and temperature evolution were analyzed. The results show complete rib filling, uniform deformation, and absence of defects, providing theoretical guidance for industrial applications of semisolid closed-die forging of scroll plates.
Xiong, Linhua, Zhang, Mengjiao, Chang, Ming, Liu, Boyang, Wang, Yongfei, Zhao, Shengdun
Three-Dimensional Transient Thermal-Fluid Coupling Numerical Simulation of the Molten Pool in Aluminum Alloy Laser Welding2026-99-08547/30/2026
Laser welding technology for aluminum alloy electrode and busbar connections: addressing challenges in battery module assembly. In this work, a CFD framework was built in ANSYS Fluent using a Gaussian rotating heat-source representation, while a VOF approach was used to capture the transient gas–liquid interface in deep-penetration welding. A three-dimensional, transient, thermal-fluid coupled numerical model of the dual-layer heterogeneous aluminum alloy laser deep penetration weld pool was established concurrently with laser deep penetration welding experiments. Results indicate: Peak flow velocities in the weld pool during welding are concentrated along the weld centerline, with flow vectors predominantly directed axially along the weld. Once a quasi-steady keyhole regime is established, vaporization-induced recoil pressure becomes the primary driver governing melt circulation. The liquid metal first impinges on the pool bottom along the keyhole wall and then recirculates upward near the pool boundary, producing strong vortical motion. These findings are intended to support parameter selection and process optimization for laser welding of layered dissimilar aluminum components used in battery tab–busbar assemblies.
Lv, Wenjun, Wu, Yan
A Virtual-Physical Mapping Model for Aluminum Alloy Pitting Corrosion2026-99-16117/24/2026
Corrosion critically damages structural strength and affects the structural safety, so there is an urgent need for a method that can accurately model and predict corrosion. Digital twin technology offers new methodologies for corrosion research. This study develops a digital twin-enabled virtual-reality mapping model for simulating aluminum alloy pitting corrosion. The model accounts for the effect of temperature on corrosion and establishes temporal correlations between field conditions and simulations through damage factor (DF) analysis coupled with detailed fatigue rating (DFR) methodology. Experimental validation using 7A04 aluminum specimens confirms the model’s reliability, with maturity analysis demonstrating its applicability in aircraft corrosion research. Through numerical simulation methods, this study simulates the evolutionary law of pitting corrosion development, reflecting the level of structural pitting corrosion damage. This investigation establishes a fundamental theoretical framework for condition monitoring and lifetime prediction of aircraft components affected by pitting corrosion.
Lv, Shengli, Liu, Chenglong, Sun, Jingjue
Research on the Precision of 2A12 Aluminum Alloy Plate Incremental Forming Assisted by Electric Pulse2026-99-16067/24/2026
This paper introduces the electroplastic effect into the sheet metal incremental forming process, using 2A12 aluminum alloy as the research material. An orthogonal experiment was designed, and the results were analyzed using range analysis and matrix analysis methods. The influence of electric current, frequency, and traditional incremental forming parameters on the forming accuracy of 2A12 aluminum alloy sheets was investigated. The results show that the introduction of pulse current can improve the forming accuracy of 2A12 aluminum alloy sheet. And within a certain range, as the electric current increases, the geometry accuracy of the part is significantly improved. Based on two accuracy indicators—average springback amount and springback angle, a comprehensive analysis determined that the optimal forming parameters are electric current 375 A, feed rate 600 mm/min, step size 0.6 mm, tool diameter 12 mm, and current frequency 400 Hz.
Pan, Fei, Zhao, Quanguang, Huang, Xu, Fang, Jinxiu
Research on the Damage Behavior of the Aluminum Alloy Nozzle Closure in Solid Rocket Motor during the Bursting Process2026-99-16127/24/2026
When the aluminum alloy closure of the solid rocket motor nozzle is opened, tearing occurs at the root of the adhesive surface, which belongs to damage failure under a complex stress state. To help in the prediction and control of blasting pressure and nozzle closure failure morphology, this work designed and manufactured various shapes of 1060 aluminum alloy test specimens, performed damage tests, and calibrated the damage constitutive model parameters. The results gathered were utilized to create a finite element model of the nozzle aluminum alloy closure, and the blasting procedure was calculated. We conducted air pressure explosive tests on closures to confirm the finite element results. The numerical predictions and experimental results are very consistent, and the closure breaks along the adhesive surface. The constitutive characteristics obtained during material testing accurately characterize the closure’s damage process, providing a theoretical framework for the design and verification of aluminum alloy closures.
Jia, Kai, Li, Weinan
Core, Flexible Honeycomb, Aluminum Alloy, Treated for Sandwich Construction, 5052, 350 Fahrenheit (177 Celsius)AMS4178H (Current)6/19/2026
This specification covers an aluminum alloy in the form of honeycomb core in a non-hexagonal, flexible cell configuration with the core being treated for increased corrosion resistance and furnished only in the expanded form (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Rolled or Cold-Finished, Bars, Rods, Wire, and Flash-Welded Rings, Annealed, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-O)AMS4115L (Current)6/19/2026
This specification covers an aluminum alloy in the form of rolled or cold-finished bars, rods, wire, and flash-welded rings and of stock for flash-welded rings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Plate, 8.1Zn - 2.3Mg - 1.0Cu - Zr (7449-T7651), Solution Heat Treated, Stress Relieved, and OveragedAMS4250D (Current)6/19/2026
This specification covers an aluminum alloy in the form of plate 0.250 to 4.000 inches (6.35 to 102.0 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extrusions, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-O), AnnealedAMS4476B (Current)6/19/2026
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 5.000 inches (127.00 mm), inclusive, in nominal diameter or least thickness between parallel sides (bars, rods, wire, profiles) or nominal wall thickness (tubing) (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, 7.0Si - 0.58Mg - 0.15Ti (E357.0-T6), Solution and Precipitation Heat TreatedAMS4288A (Current)6/15/2026
This specification covers an aluminum alloy in the form of castings (see 8.10).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Plate, 4.0Zn - 2.0Mg - 0.32Mn (7019-T651), Solution Heat Treated, Stress Relieved, and Artificially AgedAMS4409B (Current)6/15/2026
This specification covers an aluminum alloy in the form of plate 0.500 to 4.500 inches (12.7 to 114.3 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Uphill Quenching of Aluminum Alloy ProductAMS2767B (Current)6/8/2026
This specification establishes the engineering requirements for the uphill quenching process of aluminum alloy product. Uphill quenching immerses product in liquid nitrogen followed by exposure to a high-pressure/high-velocity steam blast or boiling water.
AMS D Nonferrous Alloys Committee
Investigation of Aluminium Alloy Composites Reinforced with Zirconium oxide and Solid Lubricant Attributes for Brake and Clutch Components of Aircrafts2026-26-07526/1/2026
For brake and clutch components of aircraft vehicles which require higher mechanical strength and wear resilient, light-weight aluminium composites were developed infusing solid lubricant. In this study, hybrid composites were developed using powder metallurgy route with aluminum alloy AA356 and various amounts of zirconium oxide (ZrO2) (0, 5, 10, 15, and 20 wt.%) as reinforcements. A solid lubricant hexagonal boron nitride (hBN) at a fixed 5 wt.% is considered. Following the appropriate ASTM guidelines, the specimens were mechanically characterized by measuring their density, porosity, micro-hardness, compression strength, impact strength, and flexural strength, among other properties. The findings showed that the composites' mechanical and physical behaviour were greatly affected by the inclusion of ZrO2. Porosity increased as a result of particle clustering and interfacial voids, while density increased gradually as ceramic content increased. Consistently increasing ZrO2 addition led to micro-hardness improvements; at 20 wt.% reinforcement, values reached their maximum, indicating that the hard ceramic phase contributed to better surface resistance. The best balance between particle reinforcement and matrix continuity was suggested by the compression and flexural strengths peaking at 15 wt.% ZrO2. However, when the addition was raised to 20 wt.%, brittleness and porosity began to marginally deteriorate. Unreinforced and lower ZrO2 composites had superior toughness in impact, whereas materials with a higher content had a poorer energy absorption capacity. The 5 wt.% hBN improved fracture arresting capabilities and helped load transmission over the interface. Inclusion of hBN provides solid-lubricating tribofilm formation that enhances the tribological performance. This study reveals that AA356/ZrO2-hBN hybrid composites have good hardness and compressive strength improvements, with 15 wt.% ZrO2 being the best composition with good strength, toughness, and wear resistance.
Senthilkumar, N.
Aluminum Alloy Sheet, 2.7Cu - 2.2Li - 0.12Zr (2090-T83), Solution Heat Treated, Cold Worked, and Precipitation Heat TreatedAMS4251D (Current)5/26/2026
This specification covers an aluminum alloy in the form of sheet 0.040 to 0.249 inch (1.02 to 6.32 mm) in nominal thickness (see 8.7).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Heat-Resistant, Castings 5.0Cu - 1.5Ni - 0.25Mn - 0.25Sb - 0.25Co - 0.20Ti - 0.20Zr (203.0-T6) Solution Heat Treated and Precipitation Heat TreatedAMS4225F (Current)5/14/2026
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extruded Profiles (2196-T8511), 2.9Cu - 1.7Li - 0.4Mg - 0.4Ag - 0.10Zr, Solution Heat Treated, Stress Relieved by Stretching, and Artificially AgedAMS4416C (Current)5/14/2026
This specification covers an aluminum-lithium alloy in the form of extruded profiles 0.040 to 1.000 inch (1.00 to 25.40 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Hardness and Conductivity Inspection of Wrought Aluminum Alloy PartsAMS2658E (Current)5/6/2026
This specification establishes hardness and electrical conductivity acceptance criteria for finished or semifinished parts made from wrought aluminum alloys after heat treatment (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Clad Two Sides Sheet, 0.6Mg - 0.35Si - 0.28Cu (No. 24 Brazing Sheet), As FabricatedAMS4460C (Current)4/30/2026
This specification covers an aluminum alloy in the form of sheet, clad on two sides.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Clad One Side Sheet, 0.6Mg - 0.35Si - 0.28Cu (No. 23 Brazing Sheet), As FabricatedAMS4465C (Current)4/26/2026
This specification covers an aluminum alloy in the form of sheet, clad on one side.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, 7.0Si - 0.58Mg - 0.15Ti - 0.06Be (D357.0-T6), Solution and Precipitation Heat Treated, Dendrite Arm Spacing (DAS) ControlledAMS4241F (Current)4/24/2026
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Castings, 5.0Si - 1.2Cu - 0.50Mg (355.0-T51), Precipitation Heat TreatedAMS4210N (Current)4/24/2026
This specification covers an aluminum alloy in the form of castings (see 8.6).
AMS D Nonferrous Alloys Committee
Castings, Aluminum Alloy Sand, 5.0Si - 1.2Cu - 0.50Mg (355.0-T71), Solution Heat Treated and OveragedAMS4214L (Current)4/23/2026
This specification covers an aluminum alloy in the form of sand castings (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extrusions, 0.68Mg - 0.40Si (6063-T6), Solution and Precipitation Heat TreatedAMS4156M (Current)4/22/2026
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to and including 1.000 inch (25.4 mm) in diameter, least thickness, or tube wall thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extruded Profiles (2065-T84), 4.2Cu - 1.2Li - 0.52Mg - 0.32Mn - 0.32Ag - 0.1Zr, Solution Heat Treated, Stress Relieved by Stretching and Artificially AgedAMS4366B (Current)4/21/2026
This specification covers an aluminum-lithium alloy in the form of extruded profiles with a maximum cross-sectional area of 19 square inches (123 cm2) and a maximum circle size of 11 inches (279 mm) from 0.040 to 0.499 inch (1.00 to 12.50 mm) in thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Hand Forgings, 6.2Zn - 2.3Cu - 2.2Mg - 0.12Zr (7050-T7452), Solution Heat Treated, Compression Stress-Relieved, and OveragedAMS4108G (Current)4/20/2026
This specification covers an aluminum alloy in the form of hand forgings 8 inches (203 mm) and under in nominal thickness and of forging stock (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy Bars, Rolled or Cold Finished, 1.0Mg - 0.60Si - 0.30Cu - 0.20Cr (6061-T451), Solution Heat Treated and Stress Relieved by StretchingAMS4128F (Current)4/19/2026
This specification covers an aluminum alloy in the form of bars and rods 0.500 to 8.000 inches (12.7 to 203.2 mm) in nominal diameter or least difference between parallel sides and up to 50 square inches (322.6 cm2) in cross-sectional area (see 8.6).
AMS D Nonferrous Alloys Committee
Investigation of Metallurgical and Mechanical Behaviors of AA6061-AA2017 Joints Produced by Single- and Double-Pass Friction Stir Welding: Influence of Base Material Position and Post-Weld Shot Peening Technique05-19-04-00264/13/2026
The growing demand for lightweight, high-strength materials in marine and aerospace structures has promoted the use of friction stir welding (FSW) for welding dissimilar aluminum alloys. However, tensile residual stresses and microstructural heterogeneities often degrade weld integrity. This study investigates the combined impact of base material positioning, single- and double-pass FSW, and post-weld shot peening (SP) on the metallurgical and mechanical properties of AA6061–AA2017 joints. Five welding configurations were examined to evaluate how varying base material positions on the advancing and retreating sides affect material flow and mechanical behavior. Post-weld SP effectively presented compressive residual stresses, reduced surface defects, and refined surface grains. The average grain size in the stir zone was reduced from 5.2 μm (single-pass) to 2.0 μm (double-pass U-turn) after SP, confirming significant grain refinement through dynamic recrystallization. Mechanical testing revealed that double-pass FSW with opposite weld direction (U-turn) followed by SP achieved the highest performance, with ultimate tensile strength (UTS) improving from 246 MPa to 289 MPa (≈17% increase) and tensile elongation rising from 8.78% to 9.41%. Microhardness in the heat-affected zone improved up to 127 VHN, countering thermal softening effects. The synergistic effect of double-pass welding and SP enhanced homogeneity, fatigue resistance, and surface integrity. The results establish SP as an efficient post-FSW treatment for dissimilar aluminum joints, offering quantifiable improvements in strength and ductility, making the process highly suitable for demanding marine and aerospace structural applications.
Nukathoti, Raja Sekhar, Battina, N. Malleswara Rao, Vanthala, Varaha Siva Prasad, Chirala, Hari Krishna, Maloth, Balu
Aluminum Alloy, Rolled or Forged Rings, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-T651, 7075-T652), Solution Heat Treated, Mechanically Stress Relieved, and Precipitation Heat TreatedAMS4310G (Current)4/9/2026
This specification covers an aluminum alloy in the form of rolled or forged rings up to 6 inches (152 mm), inclusive, in thickness (see 3.3.1.1.1) and an OD to wall thickness ratio of 10 or greater (see 8.5).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate, Alclad 4.4Cu - 1.5Mg - 0.60Mn (2024 -T361 Sheet/Plate with 1½% Alclad) Solution Heat Treated, 6% Cold Worked and Naturally AgedAMS4194F (Current)4/8/2026
This specification covers an aluminum alloy in the form of sheet and plate, alclad both sides, supplied in the -T361 temper.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet, 3.2Cu - 0.52Mg - 0.30Ag - 0.95 Li - 0.12Zr (2198-T8), Solution Heat Treated, Cold Worked, and Artificially AgedAMS4412C (Current)4/8/2026
This specification covers an aluminum alloy in the form of sheet from 0.063 to 0.249 inch (1.60 to 6.30 mm) in nominal thickness (see 8.6).
AMS D Nonferrous Alloys Committee
A Study on Fatigue Life Prediction Method for Point-Based Joints Considering Multiple Fracture Modes – FDS, Blind Rivet, and Blind Nut Focus2026-01-01804/7/2026
The application of multiple materials in vehicle bodies is accelerating as the adoption of lightweight aluminum alloys and composite materials advances rapidly. These materials play a crucial role in reducing overall vehicle weight, enhancing fuel efficiency, and complying with increasingly strict environmental regulations. As the automotive industry continues to evolve toward electrification and sustainability, the integration of lightweight and high-performance materials has become a key design strategy. However, the use of multiple materials creates new challenges in manufacturing, particularly for joining technologies. Since different materials have varying mechanical properties, thermal behavior, and surface characteristics, the selection of appropriate joining methods is essential for ensuring structural integrity and durability. Depending on material types, thicknesses, production processes, and cost constraints, various joining techniques—such as mechanical fastening, welding, and adhesive bonding—are selectively applied. This study focuses on fatigue life prediction for point-based joints commonly used in automotive structures, including flow drilling screws (FDS), blind rivets, and blind nuts. Fatigue fractures in these joints typically propagate in multiple directions: through the sheet thickness and along the in-plane direction. Accurate fatigue life prediction requires numerical simulations that account for both crack propagation paths and the interaction of these paths with joint geometry and loading conditions. Traditional fatigue models often assume a single fracture mode, limiting the ability of these models to evaluate multiple failure mechanisms simultaneously. To address this issue, this study proposes a simplified modeling approach that enables the simultaneous consideration of multiple fracture modes. This paper introduces a numerical analysis-based method capable of predicting the fatigue strength of point joints, and describes the fatigue tests that were conducted to validate the proposed approach. This research contributes to the development of more reliable and efficient design strategies for multi-material automotive structures.
Takuno, Sougo, Isono, Toshiyuki, Urakawa, Kazushi, Goto, Suguru, Kawamura, Hiroaki, Niisato, Eita, Ishigami, Yuta
Design and Simulation Analysis of an Integrated Honeycomb-Filled Front Bumper for a Special Vehicle2026-01-04754/7/2026
In frontal collisions of automobiles, the bumper beam at the front of the vehicle plays a crucial role in absorbing energy and protecting the vehicle body during a collision. To enhance the collision resistance of a specific type of special vehicle with a non-load-bearing body structure, this paper focuses on this type of vehicle and conducts a study on the design and collision performance of an integrated vehicle front bumper - anti-collision beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front anti-collision beam of the vehicle and is integrally formed using aluminum alloy additive manufacturing technology. This integrated structure is directly connected to the vehicle frame. Firstly, based on the appearance of the special vehicle body and the form of the front anti-collision beam of traditional passenger vehicles, an integrated design of the vehicle front bumper- anti-collision beam structure is carried out and connected to the vehicle body. Subsequently, based on the previous bumper design, a honeycomb structure is introduced internally, and the introduced honeycomb structure is integrally formed with the front bumper. Finally, finite element simulation analysis of two types of frontal bumper collisions under the same collision conditions is conducted. The results show that the initial integrated front bumper can achieve basic anti-collision beam functions, while the front bumper with a honeycomb composite structure can improve the transmission path of collision force, ensure stable deformation, significantly enhance the energy absorbed during a collision, and increase the specific energy absorption, indicating that the integrated honeycomb-filled front bumper can effectively enhance the collision resistance of special vehicles.
王, Xufan, Yuan, Liu-Kai, Zhang, Tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo
Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures2026-01-02344/7/2026
Tensile and cyclic behavior of high pressure die cast AE44 magnesium alloy have been studied at room temperature and elevated temperatures up to 350°C. Anelastic behavior has been found in both tensile and cyclic loading at the temperature below 200°C. With increasing temperature, the anelasticity disappears, and tensile and cyclic behaviors become like other engineering materials, such as steels and aluminum alloys, i.e. the total strain contains only elastic strain and plastic strain. A method to determine the yield strength at 0.2% plastic strain (σ0.2) is proposed. By using the proposed method, the yield strength σ0.2 is found to be higher than that determined using the traditional method, which is more suitable to the materials that do not exhibit anelasticity. It is believed that the anelasticity is closely related to twinning in Mg alloy, which disappears at elevated temperatures.
Liu, Yi, Yang, Wenying, Coryell, Jason
Optimizing Joint Efficiency in Stainless Steel-Aluminum Alloy FSW Joints through Advanced Parameter Control2026-01-02284/7/2026
The present study investigates optimization of ultimate tensile strength (UTS) in FSW of AA2024-T3 and SS304 in a butt joint configuration. An L18 mixed-level orthogonal array was used to design 18 experiments, varying tool rotational speed (450, 560, and 710 rpm), traverse speed (20, 25, and 40 mm/min), and pin offset (1 and 1.5 mm toward the Al side). The tool rotational speed had the greatest influence on UTS, contributing nearly one-third of the total variance, followed by pin offset and traverse speed. The optimal combination, 450 rpm, 20 mm/min, 1.5 mm offset, yielded a UTS of 344.7 MPa and a joint efficiency of 78.3%. At this setting, peak temperatures reached ~356 °C, ensuring sufficient plasticization and uniform mixing of the Al–SS interface, producing a refined stir zone with an average grain size of 4.2 μm. Fracture analysis revealed ductile failure at the optimal parameters, whereas suboptimal conditions resulted in brittle or mixed fractures due to either insufficient or excessive heat input. These results demonstrate that Taguchi optimization effectively correlates process parameters, thermal profile, material mixing, and mechanical performance, enabling reliable, defect-free dissimilar FSW joints for structural and aerospace applications.
Mir, Fayaz Ahmad, Khan, Noor Zaman, Pali, Harveer Singh
Aluminum Alloy Sheet, 1.0Mg - 0.8Si - 0.8Cu - 0.5Mn (6013-T4), Solution Heat Treated and Naturally AgedAMS4347F (Current)4/1/2026
This specification covers an aluminum alloy in the form of sheet from 0.020 to 0.249 inch (0.51 to 6.32 mm), inclusive, in thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Welding Wire, 7.0Si - 0.52Mg (357)AMS4246G (Current)3/25/2026
This specification covers an aluminum alloy in the form of welding wire.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Rolled or Cold-Finished, Bars, Rods, and Wire, and Flash-Welded Rings, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061; -T6, -T651)AMS4117M (Current)3/25/2026
This specification covers an aluminum alloy in the form of rolled or cold-finished bars, rods, and wire and of flash-welded rings and stock for flash-welded rings.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Castings, 4.6Cu - 0.35Mn - 0.25Mg - 0.22Ti (A206.0-T4), Solution Heat Treated and Naturally AgedAMS4236E (Current)3/25/2026
This specification covers an aluminum alloy in the form of sand, investment, permanent mold, and composite mold castings with nominal wall thicknesses of up to 1.0 inch (25.4 mm), inclusive (see 8.8).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet, 3.5Cu - 1.1Li - 0.50Mg - 0.40Ag - 0.12Zr (2098-T8), Solution Heat Treated, Cold Worked, and Artificially AgedAMS4457B (Current)3/25/2026
This specification covers an aluminum alloy in the form of sheet 0.125 to 0.249 inch (3.18 to 6.32 mm), inclusive, in nominal thickness (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Castings, 5.0Si - 1.2Cu - 0.50Mg (C355.0-T6), Solution and Precipitation Heat TreatedAMS4215L (Current)3/18/2026
This specification covers an aluminum alloy in the form of sand, permanent mold, composite mold, and investment castings (see 8.6).
AMS D Nonferrous Alloys Committee
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