T.O.

1-1A-9 NAVAIR 01-1A-9

TECHNICAL MANUAL ENGINEERING SERIES FOR AIRCRAFT REPAIR

AEROSPACE METALS GENERAL DATA AND USAGE FACTORS

(ATOS)

BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION
DISTRIBUTION STATEMENT - Approved for public release; distribution is unlimited. Other request for this document should be referred to WR-ALC/LKC, Robins AFB GA 31098. Questions concerning technical content should be referred to WR-ALC/LESG, Robins AFB GA 31098.

PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE AND BY DIRECTION OF THE CHIEF OF THE NAVAL AIR SYSTEMS COMMAND.

26 FEBRUARY 1999
CHANGE 4 - 17 JANUARY 2003

T.O. 1-1A-9
INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original ........................... 0........ 26 February Change............................. 1............... 25 June Change............................. 2.............1 October Change............................. 3................ 26 July 1999 2001 2001 2002 Change............................. 4..........17 January 2003

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 290, CONSISTING OF THE FOLLOWING:

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TABLE OF CONTENTS

Section

Page

Section

Page

I INTRODUCTION..................................................... 1-1 1-1 PURPOSE ............................................. 1-1 II FERROUS 2-1 2-2 2-4 2-7 2-8 2-9 2-11 2-12 2-13 2-14 2-19 2-26 2-29 2-30 2-35 2-41 2-42 2-43 2-48 (STEEL) ALLOYS................................. 2-1 Classification ........................................ 2-1 SAE Numbering System ...................... 2-1 Carbon Steels ........................................ 2-1 Nickel Steels ......................................... 2-2 Chromium Steels .................................. 2-2 Chromium - Nickel Steels.................... 2-2 Chrome - Vanadium Steels .................. 2-3 Chrome - Molybdenum Steels .................................................. 2-3 Principles of Heat Treatment of Steels .................................... 2-3 Hardening ............................................. 2-3 Quenching Procedure ........................... 2-4 Tempering (Drawing) ........................... 2-4 Normalizing........................................... 2-5 Case Hardening .................................... 2-5 Carburizing ........................................... 2-6 Cyaniding .............................................. 2-7 Nitriding................................................ 2-7 Heat Treating Equipment.................... 2-7 Heat Control, Furnace Temperatures Survey and Temperature Measuring Equipment.......................................... 2-8 Furnace Control Instruments Accuracy.................................. 2-8 Salt Bath Control ............................... 2-10 Quenching Tanks and Liquids.............................................. 2-10 Heat Treating Procedures.................. 2-10 Hardness Testing................................ 2-11 Specification Cross Reference.......................................... 2-11 General Heat Treating Temperatures, Composition (Chemical) and Characteristics of Various Steel and Steel Alloy ................ 2-35 Machining of Steels (General) .......................................... 2-60 Machining Corrosion Resisting Steel ..................................... 2-65 Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted

2-199 2-200 2-201 2-202 2-203 2-216 2-234 2-292

Deleted Deleted Deleted Deleted Deleted Deleted Fabrication of Ferrous Alloys .............................................. 2-121 Steel Surface Finishes...................... 2-130

2-53 2-55 2-58 2-60 2-68 2-73 2-74

2-75 2-81 2-117 2-128 2-131 2-135 2-147 2-152 2-168 2-184 2-186 2-195

III ALUMINUM ALLOYS............................................. 3-1 3-1 Classification ........................................ 3-1 3-4 Commercial and Military Designations ...................................... 3-1 3-8 Mechanical Properties.......................... 3-2 3-16 Physical Properties............................. 3-18 3-17 Heat Treatment of Aluminum Alloys ....................................... 3-18 3-51 Heat Treatment .................................. 3-24 3-56 Heat Treating Equipment.................. 3-24 3-70 Fabrication .......................................... 3-28 3-73 Forming Sheet Metal.......................... 3-28 3-96 Deleted 3-97 Deleted 3-118 Deleted 3-123 Deleted 3-131 Deleted 3-145 Deleted 3-154 Deleted 3-175 Machining............................................ 3-45 3-179 Cutting Tools for Machining Aluminum.................................. 3-45 3-180 Turning................................................ 3-46 3-183 Milling-Aluminum .............................. 3-46 3-189 Shaping and Planing .......................... 3-49 3-195 Tapping................................................ 3-56 3-198 Filing ................................................... 3-56 3-202 Reaming .............................................. 3-57 3-204 Sawing ................................................. 3-57 3-210 Grinding .............................................. 3-58 3-216 Polishing.............................................. 3-58 3-218 Roughing ............................................. 3-58 3-219 Greasing or Oiling .............................. 3-58 3-221 Buffing ................................................ 3-59 3-223 Hardness Testing................................ 3-59 3-226 Non-Destructive Testing/Inspection ........................... 3-59 3-228 Anodizing Process for Inspection of Aluminum Alloy Parts ....................................... 3-59 3-231 Aluminum Alloy Effects on Scratches on Clad Aluminum Alloy .................................... 3-59 3-233 Allowable Defects................................ 3-59 3-234 Harmful Scratches.............................. 3-60

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TABLE OF CONTENTS - Continued

Section

Page

Section

Page

3-241 3-242

Disposition of Scratches Sheets/Parts ..................................... 3-60 Cleaning of Aluminum Alloy Sheet (Stock).............................. 3-60

IV MAGNESIUM ALLOYS .......................................... 4-1 4-1 Classification ........................................ 4-1 4-4 Definitions............................................. 4-1 4-13 Safety Requirements for Handling and Fabrication of Magnesium Alloys ......................... 4-2 4-19 Safety Precautions for All Alloys (Including Fire Hazards) ............................................. 4-3 4-22 Grinding and Polishing Safety Practices ............................... 4-14 4-24 Deleted 4-25 Heat Treating Safety Practices ........................................... 4-15 4-26 Identification ...................................... 4-16 4-29 Heat Treating Magnesium Alloys -(General).............................. 4-16 4-45 Alloy General Characteristic Information................................. 4-19 4-47 Deleted 4-77 Deleted 4-78 Deleted 4-79 Deleted 4-82 Deleted 4-93 Deleted V TITANIUM AND TITANIUM ALLOYS................. 5-1 5-1 Classification ........................................ 5-1 5-4 General .................................................. 5-1 5-5 Military and Commercial Designations ...................................... 5-1 5-6 Physical Properties............................... 5-1 5-7 Mechanical Properties.......................... 5-1 5-10 Methods of Identification..................... 5-1 5-11 Hardness Testing.................................. 5-1 5-12 Tensile Testing ..................................... 5-1 5-13 Non-Destructive Testing ...................... 5-1 5-14 Fire Damage ......................................... 5-6 5-15 Heat Treatment - (General) ................. 5-6 5-22 Hydrogen Embrittlement ..................... 5-8 5-25 Fabrication .......................................... 5-11 5-26 Forming Sheet Metal (General) .......................................... 5-11 5-28 Draw Forming..................................... 5-11 5-29 Hydraulic Press Forming ................... 5-11 5-32 Stretch Forming.................................. 5-11 5-33 Drop - Hammer Forming ................... 5-11 5-34 Joggling ............................................... 5-12 5-35 Blanking and Shearing ...................... 5-12 5-37 Deleted 5-38 Deleted

5-39 5-40 5-42 5-43 5-45 5-47 5-48 5-51 5-52 5-54 5-57 5-63 5-66 5-69 5-70

Deleted Deleted Deleted Deleted Deleted Soldering ............................................. 5-15 Riveting ............................................... 5-15 Machining and Grinding.................... 5-17 Machining............................................ 5-17 Turning................................................ 5-17 Milling ................................................. 5-17 Drilling ................................................ 5-17 Tapping................................................ 5-19 Reaming .............................................. 5-19 Grinding .............................................. 5-19

VI COPPER AND COPPER BASE ALLOYS .................................................................... 6-1 6-1 Copper and Copper Base Alloys .................................................. 6-1 6-3 Copper Alloying Elements ................... 6-1 6-5 Heat Treatment and Hot Working Temperature of Copper Alloys..................................... 6-1 6-7 Stress Relief of Copper Alloys .................................................. 6-1 6-9 Machining Copper and Copper Alloys ........................................... 6-1 6-10 Wrought - Copper - Beryllium Alloys ........................................... 6-1 6-12 Heat Treating Procedures and Equipment Requirements................................... 6-10 6-15 Solution - Heat Treatment Copper Beryllium ............................ 6-11 6-17 Precipitation or Age Hardening ........................................ 6-11 VII TOOL STEELS......................................................... 7-1 7-1 General .................................................. 7-1 7-4 Alloying Elements in Tool Steels .................................................. 7-1 7-5 Specifications ........................................ 7-1 7-6 Class Designations ............................... 7-5 7-7 Applications of Tool Steels................... 7-5 7-9 Selection of Material for a Cutting Tool ....................................... 7-5 7-16 Heat Treat Data ................................... 7-6 7-18 Distortion in Tool Steels ...................... 7-6 7-19 Deleted 7-21 Deleted 7-22 Deleted 7-23 Deleted VIII TESTING AND INSPECTION, HARDNESS TESTING....................................................... 8-1

ii

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TABLE OF CONTENTS - Continued

Section

Page

Section

Page

8-1 8-3 8-5 8-8 8-15 8-18 8-20 8-21 8-22 8-24 8-27 8-33 8-34

General .................................................. 8-1 Methods of Hardness Testing................................................ 8-1 Brinell Hardness Test .......................... 8-1 Rockwell Hardness Test....................... 8-1 Vickers Pyramid Hardness Test ..................................................... 8-4 Shore Scleroscope Hardness Test ..................................................... 8-8 Testing with the Scleroscope ......................................... 8-9 Tensile Testing ..................................... 8-9 Decarburization Measurement ..................................... 8-9 Hardness Method................................ 8-10 Nondestructive Inspection Methods............................................ 8-14 Chemical Analysis .............................. 8-14 Spectrochemical Analysis................... 8-14

IX HEAT TREATMENT ............................................... 9-1 9-1 General .................................................. 9-1 9-9 Special Heat Treatment Information ........................................ 9-1 9-11 Tint Test for Determining Coating Removal from Nickel Base and Cobalt Base Alloys .................................................. 9-1 9-13 Titanium Alloy Parts............................ 9-3 9-16 Solution, Stabilization, or Precipitation Heat Treatment .......... 9-3 9-38 Stress-Relief After Welding ................. 9-8 9-59 Local Stress-Relief .............................. 9-11 9-68 Description of Methods ...................... 9-11 A Supplemental Data ..................................................A-1 Glossary ...............................................................GLS 1

LIST OF ILLUSTRATIONS

Figure

Title

Page

Figure

Title

Page

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

Number and Distribution of Thermocouples............................................ 2-9 Deleted Deleted Stretch Forming......................................... 2-127 Surface Roughness .................................... 2-135 Head to Alloy Identification Method ...................................................... 3-20 Drill Designs and Recommended Cutting Angles.......................................... 3-55 Typical Dust Collectors for Magnesium................................................ 4-22

4-2 4-3 4-4 8-1 8-2 8-3 8-4 8-5 8-6 8-7

Deleted Deleted Deleted Brinell Hardness Tester................................ 8-4 Rockwell Hardness Tester ............................ 8-5 Attachments for Rockwell Tester ................. 8-6 Vickers Pyramid Hardness Tester ............... 8-7 Standard Pyramid Diamond Indentor....................................................... 8-8 Shore Scleroscope .......................................... 8-8 Test Specimens ............................................ 8-11

LIST OF TABLES

Number

Title

Page

Number

Title

Page

2-1

2-2 2-3

Soaking Periods for Hardening Normalizing and Annealing (Plain Carbon Steel)................................. 2-10 Specification Cross Reference .................... 2-12 Cutting Speeds and Feeds for SAE 1112 Using Standard High Speed Tools ..................................... 2-61

2-4 2-5

2-6

Machinability Rating of Various Metals........................................................ 2-61 Conversion of Surface Feet Per Minute (SFM) to Revolutions Per Minute (RPM).................................... 2-63 Tool Correction Chart ................................. 2-64

Change 4

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LIST OF TABLES - Continued

Number

Title

Page

Number

Title

Page

2-7

2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-26 2-27 2-28 2-29 2-30 2-31 2-32 2-33 2-34 2-35 2-36 2-37 2-38 3-1 3-2 3-3 3-4 3-5 3-6

General Machining Comparison of Corrosion Resisting Steel to Free Machining Screw Stock B1112 ........................................................ 2-65 Suggested Cutting Speeds and Feeds ......................................................... 2-66 Tool Angles - Turning ................................. 2-68 Suggested Milling Cutting Speeds and Feeds..................................... 2-69 Suggested Tool Angles - Milling................. 2-70 Drilling Speeds for Corrosion Resisting Steel.......................................... 2-70 Tapping Allowances (Holes Size to Screw Size) ........................................... 2-71 Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Cold Bend Radii (Inside) Carbon/Low Alloy Steels.............................. 2-128 Cold Bend Radii (Inside) Corrosion Resistant Steel Alloys................. 2-128 Forging Temperature Ranges for Corrosion Resistant Steel ................ 2-128 Galvanic Series of Metals and Alloys....................................................... 2-134 Surface Roughness and Lay Symbols ................................................... 2-136 Designations for Alloy Groups ..................... 3-1 Aluminum Alloy Designation and Conversions to 4 Digit System .................. 3-1 Federal and Military Specifications.............................................. 3-3 Chemical Composition Nominal and General Use Data 1/ ........................... 3-9 Mechanical Properties - Typical................. 3-14 Physical Properties - Standard Alloys......................................................... 3-16

3-7 3-8

3-9 3-10

3-11

3-12 3-13 3-14

3-15 3-16 3-17 3-18

3-19

3-20

3-21

3-22 3-23 3-24 3-25 3-26 3-27 3-28 4-1 4-2 4-3

Heat Treating (Soaking) Temperatures ........................................... 3-17 Soaking Time for Solution Heat Treatment of All Wrought Products .................................................... 3-23 Soaking Time for Solution Treatment of Cast Alloys......................... 3-23 Recommended Maximum Quench Delay, Wrought Alloys (For Immersion Type Quenching)................................................ 3-24 Precipitation (Aging) Treating Temperatures, Times and Conditions ................................................. 3-25 Reheat Treatment of Alclad Alloys......................................................... 3-27 Cold Bend Radii (Inside) for General Applications................................ 3-29 Maximum Accumulative Reheat Times for Hot Forming Heat Treatable Alloys at Different Temperatures ........................................... 3-32 Deleted Deleted General Rivet (Alum) Identification Chart ................................................. 3-42 General Aluminum Rivet Selection Chart (Rivet Alloy vs Assembly Alloy) ............................................ 3-45 Shear Strength of Protruding and Flush Head Aluminum Alloy Rivets, Inch Pounds ....................... 3-47 Bearing Properties, Typical, of Aluminum Alloy Plates and Shapes ....................................................... 3-48 Standard Rivet Hole Sizes with Corresponding Shear and Bearing Areas for Cold Driven Aluminum Alloy Rivets............................ 3-50 Turning Speeds and Feeds ......................... 3-51 Tool Angles - Turning ................................. 3-52 Milling - Speeds and Feeds ........................ 3-52 Tool Angles - Milling................................... 3-53 Shaping and Planing - Speeds and Feeds.................................................. 3-54 Shaping Tool Angles ................................... 3-54 Thread Constant for Various Standard Thread Forms .......................... 3-56 Cross-Reference, Alloy Designations to Specifications................................ 4-3 Alloy Designation Cross-Reference .......................................... 4-6 Chemical Properties of Magnesium Alloys .................................................... 4-7

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LIST OF TABLES - Continued

Number

Title

Page

Number

Title

Page

4-4

4-5

4-6

4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26 4-27 4-28 4-29 4-30 4-31 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 6-1

Mechanical Properties Magnesium Extrusions and Forgings at Room Temperature - Typical..................... 4-9 Mechanical Properties Magnesium Alloy Sheet and Plate at Room Temperature - Typical................... 4-11 Mechanical Properties of Magnesium Alloy Castings at Room Temperatures................................. 4-12 Physical Properties - Magnesium Alloy @ 68 oF...................................... 4-13 Solution Heat Treating Temperatures and Holding Times ....................... 4-18 Artificial Aging (Precipitation Treatment) ................................................ 4-19 Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Deleted Specification Cross Reference Titanium Alloy ............................................... 5-2 Nominal Mechanical Properties at Room Temperature ................................ 5-7 Heat Treat, Stress Relief and Annealing Temperatures and Times ............. 5-9 Recommended Minimum CCLD Bend Radii ................................................ 5-12 Deleted Turning Speeds for Titanium Alloys......................................................... 5-18 Tool Angles for Alloys ................................. 5-18 Speeds and Feeds for Milling ..................... 5-18 Angles for Tool Grinding ............................ 5-19 Chemical Composition by Trade Name ........................................................... 6-2

6-2

6-3 6-4 6-5 6-6

7-1 7-2 7-3 7-4 7-5

7-6

7-7 8-1 8-2 8-3

9-1 9-2

9-3 A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 A-10 A-11 A-12 A-13

Hot Working and Annealing Temperatures for Copper and Wrought Copper Alloys.............................. 6-9 Typical Stress-Relief Treatments for Certain Copper Alloys ............ 6-11 Standard Machinability Rating of Copper Alloys ....................................... 6-12 Typical Engineering Properties.................. 6-13 Age Hardening Time-Temperature Conditions and Material Temper Designations ............................................. 6-13 Tool Steel Specifications............................... 7-2 Chemical Composition, Tool Steel................ 7-3 Tool Steel Selection ....................................... 7-5 Tool Steel Hardening and Tempering Temperatures ................................. 7-5 Forging, Normalizing and Annealing Treatments of Tool and Die Steels .................................................... 7-7 Thermal Treatment for Hardening and Tempering Tool Steel - General ................................................... 7-11 Comparison of Tool Steel Properties.................................................. 7-14 Hardness Conversion Chart ......................... 8-3 Rockwell Scales, Loads and Prefix Letters ................................................. 8-10 Approximate Hardness - Tensile Strength Relationship of Carbon and Low Alloy Steels ........................ 8-12 Typical Heat Treatment Application.................................................. 9-1 Cross-Index for Solution, Stabilization or Precipitation Heat Treatments ................................................. 9-4 Cross-Index for Stress-Relief Heat Treatments ........................................ 9-9 Chemical Symbols .........................................A-1 Decimal Equivalents .....................................A-2 Engineering Conversion Factors ..................A-6 Table of Weights - Aluminum and Aluminum Alloy................................. A-8 Table of Weights - Brass...............................A-9 Table of Weights - Bronze ..........................A-10 Table of Weights - Copper ..........................A-11 Table of Weights - Iron ...............................A-12 Table of Weights - Lead..............................A-12 Table of Weights - Magnesium and Magnesium Alloy ............................. A-12 Table of Weights - Nickel Chromium Iron Alloy (Inconel) ...................... A-13 Table of Weights - Nickel Copper Alloy................................................... A-13 Table of Weights - Steel..............................A-13

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LIST OF TABLES - Continued

Number

Title

Page

Number

Title

Page

A-14 A-15 A-16 A-17

Table of Weights - Zinc ...............................A-16 Temperature Conversion Chart .................A-17 Standard Bend Radii for 90o Cold Forming-Flat Sheet ........................ A-18 Metal Bending and Bend Radii Bend Allowances Sheet Metal Bend Allowances Per Degree of Bend Aluminum Alloys....................... A-19

A-18 A-19 A-20

Bend Set Back Chart ..................................A-21 Comparative Table of Standard Gages........................................................ A-22 Melting Points Approximate.......................A-23

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SECTION I INTRODUCTION
1-1. PURPOSE. 1-4. The information/instruction contained herein are for general use. If a conf lict exists between this technical manual and the specif ic technical manual(s) or other approved data for a particular weapon, end item, equipment, etc., the data applicable to the specif ic item(s) will govern in all cases. 1-5. The use of shall, will, should and may in this technical manual is as follows: a. Whenever the word shall appears, it shall be interpreted to mean that the requirements are binding. b. The words will, should and may, shall be interpreted as nonmandatory provisions. c. The word will is used to express declaration of purpose. d. The word should is used to express nonmandatory desired or preferred method of accomplishment. e. The word may is used to express an acceptable or suggested means of accomplishment. 1-6. Deleted 1-7. WELDING. Information on welding aerospace metals is contained in NAVAIR 01-1A-34, T.O. 00-25-252, T.C. 9-238.

1-2. This is one of a series of technical or engineering technical manuals prepared to assist personnel engaged in the maintenance and repair of Aerospace Weapon Systems and Supporting Equipment (AGE). Army Personnel: Wherever the text of this manual refers to other technical orders (T.O.s) for supporting information, refer to comparable Army documents. 1-3. This technical manual provides precise data on specif ic metals to assist in selection, usage and processing for fabrication and repair. It includes such data as specif ication cross reference; approved designation system for alloys and tempers; temperatures and other controls for heat treatments; mechanical and physical properties processing instructions for basic corrosion prevention; forming characteristics; and other information required for general aerospace weapon system repair. Procedures for general foundry practice, sand control, gating and risering of both ferrous and non-ferrous castings may be obtained from available commercial handbooks and/or publications. Due to the many types, grades, deversif ied uses and new developments of metal products, it may not include all data required in some instances and further study and citation of this data will be required. If a requirement exists for information not included, a request for assistance should be made to WR-ALC, LEM.

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1-1/(1-2 blank)

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SECTION II FERROUS (STEEL) ALLOYS

2-1. CLASSIFICATION. TYPE OF STEEL Nickel-Chromium-Molybdenum Steels 1.80% nickel; 0.50 and 0.80% Chromium; 0.25% Molybdenum 0.55% Nickel; 0.50 and 0.65% Chromium; 0.20% Molybdenum 0.55% Nickel; 0.50 Chromium 0.25% Molybdenum 3.25% Nickel; 1.20 Chromium 0.12% Molybdenum Nickel-Molybdenum Steels 1.75 Percent Nickel; 0.25 percent Molybdenum 3.50 Percent Nickel; 0.25 percent Molybdenum Chromium Steels Low Chromium Medium Chromium High Chromium Corrosion and Heat Resisting Chromium-Vanadium Steel 0.80-1.00 percent Chromium, 0.10-0.15 Vanadium Silicon Manganese Steels A Percent Silicon Low Alloy, High Tensile Boron Intensif ied Leaded Steels 43xx 86xx 87xx 93xx NUMERALS (AND DIGITS)

2-2. SAE NUMBERING SYSTEM. A numeral index system is used to identify the compositions of the SAE steels, which makes it possible to use numerals that are partially descriptive of the composition of material covered by such numbers. The first digit indicates the type to which the steel belongs; for example 1 indicates a carbon steel; 2 a nickel steel; and 3 a nickel chromium steel. In the case of the simple alloy steels, the second digit generally indicates the approximate percentage of the predominant alloying element. Usually the last two or three digits indicate the approximate average carbon content in points or hundredths of 1 percent. Thus 2340 indicates a nickel steel of approximately 3 percent nickel (3.25 to 3.75) and 0.40 percent carbon (0.38 to 0.43). In some instances, in order to avoid oonfusion, it has been found necessary to depart from this system of identifying the approximate alloy composition of a steel by varying the second and third digits of the number. An instance of such departure is the steel numbers selected for several of the corrosion --and heat resisting alloys. 2-3. The basic numerals for the various types of SAE steel are: TYPE OF STEEL Carbon Steels Plain Carbon Free Cutting (Screw Stock) Manganese Steels Nickel Chromium Steels 1.25 Percent Nickel; 0.65 percent Chromium Corrosion and Heat Resisting Molybdenum Steels 0.25 Percent Molybdenum NUMERALS (AND DIGITS) 1xxx 10xx 11xx 13xx 3xxx 31xx 303xx 4xxx 40xx

46xx 48xx 5xxx 50xx 51xxx 52xxx 514xx and 515xx 6xxx 61xx 9xxx 92xx 950 xxBxx xxLxx

2-4. CARBON STEELS. Steel containing carbon in percentages ranging from 0.10 to 0.30 percent is classed as low carbon steel. The equivalent SAE numbers range from 1010 to 1030. Steels of this grade are used for the manufacture of articles such as safety wire, certain nuts, cable bushing, etc. This steel in sheet form is used for secondary structural parts and clamps and in tubular form for moderately stressed structura1 parts. 2-5. Steel containing carbon in percentages ranging from 0.30 to 0.50 percent is classed as medium carbon steel. This steel is especially adaptable for machining, forging, and where surface hardness is

2-1

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important. Certain rod ends, light forgings, and parts such as Woodruff keys, are made from SAE 1035 steel. 2-6. Steel containing carbon in percentage ranging from 0.50 to 1.05 percent is classed as high carbon steel. The addition of other elements in varying quantities adds to the hardness of this steel. In the fully heat-treated condition it is very hard and will withstand high shear and wear, but little deformation. It has limited use in aircraf t construction. SAE 1095 in sheet form is used for making f lat springs and in wire form for making coil springs. 2-7. NICKEL STEELS. The various nickel steels are produced by combining nickel with carbon steel. Some benef its derived from the use of nickel as an alloy in steel are as follows: a. Lowers the percentage of carbon that is necessary for hardening. The lowering of the carbon content makes the steel more ductile and less susceptible to uneven stress. b. Lowers the critical temperature ranges (heating and cooling) and permits the use of lower heating temperatures for hardening. c. Hardening of the nickel alloy steels at moderate rates of cooling has the advantage of lowering the temperature gradients, reducing internal stress/warpage and permits deeper/more uniform hardening. d. The low heat treating temperatures required, reduces the danger of overheating, excessive grain growth and the consequent development of brittleness. e. The characteristics depth hardening from the addition of nickel to steel as an alloy results in good mechanical properties af ter quenching and tempering. At a given strength (except for very thin sections/parts) the nickel steels provide greatly improved elastic properties, impact resistance and toughness. 2-8. CHROMIUM STEELS. Chromium steel is high in hardness, strength, and corrosion resistant properties. SAE 51335 steel is particularly adaptable for heat-treated forgins which require greater toughness and strength than may be obtained in plain carbon steel. It may be used for such articles as the balls and rollers of anti-friction bearings. 2-9. CHROMIUM-NICKEL STEELS. Chromium and nickel in various proportions mixed with steel form the chrome-nickel steels. The general proportion is about two and one-half times as much nickel as chromium. For all ordinary steels in this group the chromium content ranges from

0.45 to 1.25 percent, while the nickel content ranges from 1 to 2 percent. Both nickel and chromium inf luence the properties of steel; nickel toughens it, while chromium hardens it. Chromenickel steel is used for machined and forged parts requiring strength, ductility, toughness and shock resistance. Parts such as crankshaf ts and connecting rods are made of SAE 3140 steel. 2-10. Chrome-nickel steel containing approximately 18 percent chromium and 8 percent nickel is known as corrosion-resistant steel. It is usually identif ied as aisi types 301, 302, 303, 304, 304L, 309, 316, 316L, 321, 347, 347F or Se, etc., however; the basic 18-8 chrome-nickel steel is type 302. The other grades/types have been modif ied by changing or adding alloying elements to that contained in the basic alloy. The alloys are varied to obtain the required mechanical properties for some specif ic purpose such as improving corrosion resistance or forming machining, welding characteristics, etc. The following are examples of variations: a. 301-Chromium and Nickel (approximate 0.5 Nickel) is lowered to increase response to cold working. b. 302-Basic Type 18 Chromium 8 Nickel.

c. 303-Sulfur(s) or Selenium (se) added for improved machining characteristics. d. 304-Carbon(c) lowered to reduce susceptibility to carbide precipitation. This alloy is still subject to carbide precipitation from exposure to temperatures 800-1500F range and this shall be considered when it is selected for a specif ic application. e. 304L-Carbon(c) lowered for welding applications. f. 309-Cr and Ni higher for additional corrosion and scale resistance. g. 316-Molybdenum (Mo) added to improve corrosion resistance and strength. h. 316L-C- lowered for welding applications.

i. 321-Titanium (Ti) added to reduce/avoid carbide precipitation (stabilized grade) j. 347-Columbium(Cb), Tantalum (Ta)- Added to reduce/avoid carbide precipitation (stabilized grade). k. 347F or Se - Sulfur(s) or Selenium (Se) added to improve machinability. The chrome-nickel steels are used for a variety of applications on aircraf t and missiles. In plate and sheet form it is used for f irewalls, surface skin,

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T.O. 1-1A-9

exhaust stacks, heater ducts, gun wells, ammunition chutes, clamps, heat shields/def lectors, fairing, stiffeners, brackets, shims, etc. In bar and rod it is used to fabricate various f ittings, bolts, studs, screws, nuts, couplings, f langes, valve stems/seats, turn-buckles, etc. In wire form it is used for safety wire, cable, rivets, hinge pins, screens/screening and other miscellaneous items. 2-11. CHROME-VANADIUM STEELS. The vanadium content of this steel is approximately 0.18 percent and the chromium content approximately 1.00 percent. Chrome-vanadium steels when heat-treated have excellent properties such as strength, toughness, and resistance to wear and fatigue. A special grade of this steel in sheet form can be cold-formed into intricate shapes. It can be folded and f lattened without signs of breaking or failure. Chrome-vanadium steel with medium high carbon content (SAE 6150) is used to make springs. Chrome-vanadium steel with high carbon content (SAE 6195) is used for ball and roller bearings. 2-12. CHROME - MOLYBDENUM STEELS. Molybdenum in small percentage is used in combination with chromium to form chrome-molybdenum steel; this steel has important applications in aircraft. Molybdenum is a strong alloying element, only 0.15 to 0.25percent being used in the chromemolybdenum steels; the chromium content varies from 0.80 to 1.10 percent. Molybdenum is very similiar to tungsten in its effect on steel. In some instances it is used to replace tungsten in cutting tools, however; the heat treat characteristic varies. The addition of up to 1% molybdenum gives steel a higher tensile strength and elastic limit with only a slight reduction in ductility. They are especially adaptable for welding and for this reason are used principally for welded structural parts and assemblies. Parts fabricated from 4130, are used extensively in the construction of aircraf t, missiles, and miscellaneous GSE equipment. The 4130 alloy is used for parts such as engine mounts (reciprocating), nuts, bolts, gear structures, support brackets for accessories, etc. 2-13. PRINCIPLES OF HEAT TREATMENT OF STEELS. 2-14. HARDENING. At ordinary temperatures, the carbon content of steel exists in the form of particles of iron carbide scattered throughout the iron matrix; the nature of these carbide particles, i.e., their number, size, and distribution, determines the hardness and strength of the steel. At elevated temperatures, the carbon is dissolved in the iron matrix and the carbide-particles appear only af ter the steel has cooled through its critical temperature (see paragraph 2-15). If the rate of

cooling is slow, the carbide particles are relatively coarse and few; in this condition the steel is sof t. If the cooling is rapid, as be quenching in oil or water, the carbon precipitates as a cloud of very fine carbide particles, which condition is associated with high hardness of the steel. 2-15. At elevated temperatures, the iron matrix exists in a form called austenite which is capable of dissolving carbon in solid solution. At ordinary temperatures the iron exists as ferrite, in which carbon is relatively insoluble and precipitates; as described in the preceding paragraph, in the form of carbide particles. The temperature at which this change from austenite to ferrite begins to occur on cooling is called the upper critical temperature of the steel, and varies with the carbon content; up to approximately 0.85 percent carbon, the upper critical temperature is lowered with increasing carbon content; from 0.85 to 1.70 percent carbon the upper critical temperature is raised with increasing carbon content. Steel that has been heated to its upper critical point will harden completely if rapidly quenched; however, in practice it is necessary to exceed this temperature by/from approximately 28o to 56oC (50o to 100oF) to insure thorough heating of the inside of the piece. If the upper critical temperature is exceeded too much, an unsatisfactory coarse grain size will be developed in the hardened steel. 2-16. Successful hardening of steel will largely depend upon the following factors af ter steel has been selected which has harden ability desires: a. Control over the rate of heating, specif ically to prevent cracking of thick and irregular sections. b. Thorough and uniform heating through sections to the correct hardening temperatures. c. Control of furnace atmosphere, in the case of certain steel parts, to prevent scaling and decarburization. d. Correct heat capacity, viscosity, and temperature of quenching medium to harden adequately and to avoid cracks. e. In addition to the preceding factors, the thickness of the section controls the depth of hardness for a given steel composition. Very thick sections may not harden through because of the low rate of cooling at the center. 2-17. When heating steel, the temperature should be determined by the use of accurate instruments. At times, however, such instruments are not available, and in such cases, the temperature of the steel may be judged approximately by its color. The accuracy with which temperatures

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may be judged by color depends on the experience of the workman, the light in which the work is being done, the character of the scale on the steel, the amount of radiated light within the furnace, and the emissivity or tendency of steel to radiate or emit light. 2-18. A number of liquids may be used for quenching steel. Both the medium and the form of the bath depend largely on the nature of the work to be cooled. It is important that a sufficient quantity of the medium be provided to allow the metal to be quenched without causing an appreciable change in the temperature of the bath. This is particularly important where many articles are to be quenched in succession. NOTE Aerators may be used in the Quench Tanks to help dissipate the vapor barrier. 2-19. QUENCHING PROCEDURE. The tendency of steel to warp and crack during the quenching process is difficult to overcome, and is due to the fact that certain parts of the article cool more rapidly than others. Whenever the rate of cooling is not uniform, internal stresses are set up on the metal which may result in warpage or cracking, depending on the severity of the stresses. Irregularly shaped parts are particularly susceptible to these conditions although parts of uniform section size are of ten affected in a similar manner. Operations such as forging and machining may set up internal stresses in steel parts and it is therefore advisable to normalize articles before attempting the hardening process. The following recommendations will greatly reduce the warping tendency and should be carefully observed: a. An article should never be thrown into quenching media/bath. By permitting it to lie on the bottom of the bath it is apt to cool faster on the top side than on the bottom side, thus causing it to warp or crack. b. The article should be slightly agitated in the bath to destroy the coating of vapor which might prevent it from cooling rapidly. This allows the bath to remove the heat of the article rapidly by conduction and convection. c. An article should be quenched in such a manner that all parts will be cooled uniformly and with the least possible distortion. For example, a gear wheel or shaf t should be quenched in a verticle position. d. Irregularly shaped sections should be immersed in such a manner that the parts of the greatest section thickness enters the bath f irst.

2-20.

QUENCHING MEDIUM.

2-21. Oil is much slower in action than water, and the tendency of heated steel to warp or crack when quenched may be greatly reduced by its use. Unfortunately, parts made from high carbon steel will not develop maximum hardness when quenched in oil unless they are quite thin in cross section. In aircraf t, however, it is generally used and is recommended in all cases where it will produce the desired degree of hardness. NOTE Alloy steels should never be quenched in water. 2-22. In certain cases water is used in the quenching of steel for the hardening process. The water bath should be approximately 18oC (65oF), as extremely cold water is apt to warp or crack the steel and water above this temperature will not produce the required hardness. 2-23. A 10%, salt brine (sodium chloride) solution is used when higher cooling rates are desired. A 10% salt brine solution is made by dissolving 0.89 pound of salt per gallon of water. 2-24. For many articles such as milling cutters and similar tools, a bath of water covered by a film of oil is occasionally used. When the steel is plunged through this oil f ilm a thin coating will adhere to it, retarding the cooling effect of the water slightly, thus reducing the tendency to crack due to contraction. 2-25. STRAIGHTENING OF PARTS WARPED IN QUENCHING. Warped parts must be straightened by f irst heating to below the tempering temperature of the article, and then applying pressure. This pressure should be continued until the piece is cooled. It is desirable to retemper the part af ter straightening at the straightening temperature. No attempt should be made to straighten hardened steel without heating, regardless of the number of times it has been previously heated, as steel in its hardened condition cannot be bent or sprung cold with any degree of safety. 2-26. TEMPERING (DRAWING). Steel that has been hardened by rapid cooling from a point slightly above its critical range is of ten harder than necessary and generally too brittle for most purposes. In addition, it is under severe internal stress. In order to relieve the stresses and reduce the brittleness or restore ductility the metal is always tempered. Tempering consists in reheating the steel to a temperature below the critical range (usually in the neighborhood of 600 1200oF). This reheating causes a coalescence and enlargement of the f ine carbide particles produced

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by drastic quenching, and thus tends to sof ten the steel. The desired strength wanted will determine the tempering temperature. This is accomplished in the same types of furnaces as are used for hardening and annealing. Less ref ined methods are sometimes used for tempering small tools. 2-27. As in the case of hardening, tempering temperatures may be approximately determined by color. These colors appear only on the surface and are due to a thin f ilm of oxide which forms on the metal af ter the temperature reaches 232oC (450oF). In order to see the tempering colors, the surface must be brightened. A buff stick consisting of a piece of wood with emery cloth attached is ordinarily used for this purpose. When tempering by the color method, an open f lame of heated iron plate is ordinarily used as the heating medium. Although the color method is convenient, it should not be used unless adequate facilities for determining temperature are not obtainable. Tempering temperatures can also be determined by the use of crayons of known melting point. Such crayons are commercially available for a wide range of temperatures under the trade name of Tempilstiks. The above method may be used where exact properties after tempering is not too important such as for blacksmith work. The most desireable method for general aeronautical use, is to determine temperatures by hardness checks, and subsequent adjustments made as necessary to obtain the properties required. For recommended tempering temperatures see heat treat data for material/composition involved. 2-28. Steel is usually subjected to the annealing process for the following purposes: a. To increase its ductility by reducing hardness and brittleness. b. To ref ine the crystalline structure and remove stresses. Steel which has been coldworked is usually annealed so as to increase its ductility. However, a large amount of cold-drawn wire is used in its cold-worked state when very high yield point and tensile strength are desired and relatively low ductility is permissible, as in spring wire, piano wire, and wires for rope and cable. Heating to low temperatures, as in soldering, will destroy these properties. However, rapid heating will narrow the affected area. c. To sof ten the material so that machining, forming, etc., can be performed. 2-29. NORMALIZING. Although involving a slightly different heat treatment, normalizing may be classed as a form of annealing. This process also removes stresses due to machining, forging,

bending, and welding. Normalizing may be accomplished in furnaces used for annealing. The articles are put in the furnace and heated to a point approximately 150o to 225oF above the critical temperature of the steel. Af ter the parts have been held at this temperature for a sufficient time for the parts to be heated uniformly throughout, they must be removed from the furnace and cooled in still air. Prolonged soaking of the metal at high temperatures must be avoided, as this practice will cause the grain structure to enlarge. The length of time required for the soaking temperature will depend upon the mass of metal being treated. The optimum soaking time is roughly one-quarter hour per inch of diameter or thickness. 2-30. CASE HARDENING. In many instances it is desirable to produce a hard, wear-resistant surface or case over a strong, tough core. Treatment of this kind is known as case hardening. This treatment may be accomplished in several ways, the principal ways being carburizing, cyaniding, and nitriding. 2-31. Flame Hardening/Sof tening. Surface hardening/softening by applying intense heat (such as that produced by an Oxy-Acetylene f lame) can be accomplished on almost any of the medium carbon or alloys steel, i.e. 1040, 1045, 1137, 1140 etc. The parts are surface hardened, by applying a reducing f lame (An Oxidizing f lame should never be used) at such a rate, that the surface is rapidly heated to the proper quenching temperature for the steel being treated. Following the application of the heat, the part is quenched by a spraying of water/oil rapidly. The fast quench hardens the steel to the depth that the hardening temperature has penetrated below the surface. The actual hardness resulting will depend on the rate of cooling from the quenching temperature. In hardening by this method the shape and size/mass of the part must be considered. Most operations will require special adapted spray nozzles to apply the quenching media, which is usually water. Normally, f lame hardening will produce surface hardness higher than can be obtained by routine furnace heating and quenching, because surface can be cooled at a faster rate. If a combination of high strength core and surface is required some of the medium carbon alloy steels can be heat treated and subsequently surface hardened by the f lame method. NOTE This method is not adapted for surface hardening of parts for use in critical applications. 2-32. Surface sof tening is accomplished by heating the surface to just below the temperature

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required for hardening and allowing the material to cool (in air) naturally. This method is sometimes used to sof ten material that has been hardened by frame cutting. Of ten it is necessary to apply the heat in short intervals to prevent exceeding the hardening temperature. 2-33. Induction. Hardening/Heating. The induction method of heating can be used to surface harden steels, in a manner similar to that used for f lame hardening. The exception is that the heat for hardening is produced by placing the part in a magnetic f ield (electrical) specif ically designed for the purpose. Parts hardened (surface) by this method will be limited to capability and size of loop/coil used to produce the magnetic f ield. 2-34. In some instances the induction method can be used to deep harden; the extent will depend on exposure/dwell time, intensity of the magnetic field, and the size of the part to be treated. 2-35. CARBURIZING. At elevated temperatures iron can react with gaseous carbon compounds to form iron carbide. By heating steel, while in contact with a carbon-aceous substance, carbonic gases given off by this material will penetrate the steel to an amount proportional to the time and temperature. For example, if mild or soft steel is heated to 732oC (1,350oF) in an atmosphere of carbonic gases, it will absorb carbon from the gas until a carbon content of approximately 0.80 percent has been attained at the surface, this being the saturation point of the steel for the particular temperature. By increasing the heat to 899oC/(1,650oF) the same steel will absorb carbon from the gas until a carbon content of approximately 1.1 percent has been attained, which is the saturation point for the increased temperature. 2-36. The carburizing process may be applied to both plain carbon and alloy steels provided they are within the low carbon range. Specif ically, the carburizing steels are those containing not more than 0.20 percent carbon. The lower the carbon content in the steel, the more readily it will absorb, carbon during the carburizing process. 2-37. The amount of carbon absorbed and the thickness of the case obtained increases with time; however, the carburization progresses more slowly as the carbon content increases during the process. The length of time required to produce the desired degree of carburization material used and the temperature to which the metal is subjected. It is apparent that, in carburizing, carbon travels slowly from the outside toward the inside center, and therefore, the proportion of carbon absorbed must decrease from the outside to the inside.

2-38. Solid, liquid, and gas carburizing methods are employed. a. The simplest method of carburizing consists of soaking the parts at an elevated temperature while in contact with solid carbonaceous material such as wood charcoal, bone charcoal and charred leather. b. Liquid carburizing consists of immersing the parts in a liquid salt bath, heated to the proper temperature. The carbon penetrates the steel as in the solid method producing the desired case. c. Gas carburizing consists of heating the parts in a retort and subjecting them to a carbonaceous gas such as carbon monoxide or the common fuel gases. This process is particularly adaptable to certain engine parts. 2-39. When pack carburizing, the parts are packed with the carburizing material in a vented steel container to prevent the solid carburizing compound from burning and to retain the carbon monoxide and dioxide gases. Nichrome boxes, capped pipes of mild steel, or welded mild steel boxes may be used. Nichrome boxes are most economical for production because they withstand oxidation. Capped pipes of mild steel or welded mild steel boxes are useful only as substitutes. The container should be so placed as to allow the heat to circulate entirely around it. The furnace must be brought to the carburizing temperature as quickly as possible and held at this heat from 1 to 16 hours, depending upon the depth of case desired and the size of the work. Af ter carburizing, the container should be removed and allowed to cool in air or the parts removed from the carburizing compound and quenched in oil or water. The air cooling, although slow, reduces warpage and is advisable in many cases. 2-40. Carburized steel parts are rarely used without subsequent heat treatment, which consists of several steps to obtain optimum hardness in the case, and optimum strength and ductility in the core. Grain size of the core and case is ref ined. a. Refining the core is accomplished by reheating the parts to a point just above the critical temperature of the steel. Af ter soaking for a sufficient time to insure uniform heating, the parts are quenched in oil. b. The hardening temperature for the high carbon case is well below that of the core. It is, therefore, necessary to heat the parts again to the critical temperature of the case and quench them in oil to produce the required hardness. A soaking period of 10 minutes is generally sufficient.

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c. A f inal stress relieving operation is necessary to minimize the hardening stresses produced by the previous treatment. The stress relieving temperature is generally around 350oF. This is accomplished by heating, soaking until uniformly heated, and cooling in still air. When extreme hardness is desired, the temperature should be carefully held to the lower limit of the range. 2-41. CYANIDING. Steel parts may be surfacehardened by heating while in contact with a cyanid salt, followed by quenching. Only a thin case is obtained by this method and it is, therefore, seldom used in connection with aircraf t construction or repair. Cyaniding is, however, a rapid and economical method of case hardening, and may be used in some instances for relatively unimportant parts. The work to be hardened is immersed in a bath of molten sodium or potassium cyanide from 30 to 60 minutes. The cyanide bath should be maintained at a temperature to 760oC to 899oC (1,400oF to 1,650oF). Immediately af ter removal from the bath, the parts are quenched in water. The case obtained in this manner is due principally to the formation of carbides and nitrides on the surface of the steel. The use of a closed pot and ventilating hood are required for cyaniding, as cyanide vapors are extremely poisonous. 2-42. NITRIDING. This method of case hardening is advantageous due to the fact that a harder case is obtained than by carburizing. Many engine parts such as cylinder barrels and gears may be treated in this way. Nitriding is generally applied to certain special steel alloys, one of the essential constituents of which is aluminum. The process involves the exposing of the parts to ammonia gas or other nitrogenous materials for 20 to 100 hours at 950oF. The container in which the work and ammonia gas are brought in contact must be airtight and capable of maintaining good circulation and even temperature throughout. The depth of case obtained by nitriding is about 0.015 inch if heated for 50 hours. The nitriding process does not affect the physical state of the core if the preceding tempering temperature was 950oF or over. When a part is to be only partially treated, tinning of any surface will prevent it from being nitrided. Nitrided surfaces can be reheated to 950oF with out losing any of their hardness, however, if heated above that temperature, the hardness is rapidly lost and cannot be regained by retreatment. Prior to any nitriding treatment, all decarburized metal must be removed to prevent

f laking of the nitrided case. When no distortion is permissible in the nitrided part, it is necessary to normalize the steel prior to nitriding to remove all strains resulting from the forging, quenching, or machining. 2-43. HEAT TREATING EQUIPMENT. Equipment necessary for heat treating consists of a suitable means for bringing the metal to the required temperature measuring and controlling device and quenching medium. Heat may, in some instances, be supplied by means of a forge or welding torch; however, for the treatment required in aircraf t work, a furnace is necessary. Various jigs and f ixtures are sometimes needed for controlling quenching and preventing warping. 2-44. FURNACES. Heat treating furnaces are of many designs and no one size or type perfectly fills every heat treating requirement. The size and quantity of metal to be treated and the various treatments required determine the size and type of furnace most suitable for each individual case. The furnace should be of a suitable type and design for the purpose intended and should be capable of maintaining within the working zone a temperature varying not more than + or - 14oC (25oF) for the desired value. 2-45. HEAT TREATING FURNACES/BATHS.

2-46. The acceptable heating media for heat treating of steels are air, combusted gases, protective atmosphere, inert atmosphere or vacuum furnaces, molten-fused salt baths, and molten-lead baths. The heat treating furnaces/baths are of many designs and no one size or type will perfectly fill every heat treating requirement. Furnaces and baths shall be of suitable design, type and construction for purpose intended. Protective and inert atmospheres shall be utilized and circulated as necessary to protect all surfaces of parts comprising the furnace load. 2-47. The design and construction of the heating equipment shall be such that the furnace/bath is capable of maintaining within the working zone, at any point, a temperature varying not more than 25oF (14oC) from the required heat treating temperature, with any charge. Af ter the charge has been brought up to treating/soaking temperature all areas of the working zone shall be within the permissible temperature range specif ied for the steel/alloy being heat treated (See Table 2-3, MILH-6875 or engineering data for material involved).

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NOTE Specification SAE-AMS-H-6875, Heat Treatment of Steel, will be the control document for heat treating steel material to be used on aerospace equipment. Where new alloys are involved, it will be necessary to review the involved specif ication or manufacturers engineering or design data for the appropriate heat information (temperature, control, atmosphere, times, etc). In case of conf lict the Military/Federal Specif ication will be governing factor or the conf lict will be negotiated with the responsible technical/engineering activities for resolution. 2-48. HEAT CONTROL, FURNACE TEMPERATURES SURVEY AND TEMPERATURE MEASURING EQUIPMENT. 2-49. Furnaces/baths shall be equipped with suitable automatic temperature control devices, properly calibrated and arranged, preferably of the potentiometer type to assure adequate control of temperature in all heat-treating zones. The resulting temperature readings shall be within 1.0 percent of the temperature indications of the calibrating equipment. Thermocouples shall be properly located in the working zones and adequately protected from contamination by furnace atmospheres by means of suitable protecting tubes. 2-50. A survey shall be made before placing any new furnace in operation, af ter any change is made that may affect operational characteristics, and semi-annually thereaf ter to assure conformance with temperature and control requirement previously cited. Where furnaces are used only for annealing or stress relieving, an annual survey will be acceptable. The survey may be waived at the discretion of the authorized inspector or representative provided that the results from previous tests, with the same furnace or bath and same type of load, show that the temperature and control uniformity is within specif ied limits. As a part of the inspection thermocouples should be closely inspected for condition and those severely deteriorated and of doubtful condition should be replaced. 2-51. The initial and succeeding (semi-annual and annual) surveys shall be performed with a standard production type atmosphere, controlled if required. A minimum of 9 test thermocouples or 1 per 15 cubic feet, whichever is greater, shall be used for air furnaces except circulating air furnaces used for tempering only. In the tempering

furnaces, a minimum of 9 test thermocouples or 1 per 25 cubic feet, whichever is greater, shall be used. Bath furnaces shall be tested by use of a minimum of 5 test locations or 1 per each 15 cubic feet. The locations may be surveys, using suitable protected multiple or single brake test thermocouples. For distribution of test thermocouples, see Figure 2-1. Temperature measuring and recording instruments used for controlling the furnace shall not be used to read the temperature of the test temperature sensing elements. 2-52. For all surveys, the furnace or bath temperature shall be allowed to stabilize at the potential test temperature. The initial survey shall be made at the highest and lowest temperatures of the furnace specif ied operating range. Periodic surveys may be made at a convenient temperature within the operating range. The temperature of all test locations/thermocouples shall be recorded at 5 minute intervals, starting immediately af ter insertion of the test thermocouples in the furnace or bath. Reading shall be continued for 1/2-hour or more af ter furnace control thermocouple reads within 25oF of original setting. Af ter all the test thermocouples have reached the minimum of the heat treating range, their maximum variation shall not exceed 25oF (14oC) and shall be within the specif ied heat treating temperature range in accordance with Specification SAE-AMS-H-6875 or Table 2-3. If the test indicates that conditions are not satisfactory, the required changes shall be made in the furnace and arrangements of the charge. The furnace control couples shall be corrected for any deviation from the standard electromative force (EMF) temperature chart as determined in calibration of the couples. 2-53. FURNACE CONTROL INSTRUMENTS ACCURACY. 2-54. The accuracy of temperature measuring, recording and controlling instruments shall be checked at regular intervals, not exceeding 3 months or upon request of personnel in charge or authorized (Government) inspector or representatives. The accuracy of the instrument shall be made by comparison tests with a standardized precision potentiometer type instrument of known (tested) accuracy used with a calibrated thermocouple. The test thermocouple shall be located approximately 3 inches from the installed furnace thermocouple(s). The temperature for check shall be at working temperature with a production load. If instruments are replaced or not used for 3 months they shall be checked before use.

2-8

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Figure 2-1.

Number and Distribution of Thermocouples

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2-55.

SALT BATH CONTROL.

Table 2-1.

2-56. The bath composition shall be adjusted as frequently as necessary to prevent objectionable attachment of the steel or alloy to be treated and to permit attainment of the desired mechanical properties of the f inished product. The bath will be checked at least once a month. 2-57. Temperature recording should be of the automatic controlling and recording type, preferably the potentiometer type. Thermocouples should be placed in a suitable protecting tube, unless the furnace atmosphere is such that undue deterioration of the thermocouples will not result. 2-58. QUENCHING TANKS AND LIQUIDS. Suitable tanks must be provided for quenching baths. The size of tanks should be sufficiently large to allow the liquids to remain approximately at room temperature. Circulating pumps and coolers may be used for maintaining approximately constant temperatures where a large amount of quenching is done. The location of these tanks is very important due to the fact that insufficiently rapid transfer from the furnace to the quenching medium may destroy the effects of the heat treatment in many instances. 2-59. The quenching liquids commonly used are as follows: Water at 18oC (65oF), Commercial Quenching Oil, and Fish Oil. 2-60. HEAT TREATING PROCEDURES. NOTE Additional Heat Treatment information is discussed in Section IX. 2-61. INITIAL FURNACE TEMPERATURES. In normalizing, annealing and hardening where parts are not preheated, the temperature in that zone of the furnace where works is introduced should be at least 149oC (300oF) below the working temperature at the time of insertion of parts of simple design. For parts of complicated design involving abrupt change of section or sharp corners, the temperature should be at least 260oC (500oF) below the working temperature. The furnace must be brought to the proper temperature gradually. 2-62. SOAKING PERIODS. The period of soaking is governed by both the size of the section and the nature of the steel. Table 2-1 indicates in a general way the effect of size on the time for soaking. This table is intended to be used as a guide only and should not be construed as being a mandatory requirement. It applies only to plain carbon and low alloy steels.

Soaking Periods for Hardening Normalizing and Annealing (Plain Carbon Steel)

DIAMETER OR THICKNESS INCHES 1 and less Over 1 through 2 Over 2 through 3 Over 3 through 4 Over 4 through 5 Over 5 through 8

TIME OF HEATING TO REQUIRED TEMPERATURE (APPROX) HOURS 3/4 1 1/4 1 3/4 2 1/4 2 3/4 3 1/2

TIME OF HOLDING (APPROX) HOURS 1/2 1/2 3/4 1 1 1 1/2

2-63. HARDENING. Temperatures required for hardening steel are governed by the chemical composition of the steel, previous treatment, handling equipment, size and shape of piece to be treated. Generally, parts of heavy cross section should be hardened from the high side of the given temperature range. 2-64. TEMPERING (DRAWING.) Tempering consists of heating the hardened steel to the applicable temperature holding at this temperature for approximately 1 hour per inch of the thickness of the largest section, and cooling in air or quenching in oil at approximately 27o to 66oC (80o to 150oF). The temperature to be used for tempering of steel depends upon the exact chemical composition, hardness, and grain structure obtained by hardening and the method of tempering. The tempering temperatures given are only approximate, and the exact temperature should be determined by hardness or tension test for individual pieces. The final tempering temperatures should not be more than 111oC (200oF) below the tempering, temperature given. If the center of the section is more that 1/2-inch from the surface, the tensile strength at the center will in general be reduced; therefore, a lower tempering temperature should be used for sections thicker than 1 inch in order to obtain the required tensile strength. 2-65. ANNEALING. Annealing consists of heating to the applicable temperature, holding at this temperature for approximately the period of time given, and cooling in the furnace to a temperature not higher than 482oC (900oF). The steel

2-10

T.O. 1-1A-9

may then be removed from the furnace and cooled in still air. 2-66. NORMALIZING. Normalizing consists of heating the steel to the applicable temperature, holding at this temperature for period of time, removing from furnace and cooling in still air. 2-67. CARBURIZING. Carburizing consists of heating the steel packed in a carburizing medium, in a closed container, to the applicable temperature and holding at this temperature for the necessary period of time to obtain the desired depth of case. 1020 steel will require 1 to 3 hours at a carburizing temperature of 899oC (1650oF) for each 1/64 inch of case depth, required. Parts may be cooled in the box or furnace to a temperature of approximately 482oC (900oF) then air cool. This treatment leaves the alloy in a relatively sof t condition and it is then necessary to condition by heating and quenching, f irst for core ref inement, followed by heating and quenching for case hardness. Alloy may be quenched directly from the carburizing furnace, thus producing a hard case and a core hardness of Rockwell B67. This treatment produces a coarse grain in some types of steel and may cause excessive distortion. Usually there is less distortion in f ine grain steels. The core treatment outlined above ref ines the grain as well as hardens. 2-68. HARDNESS TESTING. 2-69. GENERAL. Hardness testing is an important factor in the determination of the results of the heat treatment as well as the condition of the metal before heat treatment and must, therefore, be carefully considered in connection with this work. The methods of hardness testing in general use are: the Brinell, Rockwell, Vickers, and Shore Scleroscope. Each of these methods is discussed in section VIII. 2-70. TENSILE STRENGTH. Tempering temperatures listed with the individual steels in Table 2-3 are offered as a guide for obtaining desired tensile and yield strength of the entire cross section. When the physical properties are specif ied in terms of tensile strength, but tension tests are impractical, hardness tests may be employed using the equivalent hardness values specif ied in Table 8-3. 2-71. HARDNESS-TENSILE STRENGTH RELATIONSHIP. The approximate relationship

between the tensile strength and hardness is indicated in Table 8-3. This table is to be used as a guide. It applied only to the plain carbon and low alloy steels not to corrosion-resistant, magnet, valve, or tool steels. When a narrow range of hardness is required, the tests to determine the relationship between hardness and strength should be made on the actual part. Hardness values should be within a range of two points Rockwell or 20 points Brinell or Vickers. The tensile strength-hardness relationship is quite uniform for parts which are sufficiently large and rigid to permit obtaining a full depression on a f lat surface without def lection of the piece. For cylindrical parts of less than 1 inch in diameter, the Rockwell reading will be lower than indicated in the table for the corresponding tensile strength. Any process which affects the surface, such as buffing and plating, or the presence of decarburized or porous areas and hard spots, will affect the corresponding relation between hardness and tensile strength. Therefore, these surfaces must be adequately removed by grinding before measurements are made. 2-72. In making hardness measurements on tubular sections, correction factors must be determined and applied to the observed readings in order to compensate for the roundness and def lection of the tubing under the pressure of the penetrator. This may be impractical because every tube size end wall thickness would have a different factor. As an alternate, the following procedure may be used: Short lengths may be cut from the tube. A mandrel long enough to extend out both ends of the tube and slightly smaller in diameter than the inner diameter of the tube is then passed through the section and the ends supported in V supports on the hardness tester. Hardness readings may then be taken on the tubing. 2-73. SPECIFICATION CROSS REFERENCE. Table 2-2 is a cross reference index listing the steel and alloy types and the corresponding Federal, Military, and aeronautical material specif ications for the different conf igurations. Where two or more specif ications cover the same material, stock material meeting the requirements of a military specif ication shall be used for all aeronautical structural items. Some of the specif ications listed in Table 2-2 are for reference only, and are not approved for Air Force use.

2-11

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference

COMP/ALLOY DESIGN 1005

FORM/COMMODITY Rod, welding steel and cast iron, rod and wire, steel welding (A/C application) Steel, sheet and strip, f lat, aluminum coated low carbon, MIL-S-4174 Bars, Billets, Blooms, Slabs Bars (General Purpose) Wire Sheet and Strip Sheet and Strip Sheet and Strip Sheet and Strip Tubing, Seamless Tubing, Welded Rivets Wire (Carbon) Strip (For Small Arms, Bullets) Blooms, Billets, Slabs Steel Disks (For Deep Drawn Ammunition items) Tubes, Seamless (Marine Boiler application) Electrodes, Welding Electrodes, Welding Electrodes, Welding Rod and Wire (Welding Low Carbon Steel)

AMS 5030

FEDERAL

MILITARY MIL-R-908, C1 1

1008

MIL-S-4174

1010

MIL-S-16974 QQ-S-633 QQ-W-461 5047 5040 5042 5044 5050 5053 7225 QQ-W-409 MIL-S-13468 MIL-S-16788 C1 1 MIL-S-13852 QQ-S-698 QQ-S-698 QQ-S-698 MIL-S-11310

MIL-T-16286 C1 A

MIL-E-6843 C1 E 6013 5031 MIL-E-6843 C1 E 6013 MIL-E-18193 ty 60 MIL-R-5632 C1 1 5060 QQ-S-633 (Comp C1015-C1019) WW-T-731 Comp A

1015, 1016, 1017, 1018 and 1019

Bar (General Purpose) Bar and Billets Tube, Seamless/Welded

2-12

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 1015, 1016, 1017, 1018 and 1019 (Continued)

FORM/COMMODITY Tube, Mechanical

AMS

FEDERAL QQ-T-830 MT1015

MILITARY

Steel - Carbon Wire (Carbon) Wire (Carbon) Tubing Steel Disks Plate, Sheet and Strip (See Corten) Sheet and Strip, Bars, Billets Blooms, Slabs 1020 Bars, Billets, Blooms, Slabs Bars Sheet and Strip Wire (Carbon) Wire Wire (Book Binder) Sheet and Strip Plate (Carbon) Wire (Carbon) Tubing (Automotive) Bars Blooms, Billets, Slabs Tubing (Welded) Tubing Steel Disks (For deep drawn ammunition items) Sheet and Strip Tubing (Seamless and Welded)

5060

QQ-S-633 Comp C1015 QQ-W-409 (Comp 1015 1019 QQ-W-461 MIL-T-3520 MIL-S-13852 MIL-S-7809 QQ-S-640 MIL-S-16974 MIL-S-16974 QQ-S-633 MIL-S-3090 MIL-S-7952

5032

QQ-W-461 QQ-W-414

5045

QQ-S-698 1020 QQ-S-635 QQ-W-409 MIL-T-3520 MIL-S-11310 MIL-S-16788 C1 2 MIL-T-20162 Gr 1 MIL-T-20169 MIL-S-13852

QQ-T-830

Change 1

2-13

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 1022

FORM/COMMODITY Bars and Forgings Plates (Up to 1) Wire (Carbon) Steel Disk (For deep drawn ammunition items) Bars, Billets, Blooms, Slabs Sheet and Strip Tubing Tubing, Mechanical

AMS 5070

FEDERAL QQ-S-633 QQ-S-691, C1 A QQ-W-409

MILITARY MIL-S-11310

MIL-S-13852

MIL-S-16974 QQ-S-640 QQ-S-643 QQ-T-830 MIL-F-20236 ty 1 QQ-S-633 MIL-T-3520 MIL-T-5066 QQ-S-681, C1 1 QQ-S-681, C1 2 MIL-S-11310 5075 5077 QQ-W-409 MIL-S-15083 C1 B MIL-S-13852 MIL-S-7952 QQ-S-643 MIL-P-20167 C1 C MIL-S-7809 6354 5080 QQ-S-633 (Bar) MIL-S-20145 Gr N MIL-P-20167 C1 A QQ-S-633 QQ-W-461 MIL-T-5066 MIL-T-5066

1025

Fittings Bars Tubing Tubing Castings Castings Bars Tubing, Seamless Tubing, Welded Wire Casting Steel Disks Sheet and Strip Tubing Plate

Corten NAX AC 9115 1035

Plate, Sheet and Strip (High Str) Sheet, Plate, Bar, Billet, Bloom, Strip Steel, Carbon (Bars, Forgings, and Tubings) Ingot Plate Bar Wire (Carbon)

2-14

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 1035 (Continued)

FORM/COMMODITY Tubes Plate (Carbon) Forgings Tubes, Seamless Plate and Disk Plates (Marine Boiler) Plates (Marine Boiler) Shapes, Bar and Plate (Structural) Wire Sheet, Strip Forgings (Naval Ship Board) Plates and Disks (For artillery ammunition cartridge cases) Tubes

AMS

FEDERAL

MILITARY MIL-T-20141

QQ-S-635 MIL-S-16900 5082 MIL-S-3289 QQ-S-691 C1 B QQ-S-691 C1 C QQ-S-741 Gr A QQ-W-409 QQ-S-640 MIL-S-19434, C1 1 MIL-S-3289

MIL-T-11823 QQ-S-633 QQ-S-635 QQ-S-681, C1 1 QQ-W-409 MIL-S-11310 MIL-S-16974 MIL-T-4377 QQ-S-633 QQ-W-461 MIL-S-20145 Gr P QQ-S-635 QQ-S-640 MIL-S-303 MIL-S-3039 QQ-S-633 QQ-S-635 MIL-S-20137

1040

Bars Plate (Carbon) Castings Wire Bars Blooms, Billets, Bars and Slabs

1045

Tubes (Welded) Bars Wire (Carbon) Ingots Plate Sheets, Strip, Tubes, Seamless Strip Strip (For ammunition cartridge clips)

1050

Bars Plate (Carbon)

2-15

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 1050 (Continued)

FORM/COMMODITY Blooms, Billets, and Slabs (For Forgings) Bars, Billets, Blooms, Slabs, Castings Tubing, Seamless/ Welded

AMS

FEDERAL

MILITARY MIL-S-16788, C1 C5

5085

QQ-S-681 QQ-T-880 MIL-S-20145 Gr R MIL-S-10520 QQ-S-633 MIL-E-18193 (Ty 201) QQ-S-633 MIL-S-16410 comp 3 QQ-W-428 Ty 1 and 2 MIL-S-2839 MIL-S-16788, C1 C6 MIL-S-16974 MIL-S-10520 comp 3 QQ-S-640 MIL-S-8143

1055

Ingots Forgings (For Shell Stock) Bars Electrodes

1060

Bar Bars, and Wire Wire, Springs, Spring Blooms, Billets, Slabs Bars, Blooms, Billets, Slabs Forgings Sheet, Strip

1070-1075

Sheet, Strip Wire, Spring Steel Tool Washers Wire Bars Steel, Strip (SpringTime Fuse) Strip, Spring 5120 (1074) QQ-S-633 QQ-T-580 C1-W1-09 7240 5115 QQ-T-580 FF-W-84 C1 A QQ-S-633

MIL-S-12504 MIL-S-11713 comp 2

1080, 1086, 1090

Bars Steel, Tool Blooms, Billets, Slabs (For Forgings) Wire, Drawn Metal (Stitching, (Galvanized)

MIL-S-16788 C1 C8 MIL-W-6714

2-16

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 1080, 1086, 1090 (Continued)

FORM/COMMODITY Blooms, Billets, Bars, Slabs Wire, Comm Quality Wire, Carbon Spring, Music

AMS

FEDERAL

MILITARY MIL-S-16974

5110 5112 5132 QQ-W-470 QQ-S-633 QQ-W-428 MIL-S-11713 comp 3 QQ-W-470 5121 Strip 5122 Strip 7340 MIL-W-13604 MIL-S-7947 cond A MIL-S-7947 cond H MIL-S-8559 MIL-S- 16410 comp 1

1095

Bars Bars, Wire Wire, Spring Sheet, Strip Wire (High Carbon) Sheet, Strip Sheet, Strip Springs Wire, Spring (For small arms application) Blooms, Billets, Slabs Steel Bars, Round, Square and Flat for Forgings Strip Bars, Blooms, Billet and Slabs

MIL-S-16788 MIL-S-46033

MIL-S-17919 MIL-S-16974 5010

1112

Steel, Carbon, Bars Forging and Mechanical Tubing Bars

5010 5022

QQ-S-633

1117

Steel - Carbon, Bars, Forging and Mechanical Tubing Bars Bars Forgings

MIL-S-16124, C1 1, comp A 5022 QQ-S-633 MIL-S-10520 5024

1137

Steel - Carbon, Bars, Forging and Mechanical Tubing

2-17

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 1137 (Continued)

FORM/COMMODITY Bars Bars Tubing, Seamless

AMS 5024

FEDERAL QQ-S-633

MILITARY MIL-S-43 MIL-S-16124, C1 2

QQ-S-643 QQ-S-624 QQ-W-405 MIL-S-20145 QQ-S-624 QQ-W-405 QQ-S-629 QQ-S-624 QQ-S-629 QQ-W-405 MIL-S-20145 Gr V QQ-S-624 QQ-W-405 QQ-S-624 QQ-W-405 MIL-S-866 QQ-S-624 QQ-W-405 MIL-S-16974 QQ-S-624 QQ-S-405 MIL-S-1393 comp 2 6300 QQ-S-624 QQ-W-405 QQ-T-570 C1 1 6370 QQ-S-624 MIL-S-6758 MIL-S-7397 comp 1

2317

Bars Wire (Alloy)

2330

Ingots Bars Wire (Alloy) Tubing

2340

Bars Tubing Wire (Alloy) Ingots

2515

Bars Wire (Alloy)

3115

Bars Wire (Alloy) Bars, Billets (For carburizing)

3140

Bars Wire (Alloy) Bars, Blooms, Billets

3310

Bars Wire

3316 4037

Bars Bars, Wire Bar Wire

4050 4130

Steel, Tool Bars, Rods, Forgings (A/C Quality)

2-18

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 4130 (Continued)

FORM/COMMODITY Plate, Sheet Strip (A/C Quality) Bars, Blooms, Billets and Slabs Tubing, Seamless

AMS 6350 6351

FEDERAL

MILITARY MIL-S-18729 MIL-S-16974

6360 6361 6362 6371 QQ-S-626 QQ-S-627 QQ-W-405 QQ-S-624

MIL-T-6736 MIL-S-6731

Tubing, Welded Tubing, Mechanical Plate (Commercial Quality) Sheet, Strips Wire (Alloy) 4135 Bars Plate, Sheet, Strip Tubing, Seamless Tubing, Seamless Bars, Blooms Tubing, Seamless Tubing 17-22-A(V) 4137C0 Mellon 4140 Bar, Forging, Forging Stock 6303 6372 6365

MIL-S-18733 MIL-T-6735 cond N MIL-T-6735 MIL-S-16974

- Alternate designation: Unimuch UCX2, MX - 2, Rocoloy. XMDR-2, Sheet, Steel. Bars, Rods, Forgings, Plates (Commercial Grade) Tubing Bar, Blooms, Billets Wire (Alloy) QQ-W-405 QQ-S-624 6882 QQ-S-624 QQ-S-626

Specification: MIL-S-5626

6381 MIL-S-16974

4150

Bar Bar (For Small arms Weapons Barrels) Bar (Special Bar for AF Bullet Cores and Shot)

MIL-S-11595 MR MIL-S-12504 MR

2-19

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 52100

FORM/COMMODITY Bars, Forgings Tubing, Mechanical

AMS 6440 6441

FEDERAL

MILITARY MIL-S-7420

Ladish D-6-A - Alternate designation, D-6-A-V - and D-6-A-C. Nitralloy 135 Bar, Forging, Forging Stock (Nitriding) 6470 Bar and Forgings MIL-S-6709, comp A

Alternate designations, Nitralloy Type G, Modif ied and ASTM-A355-57T C1 A Nitralloy 4330 Bars and Forgings Stock (Mod) Nitralloy 4337 Bars, Forging Tubing, Seamless Wire (Alloy) Ingot 4340 Plate, Sheet and Strip Bar, Forging and Tubing Bar, Forging and Tubing Bar, Reforging Bar Bar, Forging and Tubing Strip and Sheet Bar, Rod, Plate and Sheet Wire (Alloy) Bars, Blooms, Billets 4335 (Mod) HyTuf 4615 Bars, Plates, Sheets and Strips Bar, Forging and Mechanical Tubing Bars 6418 QQ-S-624 QQ-W-405 MIL-S-16974 MIL-S-21515 MIL-S-7108 6428 QQ-S-627 MIL-E-21515 QQ-S-624 6359 6414 6415 MIL-S-5000 MIL-S-8844 C1 1 64126475 6413 QQ-W-405 MIL-S-20145 Gr U QQ-S-624 MIL-E-8699

2-20

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 4615 (Continued)

FORM/COMMODITY Wire Bars, Billets

AMS

FEDERAL QQ-W-405

MILITARY

MIL-S-866 MIL-S-7493 QQ-S-624 QQ-W-405 MIL-S-16974 6312 6317 QQ-S-624 QQ-S-624C Bars QQ-W-405 MIL-S-18731 QQ-S-624 6448 6450 QQ-W-428 comp D MIL-S-16410 comp 4 MIL-S-20145 Gr Z 6455 7301 QQ-S-627 MIL-W-22826 6270 QQ-S-624 (Bar) QQ-W-405 MIL-S-866 MIL-S-16974 5333 (8615 mod) 6272 QQ-S-624 (Bar) QQ-S-624 QQ-S-627 MIL-S-18731 MIL-S-8503 MIL-S-46033 MIL-S-8503 MIL-S-7493

4617 4620

Bars Bars Wire

4640

Bars, Blooms, Billets Bars Bars and Forgings Wire (Alloy)

6150

Sheet, Strip Bars Bar Bars, Forging Wire Wire, Spring Bars, Wire (Spring) Ingots Sheet, Strip (Springs) Springs (Highly Stressed) Sheet, Strip Wire

8615

Bars, Forgings, Tubing Wire (Alloy) Bars, Billets Bars, Blooms, Billets and Slabs Castings

8617

Bars, Forgings, Tubing Bars Bars Sheet and Strip

2-21

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 8617 (Continued) 8620

FORM/COMMODITY Wire Bars Bars, Forgings, Tubing Plates (Commercial Grade) Sheet and Strip Wire Bars, Blooms, Billets

AMS

FEDERAL QQ-W-405 QQ-S-624

MILITARY

6274 QQ-S-626 QQ-S-627 QQ-W-405

MIL-S-8690

MIL-S-16974 MIL-S-18728 MIL-T-6732 QQ-S-624 6280 6281 6530 6550 6355 MIL-S-16974 QQ-S-626 QQ-W-405 QQ-S-627 MIL-S-6050 QQ-S-624 MIL-S-16974 QQ-S-626 MIL-T-16690 QQ-W-405 6535 6282 MIL-T-6733 cond N MIL-S-6098 MIL-T-6732 cond N MIL-T-6734 cond N MIL-S-6050

8630

Plate, Sheet, Strip (A/C Quality) Tubing Bars Bars, Forgings Tubing Tubing, Seamless Tubing, Welded Sheet, Strip Bars, Blooms, Billets Slabs Plate (Commercial Grade) Wire (Alloy) Sheet, Strip (Hot Rolled) Bars, Rods, Forgings

8640

Bars Bars, Blooms, Billets Slabs Plate Tubing, Seamless Tubing Wire (Alloy)

8735

Tubing, Seamless Tubing, (Mechanical)

2-22

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 8735 (Continued)

FORM/COMMODITY Tubing, rods, bars and forging stock (A/C quality) Sheet, Strip and Plate Bars, Forgings Bars, Rods, Forgings

AMS

FEDERAL

MILITARY MIL-S-6098

6357 6320

MIL-S-18733 MIL-S-6098 MIL-S-6098

8740

Bars, Forgings Bars Bars, Forgings Plate, Sheet and Strip Tubing, Mechanical Plate (Commercial) Wire (Alloy) Bars, Rods, Forgings

6322 QQ-S-624 6325 6327 6358 6323 QQ-S-626 QQ-W-405

MIL-S-6049 cond C MIL-S-6049

MIL-S-6049 MIL-S-8844 C1 2/3 QQ-S-624 MIL-S-46033 QQ-W-474, comp E MIL-S-16410, comp 5 MIL-S-17919, C1 6 QQ-W-428 MIL-S-46033 QQ-S-624 QQ-S-627 6260 6265 QQ-W-405 6263 5358 5515 MIL-S-5059 QQ-S-624 (Bar)

9250 9620

Bars, and Reforging Stock Bars Bar Wire, Spring Bars, Wire (Spring) Steel, Strip

9262

Wire, Spring Bar Bars Sheet and Strip

9310

Bars, Forgings, Tubings Bar, Forgings and Tubing Wire (Alloy)

9315 Type 301 (30301)

Bars Casting Prec Invest (S) Sheet, Strip, Plate (ST)

2-23

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN Type 301 (30301) (Continued)

FORM/COMMODITY Sheet, Strip, Plate (1/4 H) Sheet, Strip, Plate (1/2 H) Sheet, Strip, Plate (Full H) Plate, Sheet, Strip Shape Wire, (Spring Temper)

AMS 5517

FEDERAL

MILITARY MIL-S-5059

5518 5519 QQ-S-766 5688 5636 5637 QQ-W-423 comp 502 QQ-S-763 CL 303 QQ-S-763 C1 302 QQ-S-763, C1 1 5516 7210 7228 FF-P-386 Type C

MIL-S-5059 MIL-S-5059

302 (30302)

Bars (CD to 100000 tensile) Bars (CD to 125000 tensile) Bars, Forgings Sheet, Strip Plate, Sheet, Strip Pins, Cotter Rivets (18CR 8N:) Steel, Stainless, Bar and Billets (Reforging Applications) Bars, Forgings

MIL-S-5059 comp 302 MIL-S-5059

MIL-S-862 C1 302

MIL-S-7720 5358 QQ-W-423 MIL-S-17509, C1 1 QQ-S-682 QQ-S-766 MIL-W-17481 7241 5640 5738 MIL-S-862 MIL-S-7720 5641 5642 FF-W-84 C1 C QQ-S-763

(60302)

Steel, Castings Wire, Annealed Castings Plate, Sheet, Strip Plate, Sheet, Strip Wire Lockwashers, Helical

303

Bar, Forging Bar Bar, Billets, Reforging Bars, Forgings Bar, Forging (Swaging) Bar, Forging

2-24

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 304

FORM/COMMODITY Tubing Tubing Castings Plate, Sheet, Strip Plate Plate, Sheet, Strip Castings, Precision Invest Castings, Sand Wire Bars, Forgings, Mechanical Tubing Bar Plate, Sheet, Strip Tubing, Bar, Forging Wire Tubing Bars, Forgings Tubing, Seamless Tubing, Welded

AMS 5566 5567

FEDERAL

MILITARY MIL-T-6845 MIL-T-8504 MIL-S-867 C1 1 MIL-S-4043 MIL-F-20138

QQ-S-766 5370 5371 5697 5647 QQ-S-763 5511 5639 5697 QQ-S-763 QQ-W-423 MIL-T-5695 QQ-S-763 5560 5565 5652 MIL-T-8506 MIL-S-8506 MIL-S-4043 MIL-S-7720 QQ-W-423

314

Bar, Forging, Mechanical Tubing and Rings Sheet, Strip, Plate

5522 5360 5361 5524 5573 5648 5698 QQ-W-423 5691 5649 QQ-S-763 MIL-S-7720 comp MCR QQ-S-766 MIL-S-867 (C1 III) MIL-S-5059 comp 316

316

Casting, Investment Casting, Sand, Centrifugal Sheet, Strip, Plate Tubing, Seamless Bar, Forging, Tubing Wire, Screen Wire Electrode, Coated, Welded Bar, Forging (Free Machining)

2-25

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 316 (Continued)

FORM/COMMODITY Wire Pipe, Seamless and Welded Bar, Billets, Reforgings

AMS

FEDERAL QQ-W-423

MILITARY

MIL-P-1144 MIL-S-862 5645 5510 QQ-S-766 5570 MIL-T-8606 T1, G321 MIL-T-8887 5576 5689 7211 5557 MIL-T-6737 QQ-S-763 MIL-T-8606 QQ-S-682 MIL-T-8808 5559 MIL-T-8606 7229 5646 QQ-S-763 C1 347 MIL-S-867 C1 II 5512 5363 MIL-S-17609 C1 II 5571 MIL-T-8606, Type 1, G347 MIL-T-8606 MIL-S-6721 Type CB + TA) (CB) MIL-T-6737, T 321 MIL-T-7880 QQ-S-763 C1 321 MIL-S-6721, comp T1

321

Bar, Forgings, Tubing Mechanical Plate, Sheet, Strip Plate, Sheet, Strip Tubing, Seamless Tubing, Welded, Thin Wall Tubing, Welded Tubing, Flexible Wire, Screen Pins, Cotter Tubing, Hydraulic Tubing, Welded Bar, Forgings Tubing Plate, Sheet, Strip Tubing, Hydraulic Tubing, Welded, Thin Wall

347

Tube Rivets Bars, Forgings, Tubing Castings Sheet, Strip Casting, Sand Casting Tubing, Seamless Tubing, Seamless, Welded Drawn

2-26

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 347 (Continued)

FORM/COMMODITY Tubing, Welded Tubing, Flexible Tubing, Hydraulic Tubing, Welded Plate, Sheet, Strip Tubing, Welded Bars, Forgings Plate, Sheet, Strip Castings Rods, Welding Plate, Sheet, Strip Tubes, Seamless (Marine Boiler Application) Tubes, Hydraulic Casting, sand and Centrif

AMS 5575

FEDERAL

MILITARY MIL-T-6737, Type 347 MIL-T-7880

5556 5558 QQ-S-682 MIL-T-6737 QQ-S-763 MIL-S-6721 MIL-S-17509, C1 2 MIL-R-5031 QQ-S-766 MIL-T-16286

MIL-T-8808 5362 5613 5612 QQ-S-763 C1 410

410 (51410)

Bars, Forgings, Mechanical Tubing Bars, Forgings, Mechanical Tubing (Ferrite Controlled Modified)

410-MO 410-MOD 410 410

Bars and Forgings Bars and Forgings, Mechanical Tubing Plate, Sheet and Strip Plate, Sheet and Strip (Ferrite Modif ied/ controlled)

5614 5609 5504 5505 QQ-S-766 C1 410

Change 1

2-27

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 410 (60410)

FORM/COMMODITY Casting Investment Casting, Sand Wire Bars Bars, and Billets (For Reforging)

AMS 5350 5351

FEDERAL

MILITARY

MIL-S-16933 C1 I QQ-W-423 comp 410 MIL-S-861 MIL-S-862

(51410)

Tubing, Seamless Tubing, Flexible

5591 MIL-T-7880 5615 QQ-S-763 C1 414 MIL-S-862 5610 5610 MIL-S-862 C1 6 MIL-S-862 C1 5 5620 5621 5621 5506 QQ-S-763 C1 420 QQ-S-766 C1 420 QQ-W-423 MIL-S-862 MIL-S-18732 5372 5682 5353 5630 5631 QQ-S-763, C1 440C QQ-S-763, C1 440A QQ-S-763, C1 431 QQ-S-763 C1 416 Se (Bar)

414

Bars, Forgings Bars

416 (51416F)

Bars Bars and Forgings Bars and Billets (Reforging)

420

Bars and Billets (For Reforging) Bars and Forgings (Free Mach)

(51420)

Bars and Forgings Bars Plate, Sheet and Strip Wire

431

Bars and Billets (For Reforging) Bars, Billets, Forgings, Tubing Castings, Sand Bars, Forgings

431 MOD 440 C 440 A

Castings, Precision Investment Bars and Forgings Bars and Forgings

2-28

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference

COMP/ALLOY DESIGN 440 F 14-4PH 15-7 MO

FORM/COMMODITY Bars and Forgings Castings, Investment Bar and Forging Plate, Sheet and Strip

AMS 5632 5340 5657 5520 5643 5342

FEDERAL QQ-S-763, C1 440F

MILITARY

17-4 PH

Bar Castings - Investment (Heat Treated 130,000 PSI) Castings - Investment (Heat Treated 150,000 PSI) Castings - Investment (Heat Treated) Electrode - Welding Castings - Investment

5343

5344 5827 5355 5528 5530 5644 5568 5369 5526 5527 MIL-S-25043

17-7 PH

Plate, Sheet and Strip Sheet and Strip (Precipitation Hardening) Bar and Forgings Tubing, Welded

19-9DL

Casting Sand (Solution Treated) Plate, Sheet and Strip Plate, Sheet and Strip (125000TS, Hot rolled, Stress Relieved) Bars (Up to 1.5 inch) Bars (Up to 1 inch) Bars and Forgings

5720 5721 5722 5723 5724 5729 5538

19-9DX

Bars, Forgings and Rings Bars (Up to 1 inch) Bars (Up to 1.5 inch) Plate, Sheet and Strip

Change 1

2-29

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 19-9DX (Continued)

FORM/COMMODITY Plate, Sheet and Strip, (Hot rolled and Stress Relieved 125,000TS) Bars, Forgings and Rings Bars (Up to 1 inch) Bars (Up to 1.5 inch)

AMS 5539

FEDERAL

MILITARY

5723 5724 5729 MIL-E-13080

19-9 MOD

Electrode, Welding, Covered (Armor applications) Bar Sheet and Strip (Cold rolled) Sheet and Strip (High Temp Annealed) Bar and Forgings Tubing, Seamless Wire, Welding Electrode, Coated Wire 5745 5540 5548

AM350

MIL-S-8840

5745 5554 5774 5775 5743 5368 5547 5549 5594 5781 5734 5735 MIL-S-8840

AM355

Bar Castings, Investment Sheet and Strip Plate (Solution Heat Treated) Plate (Equalized and Over-Tempered) Electrode, Coated Welding

A286

Bars, Forgings, Mechanical Tubing Bars, Forgings, Mechanical Tubing and Rings

2-30 Change 1

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN A286 (Continued)

FORM/COMMODITY Bars, Forgings, Mechanical Tubing and Rings (Sol Treated) Bars and Forgings and Mechanical Tubing (Annealed and Precip Treated) Rivets, Steel (Annealed 1650oF and partially precip treated)

AMS 5736

FEDERAL

MILITARY

5737

7235

Rene 41

Bars and Forgings (Solution Treated Bars and Forgings (Solution and Precip Treated) Plate Sheet and Strip (Solution Heat Treated)

5712 5713

5545

Greek Ascoloy

Castings, Investment Plate, Sheet and Strip Bars, Forgings, Mechanical Tubing and Rings

5354 5508 5616

Inconel 600

Wire, Annealed Plate, Sheet and Strip Bars, Forgings and Rings Tubing, Seamless

5687 5540 5665 5580 5542

QQ-W-390 MIL-N-6840 MIL-N-6710 MIL-T-7840 MIL-N-7786

42 Inconel Alloy X750

Sheet and Strip

Change 1

2-31

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN 42 Inconel Alloy X750 (Continued)

FORM/COMMODITY Bars and Forgings

AMS 5667

FEDERAL

MILITARY

Bars and Forgings Inconel X750 Wire, No 1 Temper Wire, Spring Temper Hastelloy C Castings, Prec Invest Casting, Sand Sheet Bar, Forgings Hastelloy W Bars and Forgings Wire Hastelloy X Castings, Alloy Prec Invest Sheet Bar and Forgings Wire HNM WASP Alloy Bars, Billet, Forging, Wire

5668 5698 5699 5388 5389 5530 5750 5755 5786 5390 5536 5754 5798

MIL-N-8550 Cond E JAN-W-562, C1 1 JAN-W-562, C1 2

MIL-N-18088

MIL-R-5031, C1 12

MIL-S-17759 NONE NONE NONE

MISC STANDARDS/SPECIFICATIONS - METAL PRODUCTS Steel: Chemical Composition and Hardenability Metal Test Methods Surface Passivation Corrosion Resistant Steel Parts QQP-35 MIL-STD-753 Fed Std 66 Fed Std 151

2-32 Change 1

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN

FORM/COMMODITY

AMS

FEDERAL

MILITARY

X-Ray Standards for Welding Electrode Qualif ication and Quality Conformance Test Welds Identification of Pipe, Hose and Tube Lines for Aircraf t, Missile Space Vehicles and Associated Support Equipment and Facilities Preparation of Test Reports Marking of Aircraf t and Missile Propulsion System Parts, Fabricated From Critical High Temp Alloys Procedures for Determining Particle Size, Distribution and Packed Density of Powdered Materials Alloy Designation System for Wrought Copper and Copper Alloys Inspection Radiographic Mechanical Tests for Weld Joints Qualification of Inspection Personal Magnetic Particle Alloy, Nomenclature and Temper Designation for Magnesium Base Alloys Tolerances for Copper and Copper Base Alloy Mill Products Continuous Identif ication Marking of Iron and Steel Identification Marking of Aluminum Magnesium and Titanium Continuous Identif ication Marking of Copper and Copper Base Alloy Mill Products FED-STD-146 MIL-STD-775 MIL-STD-1247

MIL-STD-831 MIL-STD-841

MIL-STD-1233

MIL-STD-455

MIL-STD-453 MIL-STD-418 MIL-STD-410 MIL-STD-409

FED-STD-183 FED-STD-184

FED-STD-185

Change 1

2-33

T.O. 1-1A-9

Table 2-2.

Specification Cross Reference - Continued

COMP/ALLOY DESIGN

FORM/COMMODITY

AMS

FEDERAL FED-STD-187

MILITARY

Identification of Pressed Bonds, Forms, Seams and Joints Sheet Metal Tolerance for Aluminum Alloy and Magnesium Alloy Wrought Products Heat Treatment of Steels (Aircraf t Practice) Process for Steel Mill Products Preparation for Shipment and Storage Tolerances for Steel and Iron Wrought Products

FED-STD-245

SAE-AMS-H-6875 MIL-STD-163 FED-STD-48

2-34

Change 4

T.O. 1-1A-9

2-74. GENERAL HEAT TREATING TEMPERATURES, COMPOSITION (CHEMICAL) AND CHARACTERISTICS OF VARIOUS STEEL AND STEEL ALLOYS. See supplement data for chemical symbols. 1010. Low Carbon steel of this grade is used for manufacture of such articles as safety wire, certain nuts, cable bushings and threaded rod ends, and other items where cold formability is the primary requisite. Heat treatment is frequently employed to improve machinability. Welding is easily accomplished by all common welding methods. COMPOSITION RANGE C% Mn% 0.08-0.13 0.3-0.6 P% 0-0.04 S% 0-0.5 Fe% Balance

Normalize: 1700oF, air cool. Anneal: 1600oF, furnace cool. Carburize: 1600oF, quench in water, oil, or brine.
CARBO-NITRIDING

Temp Time 1560 1650 2.5 2.5

HardCase Depth ness Cool 0.019 0.018 62 59 OQ OQ

Draw 350 350

For 1560F, use 35NH3d 25CH4 generator gas*. For 1650 use 38NH3 & 24CH4 *Gas - American Gas Assoc Class 302. 1022. Low Carbon. This steel is similar in content and heat treatment requirements to 1020. Typical applications are case hardened roller chains, bearing races, cam shaf ts, etc. COMPOSITION RANGE C% Mn% Si% P% S% Fe% 0.18-0.23 0.7-0.10 0-0.2 0-.04 0-.05 Balance FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1700oF, air cool. Anneal: 1600oF, furnace cool. Carburize: 1550oF to 1650oF, water quench. Tensile: 130,000 psi. Yield: 78,000 psi. 1025. Low Carbon. Typical applications are bolts, machinery, electrical equipment, automotive parts, pipe f langes, etc. With this steel no martensite is formed and tempering is not required. This material is not generally considered a carburizing type; however, it is sometimes used in this manner for larger sections, or where greater case hardness is needed. COMPOSITION RANGE C% Mn% 0.22-0.28 0.3-0.6 P% 0-0.04 S% 0-0.05 Fe% Balance

FORMS. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1650o-1750oF, cool in still air. Anneal: 1650oF. Harden: 1650o-1750oF, Quench in oil (minimum hardness) Water, and Brine (maximum hardness). 1015. Low Carbon. This material is similar in content and characteristics to 1010. Of low tensile value, it should not be selected where strength is required. COMPOSITION RANGE C% 0.13-18 Mn% 0.3-0.6 P% 0-0.04 S% 0-0.05 Fe% Balance

FORMS. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1650o-1750oF Anneal: 1600o-1650oF Harden: 1650o-1700oF Quench with water, oil, brine. 1020. Low Carbon. Because of the carbon range this metal has increased strength and hardness but reduced cold formability compared with the lowest carbon group. It f inds wide application where carburizing is required. It is suitable for welding and brazing. COMPOSITION RANGE C% 8-0.23 Mn% 0.3-0.6 P% 0-0.04 S% 0-0.05 Fe% Balance

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1600o-1700oF, furnace cool. Hardening: 1575o-1650oF, water quench. Carburize: 1650o-1700oF, water or brine quench. Tempering: 250o-400oF is optional. Tensile strength: hot rolled 67000, cold rolled 80000. Yield strength: hot rolled 45000, cold rolled 68000. This steel is readily welded by common welding

FORMS-SPECIFICATIONS. See specif ications Table 2-2. HEAT TREATMENT

2-35

T.O. 1-1A-9

methods. Temper: 1150oF for 70,000 psi. CORTEN Low Carbon, Low Alloy. This steel is not heat treatable, but in the annealed or normalized condition it is stronger than plain carbon steel, is easily formed, welded and machined. In addition, this alloy is 4-6 times more resistant to atmospheric corrosion than plain carbon steel. COMPOSITION RANGE C% 0-0.12 Cr% 0.30-1.25 Cu% Mn% 0.25-0.055 0.2-0.5 S% 0-0.05 Ni% 0-0.65

Stress relief anneal 900o-1150oF, air cool, 30 minutes to 6 hours. Typical room temperatures: tensile 76,500, yield 53,000. For arc welding, use low hydrogen electrodes E6015 (thin gauges) and E7015. For heliarc welding use drawn f iller wire of MIL-R-5032. Perform spot welding by pulsation method for heavier gauges; use post heat cycle for lighter gauges. 1035. Medium Carbon. This steel is selected where higher mechanical properties are needed since it may be further hardened and strenghtened by heat treatment or by cold work. Typical applications are gears, clutch pedals, f lywheel rings, crank shaf ts, tools and springs. COMPOSITION RANGE C% Q 0.32-0.38 Mn% 0.6-0.9 P% 0-0.04 S% 0-0.05 Fe% Balance

Si% 0.25-0.75

P% 0.07-0.15

Fe% Balance

HEAT TREATMENT Normalize: 1650oF, air cool. Anneal: 1550oF, furnace cool. Stress relief 1150oF, 1 hour per inch of maximum section thickness. This alloy cannot be hardened. Tensile strength, annealed or normalized 67,000 psi. Yield strength, annealed or normalized 47,000 psi. This alloy is readily welded by the usual gas and arc methods with complete freedom from air hardening. ASTM A233 or E60 electrodes are recommended for shielded arc welding. For gas welding, high strength welding rods such as ASTM A251, CA-25, are recommended. This steel may be resistance welded to itself or other resistance weldable ferrous alloys, using the same methods applied to plain carbon steel. NAXAC9115 Low Carbon, Low Alloy. This material is usually in the stress relieved condition. Moderate strength is maintained with high toughness up to approximately 800oF. Weldability is excellent and it machines better than carbon steels of the same tensile strengths. COMPOSITION RANGE C% 0.1-0.17 Mo% 0.15-0.25 P% 0-0.04 Cr% 0.5-0.75 Ni% 0-0.25 S% 0-0.04 Cu% 0-0.35 Si% 0.6-0.9 Fe% Balance Mn% 0.5-0.8 Zn% 0.05-0.15

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1575o-1650oF, cool in still air. Anneal: 1575o-1650oF, 1 hour per 1 of section, (Preheat) Temper at 900oF for 100,000 psi. Spheroidize: 1250o-1375oF. Harden: 1525o-1600oF, quench in water or oil. (Brine or caustic may also be used for quenching.) Weldability is very good by all common welding methods. Cold formability is poor, but hot formability is excellent. Tensile strength, hot rolled 85,000 psi, cold rolled 92,000 psi, yield strength, hot rolled 54,000 psi, cold rolled 79,000 psi, Brinill 183-201, respectively. 1040. Medium Carbon is selected where intermediate mechanical properties are needed and may be further hardened and strengthened by heat treatment or cold work. COMPOSITION RANGE C% Mn% Si% P% S% Fe% 0.37-0.44 0.6-0.9 0-0.2 0-0.04 0-0.05 Balance FORM-SPECIFICATION. See Specif ication Table2-2. HEAT TREATMENT

SPECIFICATIONS AMS 6354 6440 HEAT TREATMENT Anneal: 1625o-1650oF, furnace cool. Normalize: 1650o-1675oF, air cool. FORM Sheet, strip, plate. Wire.

Normalize: 1575o-1650oF, air cool. Anneal: 1550o-1625oF, furnace cool. (Tensile 79,000 psi, yield 48,000 psi annealed). Harden: 1500o-1575oF, water or oil quench. Temper: 1100o-1150oF, to obtain tensile 100,000 psi, yield 80,000 psi. For tensile 125,000 and yield 85,000 psi temper at 700oF. Suitable heat treatment is required to permit machining.

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T.O. 1-1A-9

1045. Medium Carbon. Forgings such as connecting rods, steering arms, axles, axle shaf ts and tractor wheels are fabricated from this steel. Not recommended for welding. COMPOSITION RANGE C% 0.43-0.5 Mn% 0.6-0.9 P% 0-0.04 S% 0-0.04 Fe% Balance

FORMS-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1550o-1650oF, air cool. Anneal: 1550o-1575oF. Harden: 1450o-1550oF, water or oil quench. Temper: 1250oF for 100,000 psi tensile, 1050oF for 125,000 tensile, 600oF for 150,000 tensile. 1060. High Carbon. See 1055 for application and characteristics COMPOSITION RANGE C% Mn% 0.55-0.65 0.6-0.09 P% 0-0.04 S% Fe% 0-0.05 Balance

FORMS-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1575o-1675oF, air cool. Anneal: 1550o-1600oF, furnace cool for maximum softness. Harden: 1475o-1550oF, quench, water or oil. Temper: 1100oF for tensile 100,000 psi, yield 65,000 psi. Temper: 1000oF for tensile 125,000 psi, yield 95,000 psi. 1050. Medium Carbon. This is a medium carbon type steel with high mechanical properties which may be further hardened and strengthened by heat treatment or by cold work. Application is similar to 1045. Not recommended for welding. COMPOSITION RANGE C% Mn% 0.46-0.55 0.6-0.9 P% 0-0.04 S% 0-0.05 Fe% Balance

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1525o-1625oF, air cool. Anneal: 1500o-1575oF (Tensile 104,000 psi, yield 54,000 psi annealed). Harden: 1450o-1550oF, water or oil quench. Temper: 1125oF for 130,000 tensile, 80,000 yield. Temper: 1025oF for 139,000 tensile, 96,000 yield. Temper: 925oF for 149,000 tensile, 99,000 yield. 1070. High Carbon. See 1055 for application and characteristics. In addition this alloy is used for f lat springs and wire form as coil springs. COMPOSITION RANGE C% Mn% 0.65-0.75 0.6-0.9 P% 0-0.04 S% 0-0.05 Fe% Balance

FORMS-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1550o-1650oF, air cool. Anneal: 1450o-1525oF, furnace cool (Tensile 90,000 yield 50,000 annealed.) Harden: 1475o-1550oF, oil or water quench. Temper: 1250oF for 100,000 psi tensile, 75,000 for yield. Temper: 1025oF for 125,000 psi tensile, 90,000 for yield. Temper: 700oF for 150,000 psi tensile, 114,000 for yield. 1055. High Carbon. Steels of this type (1060, 1070, 1080 are in same category) have similiar characteristics and are primarily used where higher carbon is needed to improve wear characteristics for cutting edges, as well as for manufacture of springs, etc. Not recommended for welding. COMPOSITION RANGE C% Mn% 0.50-0.60 0.6-0.9 P% 0-0.04 S% 0-0.05 Fe% Balance

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1525o-1625oF, air cool, retard cooling rate to prevent hardness. Anneal: 1500o-1575oF, furnace cool. Harden: 1450o-1550oF, water or oil quench (Preheat). Hot Working Temperature: 1550o-1650oF. Temper: 1250oF for 100,000 psi tensile. Temper: 1100oF for 125,000 psi tensile. Temper: 1000oF for 150,000 psi tensile. The high carbon content of this steel causes difficulties in arc or gas welding processes. Welding by the thermit process is satisfactory. Hot formality is very good at 1550o-1650oF. 1080. High Carbon. See 1055 for applications and characteristics. COMPOSITION RANGE

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T.O. 1-1A-9

C% Mn% 0.75-0.88 0.6-0.9

P% 0-0.04

S% 0-0.05

Fe% Balance

screws, but not for parts subjected to severe stresses and shock. COMPOSITION RANGE C% Mn% P% S% Fe% 0-0.13 max 0.7-0.9 0.07-0.12 0.16-0.23 Balance FORM-SPECIFICATION. See Specification Table 2-2. HEAT TREATMENT May be surface hardened by heating in cyanide at 1500o-1650oF, followed by single or double quench and draw. Preheat and soak at 1500oF to 1650oF and quench in oil or water; tempering is optional. Tensile strength hot rolled bars 65,000. Tensile strength cold drawn 83,000. 1117. Carbon (Free Cutting Steel). This material is used where a combination of good machinability and uniform response to heat treatment is needed. It is suited for fabrication of small parts which are to be cyanided or carbonitrided and may be oil quenched af ter case hardening heat treating. COMPOSITION RANGE C% 0.41-0.2 Mn% 1.0-1.3 P% S% Fe% 0-0.04 0.08-0.13 Balance

FORM-SPECIFICATION. See Specification Table 2-2. HEAT TREATMENT Normalize: 1550o-1650oF, air cool. Anneal: 1475o-1525oF (Tensile 120,000, yield 66,000 psi annealed). Harden: 1450o-1550oF, quench oil. Temper: 1200oF for 129,000 tensile, 87,000 yield. Temper: 1100oF for 145,000 tensile, 103,000 yield. Temper: 900oF for 178,000 tensile, 129,000 yield. 1095. High Carbon. See 1055 for applications. In addition these steels are used for f lat spring applications and in wire form as coil springs. COMPOSITION RANGE C% 0.9-1.03 Mn% 0.3-0.5 P% 0-0.04 S% 0-0.05 Fe% Balance

FORM-SPECIFICATION. See Specification Table 2-2. HEAT TREATMENT OIL QUENCH Normalize: 1550o-1650oF, air cool. Anneal: 1425o-1475oF (Tensile 98,000 psi, yield 52,000 psi annealed) furnace cool. To reduce annealing time, furnace cool to 900oF and air cool. Speroidize for maximum sof tness when required. Harden: 1425o-1550oF (oil quench). Temper: 1100oF for 146,000 psi tensile, 88,000 yield. Temper: 800oF for 176,000 psi tensile, 113,000 yield. Temper: 600oF for 184,000 psi tensile, 113,000 yield. WATER QUENCH Normalize: 1550o-1650oF, air cool. Anneal: 1425o-1475oF. Harden: 1425o-1500oF, quench with water. Temper: 1100oF for 143,000 psi tensile, 96,000 yield. Temper: 800oF for 200,000 psi tensile, 138,000 yield. Temper: 600oF for 213,000 psi tensile, 150,000 yield. 1112. Free Cutting. This steel is used as the standard for rating the machinability of other steels. It is easy to machine and resulting surface f inish is excellent. It has good brazing characteristics but is diff icult to weld except with the low hydrogen electrode E6015 (AWS). This and similar grades are widely used for parts for bolts, nuts,

FORM-SPECIFICATION. See Specification Table 2-2. HEAT TREATMENT Normalize: 1650oF, air cool. Anneal: 1575oF, furnace cool (Tensile 68,000 psi annealed) Harden: 1450oF, quench in water SINGLE QUENCH AND TEMPER Carburized 1700oF for 8 hours. Pot Cool Reheat to 1450oF. Quench in water. Temper at 350oF Case depth 0.045. Case hardness 65 RC. 1137. Carbon, Free Cutting. This steel is intended for those uses where easy machining is the primary requirement. It is characterized by a higher sulphur content than comparable carbon steels, which result in some sacrif ice of cold forming properties, weldability and forging characteristics. COMPOSITION RANGE C% Mn% P% S% Fe% 0.32-0.39 1.35-1.65 0-0.04 0.08-0.13 Balance

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T.O. 1-1A-9

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1600o-1700oF, air cool. Anneal: 1400o-1500oF, furnace cool. Harden 1525o-1575o, oil or water quench. TYPICAL STRENGTH OF OIL QUENCHED Temper: 1100oF for tensile 100,000 psi, yield 80,000 psi. Temper: 825oF for tensile 125,000 psi, yield 100,000 psi. TYPICAL STRENGTH OF WATER QUENCHED Temper: 1100 F for tensile 105,000 psi, yield 90,000 psi. Temper: 975oF for tensile 125,000 psi, yield 100,000 psi. Tensile strength: 85,000 psi, yield 50,000 psi in annealed condition. 2317. Nickel Alloy. These specif ications cover steel castings for valves, f langes, f ittings and other pressure containing parts intended principally for low temperature parts. COMPOSITION RANGE C% Mn% P% S% Si% Ni% Fe% 15-0.2 0.4-0.6 0.04 0.04 0.2-0.35 3.25 Balance FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1600 -1700 F, air cool Anneal: 1500o-1550oF Harden: 1375o-1525oF Carburize: 1650o-1700oF, reheat to 1450oF to 1550oF, temper at 250o-300oF. WATER QUENCH Temper: 1100oF for tensile 100,000 psi, yield psi 83,000. Temper: 875oF for tensile 125,000 psi, yield psi 100,000. Temper: 750oF for tensile 150,000 psi, yield psi 124,000. OIL QUENCH Temper: 1025oF for tensile 100,000 psi, yield psi 83,000. Temper: 850oF for tensile 125,000 psi, yield psi 88,000. Temper: 650oF for tensile 150,000 psi, yield psi 108,000. This steel may be welded by common welding procedures.
o o o

2330. Nickel Alloy. This is a heat treatable steel which develops high strength and toughness in moderate sections. It is used in highly stressed bolts, nuts, studs, turnbuckles, etc. COMPOSITION RANGE C% Mn% 0.28-0.33 0.6-0.8 Ni% 3.25-0.75 Fe% Balance P% 0-0.04 S% Si% 0-0.04 0.2-0.35

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1600oF, preheat, cool in air. Anneal: 1425o-1600oF, furnace cool. Harden: 1400o-1500oF. Quench with oil. Temper: 1200oF-1250oF for tensile 100,000 psi, yield 90,000 psi. Temper: 900oF for tensile 140,000 psi. Temper: 700oF for 178,000 psi. WATER QUENCH 700oF 900oF 1100oF 190,000 psi 150,000 psi 124,000 psi

2340. Nickel Alloy. This metal is similar to 2330, but has greater strength. It is an oil hardening steel. COMPOSITION RANGE C% Mn% 0.38-0.43 0.7-0.9 P% 0-0.04 S% Si% 0-0.04 0.2-0.35

Ni% 3.25-3.75 FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1600o-1700oF. Anneal: 1450o-1600oF. Harden: 1400o-1550oF, quench in oil. Temper: 1100oF for 125,000 psi tensile, 105,000 psi yield. Temper: 900oF for 150,000 psi tensile, 132,000 psi yield. Temper: 800oF for 182,000 psi tensile, 164,000 psi yield. 2515. Nickel Alloy. This steel is quite similar to SAE 2512 and 2517, both in composition and response to heat treatment. COMPOSITION RANGE

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T.O. 1-1A-9

C% Mn% 0.12-0.17 0.4-0.6 Ni% 4.75-5.25

P% 0-0.04

S% Si% 0-0.04 0.2-0.35

Fe% Balance

3140. Nickel Chrome Alloy. This is a medium deep hardening steel capable of developing good strength and toughness when oil quenched. COMPOSITION RANGE C% Mn% P% S% Si% 0.37-0.45 0.6-0.95 0-0.04 0-0.04 0.2-0.35 Ni% Cr% Fe% 1.0-1.5 0.5-0.8 Balance FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1550o-1700oF Anneal: 1475o-1550oF (Tensile 94,000 psi, yield 66,000 psi annealed). Harden: 1475o-1550oF, oil quench. Temper: 1200oF for tensile 125,000 psi, yield 105,000 psi. Temper: 1000o for Tensile 14,000 psi, yield 125,000 psi. Temper: 800oF for Tensile 184,000 psi, yield 178,000 psi. Temper: 700oF for Tensile 200,000 psi. 3310. Nickel - Chromium Alloy. This steel has execeptionally high hardenability and is well suited for heavy parts which must have high, surface hardness combined with high and uniform properties when heat treated. It is commonly used in case hardened gears, pinions, etc. It is similar to Krupp Nickel Chromium except it contains more nickel. COMPOSITION RANGE C% 0.08-0.13 Cr% 1.4-1.75 Mn% 0.45-0.6 P% 0-0.025 Si% Ni% 0.2-0.35 3.25-3.75 S% 0-0.25 Fe% Balance

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1650o-1750oF Anneal: 1500oF Quench: 1425o-1525oF, oil quench. Temper: 1200oF for tensile 104,000, yield 80,000 psi. Temper: 900oF for tensile 125,000, yield 106,000 psi. Temper: 700oF for tensile 152,000, yield 125,000 psi. WATER QUENCH Temper: 1100oF for 116,000 psi. Temper: 900oF for 138,000 psi. Temper: 700oF for 165,000 psi. 3115. Steel Nickel Chromium Alloy. COMPOSITION RANGE C% 0.11-0.2 Si% 0.18-0.37 Mn% 0.37-0.63 Ni% 1.05-1.45 P% 0-0.048 Cr% 0.52-0.78 S% 0-0.058 Fe% Balance

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1625o-1725oF Anneal: 1550o-1600oF Harden: 1425o-1525oF, with oil. Temper: 300oF for tensile, 125,000 psi, yield 86,000 psi. CORE PROPERTIES 3115 Box cooled 1425oF 3120 3115 Reheated 1475oF 3120 3115 Oil Quenched 1525oF 3120 DRAW TEMP 300oF 300oF 300oF 300oF 300oF 300oF TENSILE KSI 125 155 125 155 125 155 YIELD KSI 88 115 86 115 86 110

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1600o-1700oF, air cool. Anneal: 1475o-1575oF, furnace cool to 700oF, air cool. Quench: 1500oF-1550oF, 0il, Cool Slowly Carburize: 1700oF, for 8 hours, reheat to 1500oF, oil quench, temper 300oF, for tensile 170,000 psi, yield 142,000 typical for 1/2 diameter rod. PSI. Effective case depth 0.05. 4037. Molydenum Alloy. This steel is used for such parts as gears, shaf ts, leaf and coil springs and hand tools. COMPOSITION RANGE

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C% 0.35-0.4 Mo% 0.2-0.3

Mn% P% S% Si% 0.7-0.9 0-0.04 0-0.04 0.2-0.35 Fe% Balance

Temper: 1100oF for 125,000 tensile psi. Temper: 1050oF for 150,000 tensile psi. Temper: 850oF for 180,000 tensile psi. 17-22A(V). Structural (Ultra High Strength) Low Alloy. This is a high strength, heat resistant steel with a 1000 hour rupture strength of 1100oF (30,000 psi tensile strength). It is used in turbine rotors, and for components of guided missiles, in which high temperatures are encountered for short periods. COMPOSITION RANGE C% 0.25-0.3 Cr% 1.0-1.5 Ce% 0-0.5 Mn% Mo% 0.6-0.9 0.4-0.6

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Anneal: 1500o-1600oF, furnace cool. Normalize: 1600oF, cool in air. Harden: 1550oF, quench in oil. Temper: 1225oF for 100,000 psi. Temper: 1100oF for 125,000 psi. Temper: 975oF for 150,000 psi. 4130. Chromium - Molydenum Alloy. Typical usages for this material is in the manufacture of gear shaf ts axles, machine tool parts, etc. COMPOSITION RANGE C% Mn% P% S% Si% 0.26-0.35 0.3-0.75 0-0.04 0-0.05 0.15-0.35 Cr% 0.75-1.2 Mo% 0.08-0.25 Ni% 0-0.25 Fe% Balance

Ni% Si% V% P% S% 0-0.5 0.55-0.75 0.75-0.95 0-0.04 0-0.04 Fe% Balance FORM-SPECIFICATION. AMS6303 Bar, forging, forging stock. HEAT TREATMENT Normalize: 1700o-1850oF, hold for 1 hour per inch of thickness, air cool. Larger sections may be fancooled in order to accelerate cooling. All sections should be so placed as to provide access of air to all surfaces. Anneal: 1450oF, hold at this temperature 1 hour for each inch of section thickness. Cool down 20oF per hour to 1100oF, then air cool. Oil Quenching requires prior heating to 1750oF, for each inch of thickness. Annealed bars, 1 inch diameter have tensile strength 87,000 yield strength, 67,800. Pancake forgings normalized at 1800oF + tempering at 1225oF, 6 hours have tensile strength 142,000, yield strength 126,500, hardness BHN 311-321. This alloy may be welded by any of the commercial methods in use. A welding rod corresponding to 17-22A(S) is available. When pre-heating is required depending upon size of section and type of welding procedure, a temperature of 600oF is generally used. Post heating or stress relief is recommended. 4137CO. This ultra-high strength steel has yield strength in the 230,000-240,000 psi range. It forms and welds readily. It was developed for use in high performances solid rocket motor cases. Alternate designations are Unimach VC X 2, MX2, and Rocoloy. Machining characteristics are similar to 4140. COMPOSITION RANGE C% 0.39-0.4 Cr% 0.95-1.2 Co% 0.98-1.23 Mn% 0.6-0.79

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Harden (austenitize): 1550o-1600oF, water quench, for oil quench 1575o-1625oF. Austenitize Castings:1600o-1650oF,1 hour, oil quench. Spherodize: 1400o-1425oF, 6-12 hours, furnace cool. Temper: 1150oF for tensile 132,000, yield 122,000. Temper: 1025oF for tensile 151,000, yield 141,000. Temper: 950oF for tensile 163,000, yield 159,000. SAE Steels: 8630 and 8730 have similar characteristics. Annealed: 1525o-1585oF (tensile 80,000 psi, yield 57,000 psi annealed), furnace cool. Normalize: (cast) 1900oF, 1 hour, A.C. Hardening: 1550o-1650oF, quench in oil. Normalize: (wrought) 1600o-1700oF, air cool. 4135. Chromium Molydenum Alloy. COMPOSITION RANGE C% 0.32-0.39 Mo% 0.15-0.25 Mn% 0.6-0.95 P% 0-0.04 Si% 0.2-0.35 S% 0-0.04 Cr% 0.8-1.15 Fe% Balance

HEAT TREATMENT Normalize: 1600o-1700oF, air cool. Anneal: 1525o-1575oF, furnace cool. Harden: 1550o-1625oF, quench in oil.

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Mo% 0.22-0.35 S% 0-0.012

Si% 0.97-1.19 Fe% Balance

V% 0.14-0.16

P% 0-0.015

Anneal: 1550o-1600oF furnace cool. Harden: 1550o-1600oF 30 minutes, oil quench. Spheroidize: 1400o-1425oF furnace cool. Temper 4 hours to obtain desired strength. See table below. DRAW TEMPERATURES 1300oF - 100,000 psi 1175oF - 120,000 to 140,000 psi 1075oF - 140,000 to 160,000 psi 950oF - 160,000 to 180,000 psi 850oF - 180,000 to 200,000 psi 725oF - 200,000 to 220,000 psi SAE 4330 V Mod. This steel is 4330 improved by the addition of vanadium, and is primarily used heat treated to a tensile strength between 220 and 240 KSI. It is highly shock resistant and has better welding characteristics than higher carbon steels. CHEMICAL COMPOSITION C% Mn% Si% P% Si% Cr% 0.28-0.33 0.75-1.00 0.20-0.35 0.040 0.040 0.75-1.00 Ni% 1.65-2.00 Mo% 0.35-0.50 V% 0.05-0.10 Fe% Balance

SPECIFICATIONS: None FORMS: Sheet, strip, plate, bar, forging, wire. HEAT TREATMENT Normalize: 1750oF, 30 minutes, air cool. Spheroidize: Anneal: 1420o-1460oF, 2 hours, fast cool to 1235o-1265oF, hold 14 to 24 hours, air cool. Resulting hardness RB95 maximum. Intermediate stress relieve to restore ductility of formed parts, 1250oF for 10 minutes, air cool. Stress relieve af ter welding 1250oF, 30 minutes minimum. Austenitize: 1700oF for sections less than 1/2 inch 1725oF for sections larger than 1/2 inch, 20 minutes minimum to 1 hour maximum per inch thickness, oil or salt quench at 400oF. Maximum time in salt 12 minutes. Double temper 540o-560oF for two consecutive 2 hour periods with intermediate cooling to room temperature. Weldability characteristics are good using the Tungsten-arc-inert-gas process. 4140. Medium Carbon Chromium - Molybdenun (Nitriding Grade). This steel is widely used where the higher strength and higher hardenability of 4340 is not required. It can be nitrided. C% Mn% P% S% Cr% 0.38-0.43 0.75-1.0 0-0.040 mx 0-0.040 mx 0.80-1.1 Mo% 0.15-0.25 Si% 0.2-0.35 Fe% Balance

HEAT TREATMENT Normalize: 1600o to 1700oF, air cool. Temper: normalized condition for machinability 1250oF maximum. Full anneal at 1525oF to 1575oF furnace cool or cool in ash or lime. Austenitize: 1550o to 1600oF 15 minutes per inch thickness, oil quench 75o to 140oF. Temper: 180 to 200 KSI, 950o to 110oF, 4 hours. Temper: 200 to 220 KSI, 750o to 950oF, 4 hours. Temper: 220 to 240 KSI, 600o to 750oF, 4 hours. 4150. Chromium-Molybdenun. This metal is used for such items as gears, shaf ts, pistons, springs, axles, pins, connecting rods.

SPECIFICATIONS
TYPE 4140

AMS 5336 5338 6378 6379 6381 6382

FORM Precision Investment Castings Precision Investment Castings Bars Bars Heavy Wall Tubing Bars, Forgings, Forgings, Stock

MILITARY

COMPOSITION RANGE C% Mn% P% S% Si% Cr% 0.48-0.53 0.75-1.0 0-0.040 0-0.04 0.2-0.35 0.8-0.12 Mo% 0.18 - 0.25 Fe% Balance

FORMS-SPECIFICATIONS. See Specification Table 2-2. MIL-S5626 HEAT TREATMENT Normalize: 1550o-1650oF Anneal: 1450o-1525oF Harden: 1475o-1525oF, oil quench Temper: 1200oF for tensile 128,000 yield 116,000 Temper: 1100oF for tensile 150,000 yield 135,000

HEAT TREATMENT Normalize: 1600o-1650oF (air cool) minimum 1 hour.

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Temper: 950oF for tensile 180,000 yield 163,000 Temper: 800oF for tensile 200,000 yield 186,000 521000. High Carbon, High Chromium Alloy. This steel is used for anti-friction bearings and other parts requiring high heat treated hardness of approximately Rockwell C60, toughness and good wear resistance qualities. It is best machined in the spheroidized annealed condition. COMPOSITION RANGE C% Cr% Mn% Si% S% P% 0.95-1.1 1.3-1.6 0.25-0.45 0.2-0.35 0-0.025 0-0.025 Fe% Balance FORMS-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1650o-1700oF air cool Anneal: 1250o-1340oF hold 5 hours. Heat to 1430o-1460oF, at 10oF per hour, hold 8 hours. Cool to 1320oF at 10oF per hour. Cool to 1250oF at furnace rate and air cool. Spheroidize: Slow cool (about 5oF per hour) following austenitizing by extended heating at a temperature near the ACM point or by isothermal transformation at 1275oF following austenitizing. Harden: Quench in water from 1425oF-1475oF or quench in oil from 1550o-1600oF, then temper to desired hardness. The Rockwell hardness at various temperatures is listed below: Temper: Temper: Temper: Temper: Temper: 400oF, RC60 600oF, RC55 800oF, RC48 100oF, RC40 1200oF, RC28

Anneal: 1500o-1550oF, cool down at 50oF per hour to 1000oF. Normalize: 1600o-1650oF, 30 minutes, air cool. Austenitize: 1550o-1575oF, 30 minutes, oil quench. Sections 1 inch or less in cross sections may be air cooled. Temper: 300o-1275oF, time and temperature depend on hardness desired. Stress relieve: 1000o-1250oF one to two hours, air cool.
TYPE LADISH D-6-A

FORM Condition

UP TO 1 THICK BAR Vacuum remelt by consumable electrode process. Normalize 1650oAC 1550oF, air cool + 600oF temper.

Tensile Yield

282,000 psi 255,000 psi

Nitralloy 135 Mod. Steel ultra high strength (Nitriding Grade). This alloy is well suited for case hardening by nitriding. This process produces a case of extreme hardness without appreciably changing core tensile strength or yield strength. It is also readily machined. Af ter nitriding it may be used where high resistance to abrasion and mild corrosion resistance are required. COMPOSITION RANGE A1% C5 Cr% Mn% Mo% Si% 0.95-1.3 0.38-0.43 1.4-1.8 0.5-0.7 0.3-0.4 0.2-0.4 P% 0-0.04 S% 0-0.04 Fe% Balance

LADISH D-6-A. Low Alloy High Strength. This alloy is suitable for hot work die applications and structural material in aircraf t and missiles. It may be heat treated to strength levels up to 300,000 psi, and at 240,000 has excellent toughness. At strength levels below 220,000 psi it is suitable for elevated temperature applications below 900oF. It may readily be welded and cold formed in the annealed or spheroidized condition. It also can be temper straightened. COMPOSITION RANGE C% Cr% Mn% Mo% Ni% Si% V% Fe% 0.46 1.0 0.75 1.0 0.55 0.22 0.05 Balance SPECIFICATION. None. FORMS. Available in most wrought forms and forgings. HEAT TREATMENT

SPECIFICATIONS
TYPE NITRALLOY 135 MOD

AMS 5470

FORMS Plates, Tubing, Rods, Bar, forgings stock.

MILITARY MIL-S6701

HEAT TREATMENT Anneal: 1450oF, 6 hours, furnace cool. Normalize by slowly heating to 1790o-1810oF, air cool. Austenitize: 1700o-1750oF. Oil quench sections less than 2 inches thick. Temper: 1000o-1300oF 1 hour minimum per inch of thickness.

Change 1

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(NOTE: Temper 50oF minimum above nitriding temperatures). Nitride: 930o-1050oF.

TYPE NITRALLOY 135 MOD

FORM Condition

BAR 1725oF, oil quench sections less than 3 inches, water quench sections greater than 3 inches temper 1200oF, 5 hours. LESS THAN 1 1/2 inches 135,000 psi 100,000 psi 1 1/2 to 3 inches 3 to 5 inches

or lime. Harden: 1475o-1550oF, oil quench. Spheroidize Anneal: 1425oF, 2 hours, then furnace cool to 1210oF, hold 8 hours, furnace cool or air cool. Stress relief parts af ter straightening, machining, etc. Temper: 1100oF for tensile 150,000 yield, 142,000. Temper: 900oF for tensile 190,000, yield, 176,000. Temper: 725oF for tensile 220,000, yield, 200,000. Temper: 400o-500oF for tensile 260,000, 2 hours per thickness, 6 hours minimum. Parts heat treated to 260,000-280,000 psi tensile and subsequently subjected to grinding, machining or straightening should be tempered to 350o-400oF, 4 hours minimum. Temperature should not exceed tempering temp or reduce the tensile strength below 260,000 psi. Austenitize 1475o-1575oF, 15 minutes for each inch of thickness. Normalize, welded or brazed parts before austenitizing. Cool after austenitizing. To heat treat for regular machining, normalize or austenitize, then heat to 1200oF (maximum 1250oF) for 15-20 hours. Resulting hardness should be 229-248 BHN. Austenitize: 1575o-1625oF, oil quench. Tempering range is limited to 400o-600oF preferably no higher than 550oF. Temper: 600oF for 230,000 psi tensile, 194,000 psi yield. Temper: 550oF for 234,000 psi tensile, 193,000 psi yield. Temper: 500oF for 235,000 psi tensile, 191,000 psi yield. Temper: 400oF for 239,000 psi tensile, 183,000 psi yield. This alloy is easily welded by conventional methods using low hydrogen electrode of similar composition. 4615. Steel Nickel Molybdenum Alloy. This is a high grade carburizing steel for use where reliability and uniformity are required. COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.13-0.18 0.45-0.65 0-0.04 0-0.04 0.2-0.35 1.65-2.0 Mo% 0.2-0.3 Fe% Balance

SIZE DIA

Tensile Yield

125,000 psi 90,000 psi

110,000 psi 85,000 psi

In welding the major problem to avoid is loss of aluminum and chromium in the weld area, the loss of which would prevent subsequent nitriding. 4337, 4340 Steel Nickel - Chromium Molybdenum Alloy. These two alloys are similar except that carbon content differs slightly. The carbon content of 4337 is minimum 0.35%, maximum 0.4%, good strength, high hardenability and uniformity are characteristics. It can be heat treated to strength values within a wide range. At 260,000 to 280,000 psi tensile this steel has been found superior to other common low alloy steels as well as some of the recently developed more complex low alloy steels. It possesses fair formability when annealed and may be welded, by special processes, which require strict control. No welding shall be performed on this alloy heat treated above 200,000 psi unless specif ically approved by design engineer. COMPOSITION RANGE C% Mn% Si% P% S% Cr% 0.38-0.43 0.65-0.85 0.2-0.35 0-0.04 0-0.04 0.7-0.9 Ni% Mo% Fe% 1.54-2.0 0.2-0.3 Balance FORMS-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1600 -1700 F, 1 hour of maximum thickness, air cool. Temper, normalize condition for improved machinability 125oF maximum. Anneal: 1475o-1575oF, furnace cool or cool in ash
o o

HEAT TREATMENT Normalize: 1675o-1725oF Anneal: 1575o-1625oF Harden: 1425o-1550oF oil quench. Carburize: 1425o-1550oF

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Where case hardening is paramount, reheat to 1425o-1475oF quench in oil. Tempering 250o-350oF is optional. It is generally employed for partial stress relief and improved resistance to cracking from grinding operation. 4620. Steel Nickel Molybdenum Alloy. This is a medium hardenability case steel. Its hardenability characteristics lie between that of plain carbon steel and the high alloy carburized steel. It may be used for average size case hardened automotive parts such as gears, piston pins, crackshaf ts, etc. COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.17-0.24 0.45-0.65 0-0.04 0-0.04 0.2-0.35 1.65-2.0 Mo% 0.2-3.0 Fe% Balance

and small distortion in heat treatment. Its application is primarily gears, spline shaf ts, hand tools, and machine parts. COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.38-0.43 0.6-0.8 0-0.04 0-0.04 0.2-0.35 1.65-2.0 Mo% 0.2-0.3 Fe% Balance

FORMS-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1600o-1750oF Anneal: 1450o-1550oF Quench: 1450o-1550oF, oil quench, agitated oil. Temper: 1200oF for 100,000 psi. Temper: 1100oF for 120 to 140,000 psi. Temper: 1000oF for 140 to 160,000 psi. Temper: 900oF for 160 to 180,000 psi. Temper: 800oF for 180 to 200,000 psi. Temper: 700oF for 200 to 220,000 psi. 6150, 6152. Chromium Vanadium Alloy. These two steels are essentially the same, differing only in the amount of Vanadium. Alloy 6152 contains a minimum of 0.1% Vanadium. Typical usages are for f lat springs under 1/8 inch thick, cold formed, and 1/8 inch and over hot formed; oil quenched, and drawn at 725o-900oF to 44-48 or 48-52 RC, and for coil springs over l/2 inch diameter with same heat treatment. It is also used for valve springs, piston rods, pump parts, spline shaf ts, etc. COMPOSITION RANGE C% Mn% P% S% Si% Cr% 0.48-0.53 0.7-0.9 0-0.04 0-0.04 0.2-0.35 0.8-1.1 V% 0.15 min Fe% Balance

HEAT TREATMENT Normalize: 1650o-1750oF Anneal: 1550o-1600oF Quench: (High temperature) 1550oF Quench: (Low temperature) 1425oF Carburize: 1650o-1700oF. Recommend practice for maximum case hardness: Direct quench from pot. (1) Carburize: at 1700oF for 8 hours. (2) Quench: in agitated oil. (3) Temper: at 300oF Case depth: 0.075. Case hardness: RC62 Single Quench and Temper: (1) Carburize: 1700oF for 8 hours. (2) Pot cool. (3) Reheat: 1500oF. (4) Quench: in agitated oil. (5) Temper: 300oF. Case depth: 0.075. Case hardness: RC62 Recommended practices for maximum core toughness: Direct quench from pot. (1) Carburize: 1700oF for 8 hours. (2) Quench: in agitated oil. (3) Temper: 450oF. Case depth: 0.06 Case hardness: RC58 Single Quench and Temper: (1) Carburize: 1700oF for 8 hours. (2) Pot Cool. (3) Reheat: to 1500oF (4) Quench: in agitated oil. (5) Temper: 450oF. Case depth: .065 Case hardness: RC59 4640. Steel Nickel Molybdenum. This steel has excellent machinability at high hardness levels,

FORM-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1625o-1750oF, furnace cool. Anneal: 1500o-1600oF. (Tensile psi 90,000 yield 58,000 psi annealed.) Harden: 1550o-1600oF, oil quench. Temper: 1100oF for tensile psi 150,000 yield psi 137,000 psi. Temper: 800oF for tensile psi 210,000 yield psi 194,000 psi. Spheroidized annealed to 183-241 BHN = 45% 8615. Steel-Ni-Cr-Mo Alloy. This is a triple alloy case-hardening steel with medium hardenability.

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It is primarily used for differential pinions, engine pins, gears etc. COMPOSITION RANGE C% Mn% P% S% Si% Ni% Cr% 0.13-0.18 0.7-0.9 0-.04 0-0.04 0.2-0.3 0.4-0.6 0.4-0.6 Mo% 0.15-0.25 Fe% Balance

FORMS-SPECIFICATIONS. See Specification Table 2-2. HEAT TREATMENT Normalize: 1600o-1750oF. Anneal: 1575o-1625oF. CARBURIZING: For maximum case hardness: Direct quench from pot. (1) Carburize: 1700oF for 8 hours. (2) Quench: in agitated oil. (3) Temper: 300oF. Case depth: 0.075. Case hardness: RC64. Single Quench and temper: (1) Carburize: 1700oF for 8 hours. (2) Pot cooled. (3) Reheat: to 1550oF. (4) Quench: in agitated oil. (5) Temper: 300oF. Case depth: 0.075 Case hardness: RC64 Recommended practices for maximum core toughness. Direct quench from pot. (1) Carburize: 1700oF for 8 hours. (2) Quench: in agitated oil. (3) Temper: 450oF. Case depth: 0.050 Case hardness: RC58 Single Quench and Temper. (1) Carburize: 1700oF for 8 hours. (2) Pot cool. (3) Reheat: to 1500oF. (4) Quench: in agitated oil. (5) Temper: 450oF. Case depth: 0.076. Case hardness: RC61. 8630. Steel Ni-Cr-Mo Alloy This steel has characteristics very similar to 4130. It is used for aircraf t engine mounts, and other aircraf t parts due to good properties when normalized in light sections, and its air hardening af ter welding. COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.28-0.33 0.7-0.9 0-0.04 0-0.04 0.2-0.35 0.4-0.7 Cr% 0.4-0.6 Mo% 0.15-0.25 Fe% Balance

FORMS-SPECIFICATIONS. See Specification Table 2-2. HEAT TREATMENT Psuedo-Carburize 1650o-1700oF, box cool, reheat 1550oF, oil quench. Temper: 300oF for tensile 100,000 psi yield 72,500 psi. Normalize: 1650o-1725oF. Anneal: 1575o-1650oF. Harden: 1475o-1575oF. 8617. Steel Ni-Cr-Mo Alloy. This steel is very similar to 8615, but develops somewhat greater strength. COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.15-0.2 0.7-0.9 0-0.04 0-0.04 0.2-0.35 0.4-0.7 Cr% 0.4-0.6 Mo% 0.15-0.25 Fe% Balance

FORM-SPECIFICATIONS. See Specification Table 2-2. HEAT TREATMENT Normalize: 1650o-1725oF Anneal: 1575o-1650oF. Harden: 1474o-1575oF Carburize: 1700oF for 8 hours, oil quench. Draw at 300oF Tensile: 128,000 psi yield 94,000 psi. 8620. Ni-Cr-Mo-Alloy. This steel is similar to 8615 and 8617 though stronger. It is used for ring gears, transmission gears, cam shaf ts and for good core properties with high surface hardness af ter case hardening. It is also used in the heat treated condition as chain, at about 100,000 psi yield strength. It is classed as medium hardenable. COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.18-0.23 0.7-0.9 0-0.04 0-0.04 0.2-0.35 0.4-0.7 Cr% 0.4-0.6 Mo% 0.15-0.25 Fe% Balance

FORMS-SPECIFICATIONS. See Specification Table 2-2. HEAT TREATMENT Normalize: 1550o-1650oF. Anneal: 1500o-1550oF (Tensile 90,000 psi, tensile

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60,000 annealed), furnace cool. Harden: 1500o-1575oF, oil or water quench. Temper: 1000oF for 150,000 psi tensile, 140,000 psi yield strength. Temper: 700oF for 200,000 psi tensile, 180,000 psi yield strength. 8640. Steel Ni-Cr-Mo. Typical uses, propeller shafts, transmission gears, spline shaf ts, heavy duty bolts, etc. 4140 has higher strength and ductility and slightly better machinability. COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.38-0.43 0.75-1.0 0-0.04 0-0.04 0.2-0.35 0.4-0.7 Cr% Mo% Fe% 0.4-0.6 0.15-0.25 Balance FORMS-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1550o-1650oF. Anneal: 1475o-1575oF. Harden: 1475o-1575oF, oil quench. Temper: 1100oF for 145,000 psi tensile, 130,000 psi yield. Temper: 800oF for 200,000 psi tensile, 184,000 psi yield. Temper: 700oF for 220,000 psi tensile, 205,000 psi yield. 8735. Steel Ni-Cr-Mo. This metal is used for shapes, tubing, aircraf t engine studs, knuckles, etc. It is similar in characteristics to 8630 and 8640 FORMS-SPECIFICATIONS. See Specif ication Table 2-2. COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.33-0.38 0.75-1.0 0-0.04 0-0.04 0.2-0.35 0.4-0.7 Cr% Mo% Fe% 0.4-0.6 0.2-0.3 Balance HEAT TREATMENT Normalize: 1575 -1625 F Anneal: 1525o-1525oF. Harden: 1525o-1600oF Oil quench. Temper: 1200oF for tensile 119,000 psi, yield 93,000 psi. Temper: 1100oF for tensile 131,000 psi, yield 107,000 psi. Temper: 900oF for tensile 149,000 psi, yield 127,000 psi Temper: 800oF for tensile 170,000 psi Temper: 775oF for tensile 200,000 psi
o o

8740. 4140. joints, piston etc.

Steel Ni-Cr-Mo. This steel is similar to It may be satisfactorily used for axles, tool bits, core drills, reamer bodies, drill collars, rods, aircraf t engine bolts, shapes, tubing

COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.38-0.43 0.75-1.0 0-0.04 0-0.04 0.2-0.35 0.4-0.7 Cr% Mo% Fe% 0.4-0.6 0.2-0.3 Balance FORMS-SPECIFICATIONS. See Specif ication Table 2-2 . HEAT TREATMENT Normalize: 1575o-1625oF. Anneal: 1500o-1575oF (Tensile 103,000 psi, yield 66,000 psi annealed) Harden: 1500o-1575oF (Quench in agitated oil) Temper: 1100oF for tensile 160,000 psi, yield 152,000 psi. Temper: 900oF for tensile 190,000 psi, yield 183,000 psi. Temper: 800oF for tensile 210,000 psi, yield 198,000 psi. Temper: 725oF for tensile 220,000. 9260, 9261, 9262. Steel Silicon. These are similar alloy spring steels, oil hardening type. The quantities of chromium in each, constitutes the only chemical variations in these alloys. Typical applications are coil and f lat springs, axles, chisels, bolts. etc. COMPOSITION RANGE C% Mn% P% S% Si% 9260 0.55-0.65 -0.7-1.0 0-0.04 0-0.04 1.8-2.2 Cr% --Fe% Balance

C% Mn% P% S% Si% 9261 0.55-0.65 0.75-1.0 0-0.04 0-0.04 1.8-2.2 Cr% 0.1-0.25 Fe% Balance

C% Mn% P% S% Si% 9262 0.55-0.65 0.75-1.0 0-0.04 0-0.04 1.8-2.2 Cr% 0.25-0.4 Fe% Balance

FORMS-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Normalize: 1600o-1650oF. Anneal: 1525o-1575oF Harden: 1575o-1625oF quench in agitated oil.

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Temper: 1100oF for tensile 165,000 psi, yield 144,000 psi. Temper: 900oF for tensile 214,000 psi, yield 192,000 psi. Temper: 600oF for tensile 325,000 psi, yield 280,000 psi. 9310. Steel Ni Cr-Mo (Electric Furnace Steel). This is a high hardenability case steel, since it is a high alloy, both the case and core have high hardenability. This type of steel is used particularly for carburized parts having thick sections such as bearing races, heavy duty gears etc. COMPOSITION RANGE C% Mn% P% S% Si% Ni% 0.7-0.13 0.4-0.7 0-0.025 0-0.025 0.2-0.35 2.95-3.55 Cr% 1.0-1.45 Mo% 0.08-0.15 Fe% Balance

Type 301. Steel Austenitic Stainless. This steel belongs to the sub-family of 18-8 steels, which vary only slightly in chromium and nickel and contain no other metallic alloying element. This alloy may be strengthened to an exceptional degree by cold work. For best results, cold work should be followed by stress relieving at 400o-800oF. COMPOSITION RANGE C% Mn% Si% P% Cr% Ni% S% 0.08-0.15 0-2.0 0-1.0 0-0.04 17.0-19.0 6.0-8.0 0-0.03 Cu% 0-0.05 Fe% Balance

FORM-SPECIFICATION. See Specification Table 2-2. HEAT TREATMENT Anneal: 1950o-2050oF,1 hour per inch thickness, water quench. Cool to 800oF within 3 minutes maximum. To relieve the elastic characteristics and increase the compressive yield strength of cold worked conditions, 400o-800oF, 36 to 8 hours maximum respectively. Af ter forming in order to prevent stress cracking, full anneal, or alternately 600oF, 1/2 to 2 hours. This alloy can be hardened only by cold work. Maximum tensile strength, 1/4 hard 125,000, 1/2 hard 150,000, full hard 185,000 psi. Full anneal is mandatory when, exposed to corrosive media, such as hot chlorides, etc. which may lead to stress corrosion cracking. Type 302. Steel Austenitic Stainless. This alloy is similar to Type 301 in composition and characteristics. It is inferior in strength to 301, however, possesses superior corrosive resistance. It is generally used in the annealed conditions COMPOSITION RANGE C% Mn% Si% P% S% Cr% 0.08-0.25 0-2.0 0-1.0 0-0.045 0-0.03 17.0-19.0 Ni% 8.0-10.0 Fe% Balance

FORMS-SPECIFICATIONS. See Specification Table 2-2. HEAT TREATMENT Normalize: 1625o-1725oF, air cool. Anneal: 1475o-1575oF, furnace cool. Recommended practice for maximum case hardness: Direct quench from pot. (1) Carburize: at 1700oF for 8 hours. (2) Quench: in agitated oil. (3) Temper: 300oF. Case depth: 0.047 inch Case hardness: RC62 Single Quench and Temper: (1) Carburize: 1700oF for 8 hours. (2) Pot cool. (3) Reheat: to 1450oF. (4) Quench: in agitated oil. (5) Temper: 300oF. Case depth: 0.047 inch Case hardness: RC62. To obtain maximum core toughness: Direct quench from pot. (1) Carburize: 1700oF for 8 hours. (2) Quench in agitated oil. (3) Temper: 450oF. Case depth: 0.039 inch. Case hardness: RC54. Single quench and temper: (1) Carburize: 1700oF for 8 hours. (2) Pot cool. (3) Reheat to 1450oF. (4) Quench: in agitated oil. (5) Temper: 450oF. Case depth: 0.047 inch. Case hardness: RC59.

FORMS-SPECIFICATIONS. See Specification Table, 2-2. HEAT TREATMENT The heat treatment and resulting strength is similar to that recommended for type 301, except that the temperature range for annealing type 302 ranges between 1925o-2075oF. Type 303, Type 303Se, Steel Austenitic Stainless. These varieties of the 18-8 austenitic stainless family contain additions of sulphur and selenium for the purpose of improving machining characteristics. However the presence of these elements

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tend to decrease formability and corrosion resistance. Type 303 Se is superior to 303 in these respects. The cast form of 303Se is also known as CF-16F. ALLOY TYPE 303 PERCENT Min C Mn Si P S Cr Ni Mo Cu Se Iron (Fe) .18 17.0 8.0 Balance Max 0.15 2.0 1.0 0.04 0.35 19.0 10.0 0.75 0.5 TYPE 303Se PERCENT Min .12 17.0 8.0 0.15 Balance Max 0.15 2.0 1.0 0.17 0.04 19.0 10.0 0.5 0.5 0.35 C Mn Si P S Cr Ni Mo Cu Iron

TYPE 304 PERCENT MIN MAX 18.0 8.0 Balance 0.08 2.0 1.0 0.04 0.03 20.0 11.0 0.5 0.5

TYPE 304L PERCENT MIN MAX 0.5 18.0 8.0 0.03 2.0 1.0 0.04 0.03 20.0 11.0 Balance

HEAT TREATMENT Same as types 303 and 303Se. This alloy can only be hardened by cold work. TYPE 314. Steel-Austenitic Stainless. This is a non-heat-treatable stainless steel generally used in the annealed condition. It possesses high resistance to scaling and carburizing and is used for parts and welded assemblies requiring corrosion and oxidation resistance to 2000oF. It is subject to embrittlement af ter long time exposure to temperature in the 1200o-1600oF range. COMPOSITION RANGE C% Cr% Cu% Mn% Mo% Ni% 0.12 23.0-25.0 0.50 1.0-2.0 0.50 19.0-22.0 Si% 1.7-2.3 P% 0.04 S% 0.03 Fe% Balance

HEAT TREATMENT Anneal or solution treat: 1900 -2050 F, air cool or quench, depending on section thickness, cool to 800oF maximum within 3 minutes. Bars, forgings: 1900o-1950oF, 1/2 hour per inch of thickness, water quench. Sheet, tubing: 1900o-1950oF, 10 minutes, air cool up to 0.064 thickness, water Quench 0.065 inch and thicker. Castings: 2000o-2100oF, 30 minutes minimum. This alloy may be hardened only by cold work. Welding is not generally recommended. These steels are subject to carbide precipitation when subjected to temperature over 800oF. Type 304, Type 304L. Steel Austenitic Stainless. This steel is produced in two grades, type 304 with 0.08 carbon (maximum) and type 304L with 0.03% maximum carbon. They have properties similar to Type 302 but the corrosion resistance is slightly higher. These metals are available as castings under the designations CF-8 and CF-3 respectively. Welding may be readily accomplished by all common methods. COMPOSITION RANGE
o o

FORM-SPECIFICATION. See Specif ication Table 2-2. HEAT TREATMENT Anneal (solution treat) 1900o-2100oF using rapid air cooling for sheet and light plate and water quench for heavier sections. Stress relief and best corrosion resistance to high temperatures properties is achieved by f inal annealing at 1900oF minimum. To restore ductility af ter embrittlement has occurred, anneal 1900o-1950oF for 10-60 minutes. This alloy may be hardened only by cold work.

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TYPE 314

FORMS CONDITION THICKNESSIN Tensile Yield Hardness RB

BAR ANNEALED 1 IN DIA 100,000 50,000 89

PLATE ANNEALED

SHEET ANNEALED

WIRE ANNEALED 0.002 to 0.010 HARD DRAWN 0.002 to 0.010 245,000275,000 230,000260,000 -------------

100,000 50,000 89

100,000 50,000 89

95,000-130,000 35,000-70,000 -------------

TYPE 316 and 317. Steel Austenitic Stainless. Wrought products are readily formable and weldable. Castings are also weldable, and the metal arc method is most of ten used. These alloys have better corrosion resistance than 30302 or 30304 types. COMPOSITION RANGE C% Mn% Si% P% S% Cr% 0-.08 1.25-2.0 0-1.0 0-0.04 0-0.03 16.0-19.0 Ni% 11.0-14.0 Mo% 2.0-2.5 Cu% 0-0.5 Iron% Balance

forms a carbide of low solid solubility, the possibility of intergranular precipitation and of the associated intergranular corrosion is reduced. Therefore, type 321 is used primarily either for parts fabricated by welding without postweld annealing or for service at 800o-1500oF. This steel is available in all wrought forms. Welding rods and castings are not produced in this type. CORROSION RANGE C% Mn% Si% P% S% Cr% 0-0.08 0-2.0 0.4-1.0 0-0.04 0-0.03 17.0-20.0 Ni% Mo% 8.0-13.0 0-0.5 Ti% Cu% *6XC-0.7 0-0.5 Iron (Fe)% Balance

FORMS-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Anneal wrought products 1850o-2150oF, air cool or quench depending on section size. For sheet alloys, annealing temperature 1950oF, minimum. Castings 1950o-2100oF, water or oil quench or air cool. Low side of temperature range is used for CF 8M, (Cast Alloy) but CF 12M castings should be quenched from above 2000oF. Stabilize for high temperature service 1625o1675oF, stress relieve 400o-500oF, 1/2 to 2 hours. This alloy may be hardened only by cold work. In annealed condition, tensile 90,000 psi, yield 45,000 psi. TYPE 321. Steel Austenitic Stainless.This is one of the two stabilized 18-8 steels Since titanium

FORMS-SPECIFICATIONS. See Specif ication Table 2-2. * 6 times columbian content. HEAT TREATMENT Full anneal 1750o-1850oF, 1 hour per inch in thickness, two hours minimum for plate furnace cool or air cool. Stabilizing anneal for service 900o-1500oF, heat to 1500o-1650oF one hour per inch thickness, 2 hours minimum for plate. Stress relieve af ter fabrication 1300oF. This may be hardened only by cold work.

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TYPE 321

TENSILE - YIELD FORM CONDITION THICKNESS IN Tensile Yield

SHEET, STRIP ANNEAL -90000 35000

PLATE -85000 30000 ALL 85000 35000

BAR ANN+CD 1 INCH 95000 60000

WIRE SOFT TEMPER 0.062 115000 85000 0.50 95000 65000

Full anneal or stabilizing anneal will eliminate sensitized conditions. TYPES 347 and 348. Steel Austenitic Stainless is the second of two stabilized 18-8 steels (see type 321 for other). Since columbian forms a carbide of very low solubility, the possibility of intergranular precipitation and of the associated intergranular corrosion are practically eliminated. Therefore, Type 347 is used principally for parts fabricated by welding without postweld annealing, or for long service between 800o-1500oF. Columbian is usually associated with the similar element tantalum which is included in the columbian analysis, specifying only the total of both elements. Corrosion resistance of this alloy is similar to Type 302, however it has a greater tendency to pitting corrosion and attacks in streaks. Intergranular corrosion is absent in this steel unless it is overheated to above 2150oF. At this temperature columbian carbides are going in to solid solution and subsequent rapid cooling, followed by heating to 1200oF, will cause precipitation and reduce the resistance to intergranular attack. A stabilizing anneal will restore the corrosion resistance. COMPOSITION RANGE C% Mn% Si% P% S% Cr% 0-0.08 0-2.0 0.5-1.0 0-0.04 0-0.03 17.0-19.0 Ni% 9.0-13.0 Mo% 0-0.5 Cb1% *10XC-1.1 Iron (Fe%) Balance

Welding. Fusions welding of this alloy is comparable to type 304L. Heavy sections may crack during welding or subsequent heating. Postweld annealing is not required, although a stress relief is recommended. This steel is subject to carbide precipitation at temperatures in excess of 2150oF. Type 414. Steel Martensitic Stainless. This steel has good resistance to weather and water. It should be passivated. Stainless type 416 has similar mechanical properties, workability and resistance to corrosion, however, corrosion resistance is not as good as the 300 series stainless. It has better machinability but less weldability. Type 420 has higher mechanical properties, similar workability and machinability. COMPOSITION RANGE C% Mn% P% S% Si% Cr% 0.08-0.15 0-1.0 0-0.04 0-0.03 0-0.10 11.5-13.5 Ni% 1.25-2.5 Fe% Balance

FORMS-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Annealing: 1200o-1300oF. Hardening: 1800o-1900oF, cool rapidly. Tensile strength in annealed condition 117,000 yield, 98,000 psi. Tensile strength in annealed cold drawn 130,000 yield, 115,000 psi. TYPES 403, 410, 416. Steel-Martensitic Stainless. This is a free machining type of alloy. Best performance is obtained if heat treated or cold worked to 180-240 BHN. It is magnetic in the hardened condition and is not normally used in the annealed condition. COMPOSITION RANGE C% Mn% P% S% Si% Cr% Mo% Si% 0.15 1.25 0.06 0.15 1.0 14.0 0.6 0.6 Fe% Balance

*10 Times Columbian Content. FORMS-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Full anneal wrought products 1800o-1900oF, 1 hour per inch of thickness 2 hours minimum for plate, furnace cool or air cool. Full anneal castings 1900o-2000oF 30 minutes minimum. Stabilizing anneal for service 800o-1500oF, 1500o-1650oF, 1 hour per inch thickness, 2 hours minimum for plate. Stress relieve af ter fabrication 1300oF. Alloy may be hardened only by cold work.

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FORMS-SPECIFICATION. See Specification Table 2-2. HEAT TREATMENT Anneal: 1500o-1650oF, furnace cool 50oF per hour to 1100oF. Harden: 1700o-1850oF, cool rapidly, oil and quench. Tensile - Yield strength is as follows: (1) Annealed - Tensile 75,000 psi, yield 40,000 psi. (2) Heat Treated - Tensile 110,000 psi, yield 85,000 psi. (3) Tempered and Drawn - Tensile 100,000 psi, yield 85,000 psi. Weldability is poor except by use of low-hydrogen electrodes. Temper: range. Temper: Temper: Temper: 400o-1300oF. Avoid 700o-1075oF temper 1300oF for 100,000 psi. 1075oF for 120,000 psi. 575o-600oF for 180,000 psi.

COMPOSITION RANGE C% Mn% Si% P% 0.2 1.0 1.0 0.04 Ni% 1.25-2.5 Fe% Balance FORMS-SPECIFICATIONS. See Specification Table 2-2. HEAT TREATMENT Type 431 steel must be protected from contamination at furnace temperature by dry inert atmosphere (organ, helium) or vacuum in the furnace working zones, except that air or salt bath furnaces may be employed for tempering operations. Parts shall be transferred from furnace working zones to the oil bath within a 30-second interval prior to quenching. Materials in the solutiontreated condition (not more than 2 percent segregated ferrite or austenite in the microstructure) may be hardened by the following treat treatment. HT-200 CONDITION Austenitize at 1850o25oF for 30 minutes, quickly transfer from furnace to oil quenching bath at not over 100oF followed by refrigeration at 100oF10oF for 2 hours, tempering at 550oF25oF for 2 hours, air cool, and f inal temper at 550o25oF for 2 hours; or austenitize 1850o25oF for 30 minutes, marquench into salt bath at 400oF, air cool to room temperature, refrigerate at 100o10oF for 2 hours, temper 550o25oF for 2 hours, air cool, temper 550oF for 2 hours. HT-125 (125,000 tensile) Austenitize at 1850o25oF for 30 minutes, quickly transfer from furnace to oil quench to bath at not over 100oF, temper 1200o25oF for 2 hours, air cool, temper 1200o25oF for 2 hours. CAUTION S% Cr% 0.03 15.0-17.0

TYPE 420. Steel Martensitic Stainless. This is a medium carbon grade of martensitic stainless which in the past has been intensively used in the cutlery industry. It has recently proved satisfactory for air weapon application where its high strength permits heat treatment for tensile strength up to 240,000 psi. In the fully annealed condition formability of this alloy almost equals the 1/4 hard austenitic stainless steels. Shearing type operations such as blanking and punching are not recommended. It machines best in conditions having approximately 225 BHN. COMPOSITION RANGE C% Mn% 0.3-0.4 0-1.0 Ni% 0-0.5 Mo% 0-0.5 Si% P% S% 0-1.0 0-0.04 0-0.03 Fe% Balance Cr% 12.0-14.0

FORMS-SPECIFICATIONS. See Specification Table 2-2. HEAT TREATMENT Full anneal 1550 -1650 F one hour per inch of thickness, furnace cool (50oF per hour) to 1100oF. Subcritical anneal 1300o-1350oF, 3 hours minimum, air cool. Austenitize 1800o-1850oF oil quench, depending on section size. Heavy sections should be preheated at 1250oF. Temper 400o1500oF, 3 hours minimum. Tempering between 600o-1000oF is not generally recommended due to reduced ductility and corrosion resistance. TYPE 431. Steel Martensitic Stainless. This alloy is suitable for highly stressed parts in corrosive environment.
o o

Avoid tempering or holding within range from 700o to 1100oF. HT-115 (115,000 Tensile and Yield 90,000 PSI) Heat Cond A material to 1800o-1900oF for 30 minutes, oil quench from furnace, temper at a temperature not lower than 1100oF. HT-175 (175,000 Tensile and 135,000 Yield PSI) Heat Cond A material to 1850o-1950oF, quench in oil from furnace temper at a temperature not higher than 700oF.

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17-4PH. Steel, Martensitic Stainless, Precipitation Hardening. This stainless steel possesses high strength and good corrosion and oxidation resistance up to 600oF. COMPOSITION RANGE C% Cb% Cr% Cu% Mn% 0.07 max 0.15-0.45 15.5-17.5 3.0-5.0 1.0 max Ni% 3.0-5.0 P% 0.04 max S% .03 max Si% 1.0 max Fe% Balance

SPECIFICATION: MIL-S-81506 HEAT TREATMENT To condition A-1900o25oF 30 minutes, air cool or oil quench below 90oF. From condition A to Condition H900(RH-C 40/47) 900o 10oF, 1 hour, air cool. Condition H925(RH-C 38/45) 925o 10oF, 4 hours, air cool. Condition H950(RH-C 37/44) 950o 10oF, 4 hours, air cool. Condition H975(RH-C 36/43) 975o 10oF, 4 hours, air cool. Condition H1000(RH-C 35/42) 1000o 10oF, 4 hours, air cool. Condition H1025(RH-C 35/42) 1025o 10oF, 4 hours, air cool. Condition H1050(RH-C 33/40) 1050o 10oF, 4 hours, air cool. Condition H1075(RH-C 31/39) 1075o 10oF, 4 hours, air cool. Condition H1100(RH-C 32/38) 1100o 10oF, 4 hours, air cool. Condition H1125(RH-C 30/37) 1125o 10oF, 4 hours, air cool. Condition H1150(RH-C 28/37) 1150o 10oF, 4 hours, air cool. 17-7PH. Steel Martensitic Stainless (Precipitation Hardening). This stainless steel possesses good corrosion resistance, may be machined and formed in its annealed condition, and is used up to temperatures of 800oF. COMPOSITION RANGE A% 0.50-1.0 Si% 1.0-5.0 C% 0.10-0.12 P% 0.045 Cr% 16.0-18.0 S% 0.030 Mn% Ni% 1.00 6.0-8.0 Iron Balance

hour, air cool to 50o to 60oF within 1 hour, hold at 50o to 60oF 1/2 hour (condition TO) + 1040o to 1060oF, 1-1/2 hour. Age condition A to condition RH 950, 1735o to 1765oF, 10 minutes, refrigerate (condition A 1750o) to -90o to -110oF 8 hours (condition R100), + 940o to 960oF, 1 hour. Age condition C of cold rolled sheet or cold drawn wire to condition CH 900, 890o to 910oF for 1 hour. Condition A - 130 to 150 KSI ultimate, 55 KSI yield. Condition T - 125 to 145 KSI ultimate 75 to 100 KSI yield. Condition RH950 - 200 to 215 KSI ultimate 180 to 190 KSI yield. Condition RH1050 - 180 to 200 KSI ultimate 150 to 185 KSI yield. Condition C - 200 to 215 KSI ultimate 175 to 185 KSI yield. Condition CH900 - 240 to 250 KSI ultimate, 230 to 240 KSI yield. TYPE 440A, 440B, 550C, 440C. Steel Martensitic Stainless. These steels are similar except for carbon range, therefore they are grouped since heat treatment requirements are the same. These steels are used for cutlery, valves, etc. COMPOSITION RANGE C% Mn% Si% P% S% 440A 0.6-0.75 max 1.0 max 1.0 max 0.04 max 0.03 max Cr% Mo% Fe% 16.0-18.0 max 0.75 max Balance C% Mn% Si% P% S% Cr% Mo% 440B 0.75-0.95 1.0 1.0 0.04 0.03 16.0-18.0 0.75 Fe% Balance C% Mn% Si% P% S% Cr% Mo% 440C 0.95-1.2 1.0 1.0 0.04 0.03 16.0-18.0 0.75 Fe% Balance FORMS-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Anneal: 1550o to 1650oF. Temper: 300o-800oF. Harden: 1850o-1950oF, cool rapidly. 440A, tensile 270,000 psi, yield 260,000 psi.

SPECIFICATION: See MIL-S-25043. HEAT TREATMENT Condition A. Solution anneal 1925o-1975oF, 30 minutes per inch of thickness, air cool. Age condition A to condition TH1050, 1375o to 1425oF, 1-1/2

Change 3

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440B, tensile 280,000 psi, yield 270,000 psi. 440C, tensile 285,000 psi, yield 275,000 psi. Welding is not recommended. 15-7-MO. Steel Martensitic Stainless. This alloy is a further development of 17-7PH alloy and due to molybdenum content it can be heat treated to high strength at room and elevated temperature (up to 1000oF). The heat treatment is identical to 17-7PH and other properties are identical or similar to 17-7PH. FORMS - sheet, strip, plate, bars and forgings. SPECIFICATION - AMS 5520, AMS 5657. COMPOSITION RANGE C% Mn% Si% P% 0.09 1.0 1.0 0.4 Ni% 6.50-7.75 Mo% 2.0-3.0 A1% 0.75-1.50 S% 0.03 Cr% 14.0-16.0

Condition CH900 - 265 KSI ultimate, 260 yield, hardness RC50. PH 14-8 MO. This alloy (sheet) is similar to PH 15-7 MO except it has slightly lower tensile and yield strength but considerable higher toughness and superior welding characteristics. In general this alloy is unstable during exposure to temperatures exceeding 500oF, which is a common characteristic of precipitation hardening stainless steels. FORMS AND CONDITIONS - available - sheet and strip. Condition A - annealed C cold worker. CHEMICAL CONDITION C% Mn% 0.02-0-05 1.0 Ni% 7.50-9.50 Me% 2.0-3.0 Si% Ph% 1.0 0.015 S% 1.0 Cr% 13.50-15.50

Fe% Balance

Al% 0.75-1.50

Fe% Rem

HEAT TREATMENT Condition A. Solution anneal sheet and strip, 1925o-1975oF, 3 minutes per 0.1 inch thickness, air cool. Bar and forgings solution anneal 1925o1975oF, 30 minutes per inch thickness, water quench. Age condition A to condition TH1050, 1375o to 1425oF, 1-1/2 hour (austenite conditioning), air cool to 50o - 60oF within 1 hour, hold at 50o - 60oF, 1/2 hour (condition T) + 1040o - 1060oF, 1-1/2 hour, air cool. Age condition A to condition RH 950, 1735o - 1765oF, 10 minutes (austenite conditioning), air cool (condition A 1750) 90o to 110oF, 8 hours (condition R100) + 940o to 960oF, 1 hour, air cool. Age condition C, sheet cold rolled or wire cold drawn to condition CH 900, by heating 890o -910oF for 1 hour, air cool. TH and RH conditions are also used with difference f inal age hardening temperatures, such as TH1150, RH1050, etc. TYPICAL PROPERTIES FOR VARIOUS CONDITIONS: Condition A - 130 to 150 KSI ultimate, 55-65 KSI yield, hardness 90-100. Condition T - 125 to 145 KSI ultimate, 75-90 KSI yield, hardness 28-30. Condition TH1050 - 190 to 210 KSI ultimate, 170200 KSI yield, hardness RC40-45. Condition RH950 - 225 to 240 KSI ultimate, 200225 KSI yield, hardness RC46-48. Condition R100 - 180 KSI ultimate, 125 KSI yield, hardness RC40. Condition C - 220 KSI ultimate, 190 yield, hardness RC45.

HEAT TREATMENT Anneal to Condition A, 1800o-1850oF, 30 minutes air cool. Age condition A to SRH conditions, 1685o 1715oF, 1 hour, air cool and within 1 hour cool to 100oF, 8 hours + age 1 hour, air cool. Aging at 940o-960oF or 1040o-1060oF is generally used with the higher temperature giving somewhat lower strength but af ter better toughness. Age cold worked alloy, condition C, 890o-910oF or 1040o1060oF, 1 hour, air cool. MECHANICAL PROPERTIES TYPICAL Condition A - 150 KSI ultimate, 65 KSI yield, hardness, RB100 max. Condition SRH 950 - 220 KSI ultimate, 190 KSI yield hardness RC40. Condition SRH1050 - 200 KSI ultimate, 180 KSI yield, hardness RC38. This alloy is subject to salt stress corrosion, however, early test indicate it is superior in this respect to 17-7PH and PH 15-7 MO. This general welding characteristics is similar to 17-7 PH. Higher toughness may be obtained by annealing af ter welding and then heat treating. 19-9 DL 19-9 DX. These stainless steels are not heat treatable, but can be hardened to a limited extent by cold working or hot cold working. In chemical composition 19-9DL contains columbium which was replaced by a higher molybdenum and titanium conten in 19-9DX. CHEMICAL COMPOSITION OF 19-9DL:

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T.O. 1-1A-9

C% Mn% Si% Ph% Si% Cr% 0.28-0.35 0.75-1.50 0.30-0.80 0.040 0.030 18.0-21.0 Ni% Mo% W% Cb+Ta Ti% Cu% 8.0-11.0 1.0-1.75 1.0-1.75 0.10-0.35 0.10-0.35 0.50 Fe% Balance CHEMICAL COMPOSITION 19-9DX: C% Mn% Si% Ph% S% Cr% 0.28-0.35 0.75-1.50 0.30-0.80 0.040 0.030 18.0-21.0 Ni% Mo% W% Ti% Cu% Fe% 8.0-11.0 1.25-2.00 1.0-1.75 0.40-0.75 0.50 Balance HEAT TREATMENT Bar and forgings, 1800o to 2150oF (1/2 to 1 hour) rapid air cool, oil water quench. Sheet/strip, 1650o to 1800oF (1/2 to 1 hour) rapid air cool. Avoid higher temperatures to prevent resolution and precipitation of carbides. Castings, 1950o to 2050o, 1/2 to 1 hour minimum, air cool. Solution Treat: Same as anneal. Stress relief: 1175o to 1225oF (4 hours) air cool. This treatment is applied to hot worked or hot cold worked material for service up to 1300oF. It is also applied to cold worked materials immediately after working to prevent stress cracking. Age: Bar and forgings, 1200o to 1400oF, casting 1575o to 1625oF, 8 hours minimum, air cool. NOTE Intergranular corrosion may occur in certain environments unless annealed at 1800oF, followed by rapid cooling. AM-350. Steel - Age Hardening Stainless. This alloy is one of a series of age hardening steels which combines high strength at temperatures up to 800oF and higher with the corrosion resistance of stainless steels. COMPOSITION RANGE C% Mn% Si% P% S% Cr% 0.08-0.12 0.5-1.25 0-0.5 0-0.04 0-0.03 16.0-17.0 Ni% 4.0-5.0 Mo% 2.5-3.25 N% 0.07-0.13 Fe% Balance

condition SCT 850o, 825o - 875oF. Age to condition SCT 1000 975o to 1025oF. Double age either condition H or condition-L to condition DA, 1350o 1400oF, 2 hours, air cool to 80oF and heat to 825o 875oF, 3 hours. Thoroughly degreased and cleaned prior to annealing to avoid harmful surface reactions and to facilitate subsequent pickling. Allowance must also be made for growth which will result from heat treating. The expansion on aging from condition H to set amounts to 0.002 - 0.004 inch per inch. AM-355. Steel - Age Hardening stainless This alloy combines high strength at temperatures up to 850oF with the corrosive resistance of stainless steel. This alloy differs from AM-350 by a lower chromium and a higher carbon content. It possesses good formability in the high temperature annealed condition. Corrosion resistance of this alloy is slightly lower than that of AM-350. FORM-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Anneal to condition H for maximum formability and stability. Anneal to condition H: Plate and forgings at 1925o-1975oF, 1 hour minimum per inch, water quench: sheet and welded tubing, 1850o to 1900oF, 3/4 hour minimum per inch, rapid air cool. Bar should not be annealed to condition H unless subsequently subjected to forgings. Anneal to Condition L: 1685o-1735oF ---Sheet and strip, 3/4 hour per inch, air cool; plate 3/4 hour inch, oil or water quench. Condition H plate, if not subsequently severely cold formed, should be equalized before annealing to condition L and aging to condition SCT. Bar forgings and tubing, 1 hour minimum per inch thickness, oil or water quench. Equalize and age bar for best machineability, 1350o-1400oF, 3 hours, air cool to 80oF maximum + 1000o to 1050oF, 3 hours. Resulting should be approximately RC38 Subzero cool and age condition L to condition SCT, cool to -100oF, hold 3 hour minimum, 850o to 1050oF for 3 hours minimum. Age condition SCT 850, 825o to 875oF. Age to condition SCT 1000, 975o to 1025oF. Double age condition L to condition DA, 1300o to 1450oF 1 to 2 hours, air cool to 80oF, 825o to 875oF, 3 hours minimum. Homogenize sand and shell mold castings, 2000oF, 2-4 hours, air cool up to 1 inch thick, oil or water quench, section above 1 inch. HNM. Steel - Age Hardening Stainless. This is a precipitation hardening austenitic steel, with high rupture and creep properties in the 1000o1400oand not prone to overage at these temperatures. In the solution annealed condition it has a Brinell hardness of 201 maximum. It has a low

FORM-SPECIFICATION TABLE 2-2. HEAT TREATMENT Anneal to condition H - 1900o to 1950oF, 3/4 hour minimum per inch of thickness, rapid air cool to 80oF. Anneal to condition L - 1685o to 1735oF, 3/4 hour minimum, per inch of thickness, rapid air cool to 80oF. Subzero cool and age condition L to condition SCT, cool to 100oF, hold 3 hours minimum + 850o to 1050oF, 3 hours minimum Age to

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magnetic permeability, and is suitable for transformer parts, non-magnetic bolts, aircraf t structural, engine components, shaf ts and gears. This material is very susceptible to work hardening. It is somewhat inferior to regular 18cr-8ni stainless types, however, machining requirements are similar requiring heavy positive feeds and sharp cutting tools. Welding is not recommended, however brazing may be successfully accomplished by use of orayacetylene torch and furnace methods, using an alloy conforming to specif ication AMS 4755. COMPOSITION RANGE
AM355

C% Cr% Mn% Ni% P% Si% S% Iron 0.30 18.5 3.5 9.5 0.25 0.5 0.025 Balance FORM-SPECIFICATIONS. See Specif ication Table 2-2. HEAT TREATMENT Anneal 2000o-2150oF, 30 minutes, water quench. Sections 5/8 inches thick may be air cooled. The optimum solution treatment for best properties after aging is approximately 2050oF. Age 1300oF, 16 hours, air cool.

FORM Condition Solution Treat 2050oF 30 minutes oil quench 116,000 56,000

BAR Solution Treat 2050oF 30 minutes Water quench 145,000 92,000 Solution Treat 15 minutes air cool 106,000 55,000

SHEET Solution Treat 2050oF air cool & age 1300oF, 16 hrs 133,000 90,000

Tensile PSI Yield PSI Hardness BHN RB RC

192

302 87.5 33 V57. Steel - Nickel Chromium Stainless (Austenitic). This alloy has a good combination of tensile and creep rupture properties up to 1500oF at high stresses and is used for some parts of aircraf t gas turbines. COMPOSITION RANGE A1% B% C% Cr% Mn% Mo% Ni% Si% 0.25 0.008 0.06 15.0 0.25 1.25 25.5 0.55 Ti% 3.0 V% 0.25 S% 0.025 P% 0.025 Iron Balance

16-15-6. Steel - Iron - Chromium - Nickel - Alloy. This alloy was developed as a replacement for 1625-6 alloy and contains less nickel. However, the lower nickel content is balanced by additional manganese which allows an increase in the nitrogen content that can be retained during melting. COMPOSITION RANGE C% Cr% Mn% Mo% Ni% Si% 0-.07 15.0-17.5 6.5-8.5 5.0-7.0 14-0-17.0 0-1.0 N% 0.30-0.40 P% 0-0.03 S% .03 Iron (Fe) Balance

FORM. Bar, forging. SPECIFICATION. None. HEAT TREATMENT Anneal 1700o-2300oF. Solution treat 2125o-2175oF, air cool, water or oil quench, depending on section size. Cold work (about 20% reduction) and age (bar up to 1-1/2 inch) 1200o-1300oF, 2 to 8 hours. At a temperature of 1200oF a tensile of 145,000 and yield of 100,000 psi is obtained.

FORM. Bar, Forging. SPECIFICATION. None. HEAT TREATMENT Anneal 1700o-2300oF. Solution treat 2125o-2175oF, air cool, water or oil quench, depending on section size. Cold work (about 20% reduction) and age (bar up to1/2 inch) 1200oF-1300oF 2 to 8 hours. At a temperature of 1200oF a tensile of 145,000 and yield of 100,000 psi is obtained.

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SUPPER ALLOYS H/L V36. Steel Cobalt Base - Chromium-Nickel-Alloy. This is a solid solution - hardening alloy for service at 1300o-1800oF where strength and corrosion resistance is important. Used for guide vanes in gas turbines, af ter burner parts and high temperature springs. Chief ly furnished in sheet, but may be supplied in billet, bar, forging and wire. COMPOSITION RANGE C% Cr% C1% Ta% Iron% Mn% Mo% 0.25-0.33 24.0-26.0 1.5-2.5 0-5.0 0-1.2 3.5-4.5 Ni% Si% W% S% P% Cobalt 19.0-21.0 0-1.0 1.5-2.5 0-0.03 0-0.03 Balance SPECIFICATION. None. HEAT TREATMENT This alloy is primarily solid solution hardened and only small strength increases can be obtained by aging. Solution treatment for thick sections 2200o2275oF, 1 hour, water quench. Age 1400oF for 16 hours. Stress relieve cold worked alloy 900oF, 2 hours.
TYPE V36

SPECIFICATION. None. FORMS. Available in as cast condition. HEAT TREATMENT Stress relief: 1575o-1625oF, 2 hours, air cool. Age hardening: Above 1200oF susceptible to age hardening which increases alloy strength but causes loss in ductility. Tensile Strength: As cast, tensile strength 125,000 psi. Rockwell As cast, RC38. HAYNES ALLOY NO. 151. Cobalt Base Corrosion Resistant Alloy. This alloy may be air melted or air cast. It is used as gas turbine blades and rotors within the heat range 1200o-1700oF. COMPOSITION RANGE B% C% Cr% Iron% Mn% Ni% 0.03-0.08 0.4-0.5 19.0-21.0 0-2.0 0-1.0 0-1.0 Si% Ti% W% P% S% Cobalt% 0-1.0 0.05-0.5 12.0-13.5 0-0.03 0-0.03 Balance SPECIFICATION. None. FORMS. Available as castings and investment castings. HEAT TREATMENT

FORM Condition

SHEET Sol Treat 15 min 2250oF+ age Sol Treat +20%, cool rapidly 166,000 127,000 --Sol Treat +60%, cool rapidly 279,000 248,000 --This material is generally used in the as cast condition. The best creep rupture properties are in the 1300o-1500oF range. Solution treat 2170o2200oF 1 hour minimum, rapid air cool. This treatment reduces tensile properties below 1400oF and lowers creep rupture strength. Aging 1400oF 4 hours air cool af ter solution treating, results in higher tensile properties than as cast material, but creep rupture properties are somewhat lower than the as cast alloy. Hardenability. As-Cast hardness at room temperature RC33. GMR-235. Nickel Base Corrosive Resistant Alloy. GMR-235 and GMR-235D are nickel based alloys precipitation hardening, high temperature alloys developed for investment cast gas turbine wheels, buckets and vanes, operating above 1400oF. They are similar to Hastelloy R-235 but contain more aluminum. The composition with maximum aluminum and titanium content is designated GMR235D. COMPOSITION RANGE

Tensile Yield RC

147,000 83,000 25

W152. Steel. Cobalt Chromium Tungsten Corrosion Resistant Alloy. This is a casting alloy generally used in the as-castcondition. It is used for investment cast parts requiring high stress rupture properties at elevated temperatures, has excellent castability and foundry characteristics. Primary use has been f irst-stage turbine vanes. Alternate Designations. Haynes Alloy No 152, PWA 653, CF 239. COMPOSITION RANGE C% Cr% C1+TA Iron% Mn% Ni% 0.40-0.5 20.0-22.0 1.5-2.5 1.0-2.0 0-0.5 0-1.0 Si% 0-0.5 W% 10.0-12.0 P% 0-0.04 S% 0-0.04 Cobalt Balance

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GMR-235 % MIN A1 B C Cr Co Iron Mn Mo Si Ti Ni 2.5 0.05 0.1 14.0 0.1 8.0 0 4.5 0 1.5 Balance

GMR-235D MAX 3.5 0.1 0.2 17.0 0.2 12.0 0.25 6.0 0.60 2.5 Balance MIN MAX

3.25 4.0 0.05 0.1 0.1 0.2 14.0 17.0 0 0 3.5 5.0 0 0.1 4.5 6.0 0 0.3 2.0 3.0 Balance Balance

Solution treatment 1950o-2000oF 1/2 hour, water quench. Material treated at higher solution temperature (2200oF) is subject to strain-age cracking. Final heat treatment af ter fabrication of sheet and bar depends upon properties desired. To obtain maximum long time stress-rupture life, solution treat at 2175o 2225oF, 15 minutes, water quench. Then heat to 2025o-2075oF, hold at temperature for 30 minutes and cool in still air. To obtain maximum room and high temperature tensile strength or short time rupture strength, solution treat at 1950o-2000oF hold at temperature for 30 minutes and air cool. Then age at 1385o-1415oF hold at temperature for 16 hours and air cool.
TYPE HASTELLOY ALLOY R-235

SPECIFICATIONS. None. HEAT TREATMENT Solution treatment 2050oF 1 to 3 hours, air cool (GMR 235) Solution treatment 2100oF 2 hours, air cool (GMR-235D). For heavier sections (of both alloys) temperatures should be increased to 2150oF, 2 to 4 hours, air cool. Aging at 1800oF, 5 hours from the as cast condition improves the stress rupture life of the alloy. These alloys precipitation harden rapidly during air cooling and aging treatments are usually unnecessary. As-Cast room temperatures hardness for both alloys is RC36 maximum. Tensile 115,000 psi yield 90,000 psi. Form This material is available in wrought form only, except that GMR235 is available in cast form. HASTELLOY ALLOY R-235. Nickel Base Corrosion Resistant Alloy. This is a nickel base aluminum-titanium precipitation hardening alloy. It possesses high strength up to 1800oF with good resistance to oxidation and overaging in high temperature service. This alloy is readily fabricated and welded in the solution treated condition. COMPOSITION RANGE A1% B% C% Cr% Co% Iron% 1.75-2.25 0-0.009 0-0.16 14.0-17.0 0-2.5 9.0-11.0 Mn% Mo% Si% Ti% P% S% 0-0.25 4.5-6.5 0-0.6 2.25-2.75 0-0.01 0-0.03 Ni% Balance SPECIFICATION. None. FORMS. Sheet, Strip, Plate, Bar and Wire HEAT TREATMENT

FORM Condition Thickness-in Tensile, Max psi Yield, Max psi RC-Max

SHEET Sol Treat 1975oF Water Quench 0.021 150,000 95,000 27 Sol Treat 2200oF Water Quench 0.70 150,000 95,000 25

INCONEL ALLOY 718. Steel Nickel Chromium Stainless Alloy. This is a relatively new alloy and heat treatment and fabrication procedures are still under development. It has good properties up to 1300oF, slow response to age-hardening and good ductility from 1200o-1400oF. It is readily welded in either the annealed or aged condition. COMPOSITION RANGE A1% C% Cr% C1%+Ta% Cu% Mn% 0.4-1.0 0-0.1 17.0-21.0 4.5-5.75 0-0.75 0-0.50 Mo% Ni% Si% Ti% S% Iron 2.0-4.0 50.0-55.0 0-0.5 .3-1.3 0-0.03 Balance SPECIFICATION. None. FORMS. Sheet, Strip, Bar, Investment Castings. HEAT TREATMENT Both single age and double age treatments may be employed, however, the latter is preferred for highest strength up to 1300oF. Solution treat rods, bars and forgings 1800o-1900oF. Somewhat higher creep rupture properties are obtained at the higher temperatures. Solution treat sheet at 1725oF. Single age anneal alloy at 1325oF 16 hours, air cool. Double age anneal alloy at 1325oF 8 hours, furnace cool, 20oF per hour to 1150oF air cool or 1325oF 8 hours, furnace cool, 100oF per hour to 1150oF, hold 8 hours, air cool. Both of

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these double age treatments appear to give the same results.

TYPE INCONEL ALLOY 718

FORM Condition

HOT ROLLED BAR 0.0500 IN DIA Anneal 1800 F 1 hour 8 hour*

o

+ + 8 hour** 204,000 173,000

Age 1325oF 16 hour 193,000 154,000

hardening results and forming becomes difficult. Distortion is comparatively low if material is subsequently solution treated and water quenched. Best machinability is obtained in the fully aged condition af ter either oil or water quenching from solution treating temperature. This alloy may be fusion welded if copper and gas backing with a tight hold down is used. Start and f inish should be made on metal tab of the same thickness using an inert gas atmosphere of 2 helium to 1 argon. Following the torch with a water spray reduces the hardness and produces maximum ductility in the weld and heat affected zones. COMPOSITION RANGE C% Mn% Si% Cr% Ti% A1% 0.06-0.12 0-0.5 0-0.5 18.0-20.0 3.0-3.3 1.5-1.8 Mo% B% Co% Iron% Ni% 9.0-10.5 0-0.01 10.0-12.0 0-5.0 Balance SPECIFICATIONS: None FORMS: Sheet, Strip, Plate, Bar, Wire. HEAT TREATMENT For maximum formability 1950o-2150oF 30 minutes, water quench or cool from 2150o to 1200oF in 4 seconds maximum. Solution treat 1950o-2150oF 30 minutes, quench or air cool. Heat treatment for high short time strength: Solution treat 1950oF 30 minutes, cool to 1200oF in 4 seconds maximum + 1400oF, 16 hours. Heat treat for good ductility and high creep rupture strength, solution treat 2150oF 30 minutes + 1650oF 4 hours. Hardenability: Alloy must be water quenched to retain sof t solution treated conditions.
TYPE RENE 41

Thickness - in Tensile PSI Yield PSI

0.500 211,000 174,000

*Furnace cool at temperature reduction of 100oF per hour to 1150oF hold 8 hours air cool. ** Furnace cool at temperature reduction of 20oF per hour to 1150oF air cool. UDIMET 700. Highly Alloyed Nickel Base Corrosion Resistant. This alloy has higher elevated temperature tensile and stress-rupture strength than most wrought cobalt or nickel based alloys. It also has superior creep resistance, fatigue strength and high oxidation resistance. Welding is generally not recommended. COMPOSITION RANGE A1% 3.75-4.75 B% 0-025-0.035 C% 0.03-0.1 Cr% 14.0-16.0

Co% Cu% Iron Mn% Mo% Si% 17.0-20.0 0-0.1 0-4.0 0-0.15 4.5-6.0 0-0.2 Ti% 2.75-3.75 Zr% 0-0.06 S% 0-0.015 Ni% Balance

SPECIFICATIONS. None FORMS. Bars, Billets, Castings, Forgings HEAT TREATMENT Solution annealing for castings 2075o-2125oF 2 hours air cool. Solution annealing for forgings 2125o-2175oF 4 hours air cool. Solution treat. 1950o-2000oF 4 to 6 hours, air cool. Intermediate aging 1535o-1565oF 24 hours air cool. Final aging 1385o-1415oF 16 hours air cool. Hardens by aging and cold working. RENE 41. Nickel Base Heat Treatable Stainless Alloy. This alloy possesses exceptional mechanical properties at temperatures up to 1800oF. It can be formed and also welded in the annealed condition. If cooled at a slower rate than specif ied, e.g. in less than 4 seconds from 2150oF to 1200oF, age FORM Condition Tensile Yield Rockwell Hardness

ALL 2150oF air cooled 195,000 160,000 RC43 2150oF water quenched 130,000 65,000 RB93

NICROTUNG. Nickel Base Corrosion Resistant Alloy. This is a nickel base investment casting alloy which is strengthened by addition of cobalt, aluminum and titanium. It has high creep strength and excellent oxidation resistance in the high temperature range 1500o-1800oF combined with good room temperature strength.

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COMPOSITION RANGE A1% B% C% Cr% Co% 3.75-4.75 0.02-0.08 0.08-0.13 11.0-13.0 9.0-11.0 Ti% 3.75-4.75 W% 7.0-8.5 Zr% 0.02-0.08 Ni% Balance

e.

The structure of the steel to be machined.

2-77. The cutting tool angles (back rake, side clearance, front clearance, and side rake) are highly important in the machining of metals. The range of values based on general practice for the machining of steel and steel alloys, are as follows: a. b. c. d. Back rake angle, 8-16 degrees. Side rake angle, 12-22 degrees. Front clearance angle, 8-13 degrees. Side clearance angle, 10-15 degrees.

SPECIFICATIONS. None FORMS. Investment castings. HEAT TREATMENT Heat treatment is not recommended for this alloy. This material has as-cast hardness of RC38-40. NIMONIC 105. Nickel-Cobalt-Chromium Corrosion Resistant Alloy. This alloy has excellent resistance to creep at very high temperatures. It is designed for use as turbine blades and rotors used in gas turbines. Corrosion resistance is good and resistance to oxidation under repeated heating and cooling is very good. COMPOSITION RANGE A1% 4.2-4.8 Mn% 0-1.0 C% 0-0.2 Cr% 13.5-16.0 S1% 0-1.0 Co% Cu% 18.0-22.0 0-0.5 Ti% 0.9-1.5 Iron% 0-1.0

Mo% 4.5-5.5

Ni% Balance

SPECIFICATION. None FORMS. Sheet, Strip, Bar. HEAT TREATMENT For maximum stress-rupture life in range 1560o1740oF, fully heat treat solution treat, and double age as follows: Solution treat 2102oF 4 hours, air cool. Double age 1922oF, 16 hours, air cool and 1526oF, 8 hours, air cool. Where stress rupture strength above 1562oF is not the important property, but tensile strength, elongation and impact strength up to 1292oF is desired, the following heat treatment is recommended. Solution treat 2104oF, 4 hours, air cool. Age 1562oF, 16 hours, air cool. 2-75. MACHINING OF STEELS (GENERAL).

2-78. Regardless of the material of which the cutting tool is made, the cutting action is the same. The main difference is the cutting speed. The carbon-steel tool cuts at low speed. The highspeed tool cuts at twice the speed of carbon-steel, the cast alloys at twice the speed of high-speed steel, and the sintered carbides at twice that of the cast alloys. The cutting speeds listed in Table 2-4 are approximate speeds using high-speed steel tools, and are to be used only as a basis from which proper speeds for a particular part may be calculated. These speeds are based on SAE 1112 steel, which is assigned a machinability rating of 100%. In order to obtain an approximate starting speed for different steels, select the type of operation, the width, depth or diameter of cut and obtain the recommended cutting speed for SAE 1112 from Table 2-3 then refer to Table 2-4 for the percent rating of the metal to be machined, and multiply the SFM value from Table 2-5 by the rating in Table 2-4. The result is the recommended surface feet per minute (SFM) for the cutting operation. For a known diameter and surface feet per minute (SFM) be used for an operation, the corresponding revolution per minute (RPM) can be obtained from Table 2-5. 2-79. The term cutting feed is used to express the axial distance the tool moves in each revolution. A course feed is usually used for roughing operations, and a f ine feed for f inishing operations. In general, the feed remains the same for different cutting tool steels, and only the speed is changed. Approximate cutting feeds are listed in Table 2-3. For tool corrections when improper machining on an operation is encountered, refer to Table 2-6 for recommended checks. 2-80. The use of a proper coolant (cutting f luid) of ten results in an increase of cutting speed for the same tool life, and also acts as a lubricant giving better cutting action and surface f inish. Recommended cutting f luids for steels are lard oil, mineral oils, sulphurized oils, and soluble or emulsif iable oils.

2-76. There are f ive basic factors affecting machinability as related to steel: a. tool. b. The capacity and rigidity of the machine Cutting f luids.

c. Design composition and hardness of the cutting tool. d. Cutting condition with respect to feeds and speeds.

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Table 2-3.

Cutting Speeds and Feeds for SAE 1112 Using Standard High Speed Tools

TOOL NAME Form Circular or Dovetail

SIZE OF HOLE, IN. --

WIDTH OR DEPTH OF CUT, IN. Width Width Width Width Width 0.500 1.000 1.500 2.000 2.500

SURFACE FPM 165 160 160 155 150 105 105 115 115 120

FEED IN./REV 0.0025 0.0020 0.0018 0.0015 0.0012 0.0045 0.005 0.006 0.007 0.008 0.007 0.0065 0.0055 0.0045

Twist Drills

0.250 0.500 0.750 1.000 1.250 Depth Depth Depth Depth Over 25 Pitch 15 to 25 Pitch Less than 15 Pitch 0.062 0.125 0.187 0.250 Under 1/2 Over 1/2 Width Width Width Width Table 2-4. 0.062 0.125 0.187 0.250 0.125 0.250 0.375 0.500

Box Tools Blade

165 160 155 150 30-40 20-30 15-20 150 140 135 130 145 145 165 175 180 190

Threading and Tapping

Hollow Mills

0.010 0.008 0.007 0.0065 0.007 0.010 0.002 0.0025 0.0025 0.003

Reamers

Cut Off

Machinability Rating of Various Metals

SAE DESIGNATION 1010 1015 1020 1022 1025 1035 1040 1045 1050 1055 1060

RATING % 50 50 65 70 65 65 60 60 50 55 60

BRINELL HARDNESS 131-170 131-170 137-174 159-192 116-126 174-217 179-229 179-229 179-229 192-197 183-201

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Table 2-4.

Machinability Rating of Various Metals - Continued

SAE DESIGNATION 1070 1080 1095 1112 1117 1137 2317 2330 2340 2515 3115 3140 3310 4037 4130 4135 4137 4140 4150 4337 4340 4615 4620 4640 5210 6150 8615 8617 8620 8630 8640 8735 8740 9260 9262 9310

RATING % 45 45 42 100 85 70 55 50 45 30 65 55 40 65 65 64 60 66 50 50 45 65 62 55 30 50 67 63 60 65 60 55 60 45 45 40

BRINELL HARDNESS 183-241 192-229 197-248 179-229 143-179 187-229 174-217 179-229 187-241 179-229 143-174 187-229 170-229 170-229 187-229 170-229 187-229 179-197 187-235 187-241 187-241 174-217 152-179 187-235 183-229 197 170-217 170-217 170-217 179-229 179-229 179-229 179-229 187-255 187-255 207-217

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Table 2-5.

Conversion of Surface Feet Per Minute (SFM) To Revolutions Per Minute (RPM)

DIAMETER IN INCHES 1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 1 1/8 1 1/4 1 3/8 1 1/2 1 5/8 1 3/4 1 7/8 2 2 1/4 2 1/2 2 3/4 3 DIAMETER IN INCHES 1/16 1/8 3/16 1/4 5/16 3/8 120 7334 3667 2445 1833 1467 1222 130 7945 3973 2648 1986 1589 1324 140 8556 4278 2852 2139 1711 1436 10 611 306 204 153 122 102 87 76 68 61 56 51 47 44 41 38 34 31 28 25 24 22 20 19 17 15 14 13 15 917 458 306 229 183 153 131 115 102 92 83 76 71 65 61 57 51 46 42 38 35 33 31 29 25 23 21 19 20 1222 611 407 306 244 204 175 153 136 122 111 102 94 87 81 76 68 61 56 51 47 44 41 38 34 31 28 25 25 1528 764 509 383 306 255 218 191 170 153 139 127 118 109 102 96 85 76 69 64 59 55 51 48 42 38 35 32 30 1823 917 611 458 367 306 262 229 204 183 167 153 141 131 122 115 102 92 83 76 70 65 61 57 51 46 42 38

SURFACE FEET PER MINUTE 40 2445 1222 815 611 489 407 349 306 272 244 222 203 188 175 163 153 136 122 111 102 94 87 81 76 68 61 56 51 50 3056 1528 1019 764 611 509 437 382 340 306 278 255 235 218 204 191 170 153 139 127 117 109 102 95 85 76 69 64 60 3667 1833 1222 917 733 611 524 458 407 267 333 306 282 262 244 229 204 183 167 153 141 131 122 115 102 92 83 76 70 4278 2139 1426 1070 856 713 611 535 475 428 389 357 329 306 285 267 238 214 194 178 165 153 143 134 119 107 97 89 80 4889 2445 1630 1222 978 815 698 611 543 489 444 407 376 349 326 306 272 244 222 204 188 175 163 153 136 122 111 102 90 5500 2750 1833 1375 1100 917 786 688 611 550 500 458 423 393 367 344 306 275 250 229 212 196 183 172 153 137 125 115 100 6111 3056 2037 1528 1222 1010 873 764 679 611 556 509 470 436 407 382 340 306 278 255 235 218 204 191 170 153 139 127 110 6722 3361 2241 1681 1345 1120 960 840 747 672 611 560 517 480 448 420 373 336 306 280 259 240 224 210 187 168 153 140

SURFACE FEET PER MINUTE 150 9167 4584 3056 2292 1833 1528 160 9778 4889 3259 2445 1956 1630 170 10390 5195 3463 2597 2078 1732 180 11000 5500 3667 2750 2200 1833 190 11612 5806 3871 2903 2322 1935 200 12223 6111 4074 3056 2445 2037 225 13751 6875 4584 3438 2750 2292 250 15279 7639 5093 3820 3056 2546 270 16807 8403 5602 4202 3361 2801 300 18334 9167 6112 4584 3667 3056

2-63

T.O. 1-1A-9

DIAMETER IN INCHES 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 1 1/8 1 1/4 1 3/8 1 1/2 1 5/8 1 3/4 1 7/8 2 2 1/4 2 1/2 2 3/4 3 120 1048 917 815 733 667 611 564 524 489 458 407 367 333 306 282 262 244 229 204 183 167 153 130 1135 993 883 794 722 662 611 567 530 497 441 397 361 331 306 284 265 248 221 199 181 166 140 1222 1070 951 856 778 713 658 611 570 535 475 428 389 357 329 306 285 267 233 214 194 178

SURFACE FEET PER MINUTE 150 1310 1146 1019 917 833 764 705 655 611 573 509 458 417 382 353 327 306 287 255 229 208 191 160 1397 1222 1086 978 889 815 752 698 652 611 543 489 444 407 376 349 326 306 272 244 222 204 Table 2-6. 170 1484 1299 1154 1039 945 866 799 742 693 649 577 519 472 433 400 371 346 325 289 260 236 216 180 1572 1375 1222 1100 1000 917 846 786 733 688 611 550 500 458 423 393 367 344 306 275 250 229 190 1659 1451 1290 1161 1056 968 893 829 774 726 645 581 528 484 447 415 387 363 323 290 264 242 200 1746 1528 1358 1222 1111 1019 940 873 815 764 679 611 556 509 470 437 407 382 340 306 278 255 225 1964 1719 1528 1375 1250 1146 1058 982 917 859 764 688 625 573 529 491 458 430 382 344 313 286 250 2183 1910 1698 1528 1389 1273 1175 1091 1019 955 849 764 694 637 588 546 509 477 424 382 347 318 270 2401 2101 1867 1681 1528 1401 1293 1200 1120 1050 934 840 764 700 646 600 560 525 467 420 382 350 300 2619 2292 2037 1833 1667 1528 1410 1310 1222 1146 1019 917 833 764 705 655 611 573 509 458 417 382

Tool Correction Chart

A.

TOOL CHATTER Check: 1. Tool overhand (reduce to minimum) 2. Work Support (eliminate vibration) 3. Nose radius (too large a radius may cause chatter) 4. Tool clearance (be sure end cutting edge angle is sufficient) 5. Feed (increase feed if too light a feed has tendency to rub rather than cut) 6. Tool load (vary side cutting edge angle to correct improper load) 7. Chip breaker (widen breaker if chips are too tight.)

2-64

T.O. 1-1A-9

Table 2-6.

Tool Correction Chart - Continued

B.

CHIPPING OF CUTTING EDGE Check: 1. Edge sharpness (Hone or chamber slightly) 2. Chip Breaker (widen breaker if tight chip causes chipping) 3. Speed (Increase) 4. Coolant (Heating and cooling of tip may cause chipping)

C.

RAPID TOOL WEAR Check: 1. Feed (Increase) 2. Speed (Low and excessive speeds cause tool wear) 3. Relief angles (clearance may not be sufficient) 4. Nose radius (decrease size)

D.

UNSATISFACTORY FINISH Check: 1. Speed (rough f inishes can be eliminated by increasing speed) 2. Nose radius (too large a nose radius mats f inish)

2-81. MACHINING CORROSION RESISTING STEEL. 2-82. The corrosion resisting steels, especially the 18-8 grades, are more difficult to machine than the carbon steels and most other metals. Even though they are more difficult to machine, the same general methods are used with modif ication/compensation for the individual characteristics of each type or grade. To improve machining characteristics of some types, their chemical content is modif ied by adding selenium (Se) and sulfur (S). The modif ied alloys which are usually
Table 2-7.

designated by a suffix to type number such as 430 F or Se. Exceptions are types 416 and 303. 2-83. For comparison and as a general guide to the machining characteristics of free machining screw stock grade B1112 as an 100% machinable norm. This table is only intended as a starting point and is not intended to replace any information accumulated through experience or other available data.

General Machining Comparison of Corrosion Resisting Steel To Free Machining Screw Stock B1112

GRADE/TYPE Group I 430F 416 420F 303

MACHINABILITY RATING 80% 75% 70% 65%

GRADE/TYPE Group III 420 431 440 442 446 347

MACHINABILITY RATING 45% 45% 45% 45% 45% 40-45% 40% 40% 40% 40%

Group II 403 410 430 440F

55% 50% 50% 50%

Group IV 302 304 309 316

2-65

T.O. 1-1A-9

2-84. In machining of the corrosion resisting steels, difficulty will be experienced from seizing, galling and stringing. To overcome these problems requires control of speeds, cutting tools, and lubricants. The following general practices are recommended for shaping/grinding cutting tools, equipment, etc., for cutting corrosion resisting steel: a. Select tools of proper alloy/type and keep cutting edges sharp, smooth, free of burrs, nicks and scratches. b. Avoid overheating cutting tool when grinding to prevent surface and stress cracking. c. Grind tools with generous lip rake and with ample side and front clearance. d. Speeds are critical in machining stainless; select speed about 50% slower than those used for carbon steels as a starting point. e. In general, use slow speeds and heavy feed to reduce effect of work hardening. Avoid riding of tool on work and intermittent cutting when possible. f. Apply proper lubricant/coolant to cutting tool to prevent overheating. g. Support cutting tool rigidly near work to prevent lash and other difficulty from use of heavy cutting feeds. 2-85. Cutting Tools for Machining Corrosion Resisting Steels. Selection of cutting tool is important for machining stainless due to tough machining characteristics. The following is a recommended guide for selection of tools: a. For general machining and short runs use high speed tool steels such as Tungsten Type T1
Table 2-8.

(18-41) and Molybdenum-Tungsten Type M3 (6-63). b. For medium runs at approximately 25% higher speed, use Tungsten-Cobalt Type T5 (18-42-8) and Tungsten-Cobalt Type T4. c. For long production runs at high speed, use Tungsten Carbides. Cutting tool of these alloys can be used at approximately 100% faster speeds than the Tungsten-Cobalt type. NOTE Some types of tool steel are available in raw stock in accordance with Federal Specif ications, see paragraph 7-4. Prior to attempting local manufacture of cutting tools, facilities/equipment must be available to properly heat treat. In addition, from an economic standpoint, it is usually advisable to obtain most cutting tools pref inished to size, etc., and heat treated. 2-86. TURNING OF THE CORROSION RESISTING STEELS. 2-87. Tools for turning the corrosion steels should be ground with a heavy side rake clearance for maximum cut freedom. The upper surface of the tool should be f inished with a f ine wheel or hand stoned to prevent galling. For chip disposal or breakage a chip grove is usually necessary except with the free machining grades. In addition, the chip breakage is a safety precaution to prevent difficulty and hazards in breaking the expelled cutting. Do not allow tools to become dull to prevent surface hardening from rubbing and hard spots which are difficult to remove.

Suggested Cutting Speeds and Feeds

ALLOY TYPE/GRADE 302, 304, 309, 310, 314, 316

FEED INCH 1/ 0.020-0.040 0.008-0.015 0.020-0.040 0.008-0.015 0.010-0.030

CUTTING SPEED SURFACE FT.PER MIN 20-40 50-80 40-60 90-110 150-200

OPER Rough Finish Rough Finish Rough

TOOL MATERIAL High Speed Steel High Speed Steel TungstenCobalt TungstenCobalt Carbide

2-66

T.O. 1-1A-9

Table 2-8.

Suggested Cutting Speeds and Feeds - Continued

ALLOY TYPE/GRADE

FEED INCH 1/ 0.008-0.018

CUTTING SPEED SURFACE FT.PER MIN 150-300 20-40

OPER Finish Rough

TOOL MATERIAL Carbide High Speed Steel High Speed Steel TungstenCobalt TungstenCobalt Carbide Carbide High Speed Steel High Speed Steel TungstenCobalt TungstenCobalt Carbide Carbide High Speed Steel High Speed Steel TungstenCobalt

420, 431, 440, 442, 446, 347, 321

0.015-0.040

0.008-0.018 0.015-0.040 0.008-0.018 0.015-0.030 0.005-0.015 430F, 416 0.015-0.040 0.008-0.018 0.015-0.040 0.005-0.015 0.010-0.030 0.005-0.015 420F 303 0.015-0.050 0.005-0.015 0.020-0.050

55-90 40-80 100-130 165-220 165-330 30-60 75-120 60-105 135-180 225-300 225-450 25-55 65-105 50-90

Finish Rough Finish Rough Finish Rough Finish Rough Finish Rough Finish Rough Finish Rough

2-67

T.O. 1-1A-9

Table 2-8.

Suggested Cutting Speeds and Feeds - Continued

ALLOY TYPE/GRADE

FEED INCH 1/ 0.005-0.015 0.010-0.030 0.005-0.015

CUTTING SPEED SURFACE FT.PER MIN 100-155 175-240 195-350

OPER Finish Rough Finish

TOOL MATERIAL TungstenCobalt Carbide Carbide

NOTE: 1/ Feeds cited are based on turning 1 inch stock or larger. Feeds for smaller sizes should be reduced proportionally to size of material being turned.
Table 2-9. Tool Angles - Turning

NOTE In grinding chip breakers, allow for chip to clear work or rough f inish will result. 2-88. The sof ter condition of stainless is not necessarily the easiest to cut. It is generally preferable that material be moderately hardened (Brinell

200-240) for best machining. Another factor requiring consideration in machining stainless is high co-efficient of thermal expansion which will necessitate adjusting (slacking off) centers as material heats up.

2-68

T.O. 1-1A-9

2-89. The recommended cutting speeds, tool angles and feeds for turning corrosion resisting steel are cited in Tables 2-8 and 2-9. 2-90. MILLING CORROSION RESISTING STEEL. The same general procedures/equipment are used in working stainless as those used with carbon steel. However more power and rigid support of tool is required to accomplish cutting due to inherent strength and toughness of the various stainless alloys. 2-91. In milling the corrosion resisting steel, difficulty will be experienced from heat build-up. Heat conduction of the chromium-nickel grades is about 50% slower than the carbon steels. This problem can be controlled in most cases by adjusting cutting speeds, tool angles, method of grinding, and use of proper lubricants in adequate quantities. In close tolerance work, controlling of heat build-up is of utmost importance to meet dimensional requirements. 2-92. Cutters for Milling. High speed tool steel is used for most milling on stainless. The other grades are used under certain conditions, such as cemented carbides; however, capacity of equipment and cost of tooling for specif ic uses requires consideration. 2-93. All the standard cutter designs used for cutting carbon steel can be used to cut stainless but preferred design is those with helical (spiral) teeth. The use of helical cutter minimizes vibration and chatter especially when cutter/cut exceeds 1 inch. Chip removal and loading of cutter can be aided when milling slots by staggering teeth to cut
Table 2-10.

successively on alternate sides and half the bottom. 2-94. Cutter lands should be ground to narrow width (0.020 to 0.025) with clearance (3o-10o primary angular) behind cutting lip to reduce frictional heat resulting from rubbing. The exact amounts the land is ground will depend on diameter of cutter, material hardness, grade, etc. However, in grinding the lands, care should be taken to avoid unnecessary weakening of support for cutting edge. As a further measure against rubbing, a secondary clearance of 6o-12o starting at the back of the land is recommended. On side cutter, angular clearance of 3o to 10o to avoid frictional heat and rubbing is recommended. CAUTION Before starting operation/equipment, carefully check for proper set up, safety, rigid support of work and cutters, running condition of equipment, and f low of coolant/lubrication. Once cutting is started, it should be carried to completion to avoid the effects of changes in metal temperature. Naturally the continuous operation will depend on satisfactory operation of equipment and other factors. 2-95. The recommended cutting speeds, tools, angles, and feeds for milling are cited in tables 2-10 and 2-11. The information in these tables is only provided as a starting point, or as a guide.

Suggested Milling Cutting Speeds and Feeds

ALLOY TYPE/GRADE 301, 310, 347, 420, 446 302, 304, 309, 314, 316, 321, 17-4PH, 17-7PH, 431, 440, 442,

FEED INCH 1/ 0.002-0.005 0.002-0.007 0.002-0.008 0.002-0.008 0.002-0.008 0.002-0.006 0.002-0.006

SPEED SFPM 35-70 30-95 35-90 35-70 50-100 50-130 35-80

TOOL MATERIAL High Speed Steel High Speed Steel High Speed Steel High Speed Steel High Speed Steel High Speed Steel High Speed Steel

403-410, 430 440F 303 430F, 416 420F

1/ Use heavy feeds for rough cuts and light feeds for f inishing.

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T.O. 1-1A-9

Table 2-11.

Suggested Tool Angles - Milling

TOOL ANGLES Rake Radial 1/ Rake Axial 1/ Clearance Land Width

TOOL MATERIAL HIGH SPEED STEEL CEMENTED CARBIDE/C 10 -20 4 -8

o o o o

ALLOY

Use lower angle Use lower angle Approximately same Approximately same

30o-50o 1/64-1/16

1/ Saws, form relieved cutters, and miscellaneous prof ile cutters, etc., are sometimes used with rake angle as low as 0 degrees. 2-96. Lubrication for Milling. The lubrication of milling cutter is very important to control generation of heat which is considerable in cutting all grades of stainless, and to prevent seizing of chips to cutting edges. The cutting oils used should be applied in large quantities directly on the cutter and zone of cut. The sulphurized oils diluted to desired viscosity with paraffin oil are usually satisfactory. 2-97. DRILLING CORROSION RESISTING STEEL. High speed steel drills are commonly used for drilling stainless. Special types are used for drilling grades (420, 440, etc.) that are abrasive due to high carbon content. Speeds for drilling the high carbon types are usually reduced 25-50%o in comparison to the other grades. 2-98. Drills for use with the corrosion resisting steels are prepared with different cutting angles than used with carbon steel. Drill point/tips for use with the chromium-nickel grades are usually ground with 135o-140o (included) angle and 8o-15o lip clearance. The webb support for the point should be as heavy as possible; however, thinning of the webb at the point will relieve point pressure. When drilling the free machining 400 series grades the angle is reduced to 118o-130o. For general illustration of point designs see Figure 3-2. 2-99. Speeds used for drilling the corrosion resisting steels should be closely controlled to prevent hardening of metal and excessive drill damage from heat. For suggested drilling speed using high speed steel drill bits, see Table 2-12.
Table 2-12. Drilling Speeds for Corrosion Resisting Steel

GRADE TYPE 301, 302, 304, 310 303 309, 316, 321, 347 403, 410 416, 420F, 430F 420 AB & C 442, 446

SPEED SFPM (APPROX) 20 40 30 35 60 20 30 40 80 50 75 95 40 60

NOTE Do not let drill ride on work to prevent work hardening and heat damage to drill. On larger diameter drills use chip curling grooves to help expel and prevent chip accumulation in area of hole being drilled. 2-100. Lubrication for Drilling Stainless. The recommended lubrication for general use and light drilling is soluble oil, and for heavy work, sulphurized mineral or fatty oils. Utilization of adequate lubrication/ coolant is of utmost importance in drilling stainless due to poor heat conduction of this material. 2-101. REAMING CORROSION RESISTING STEEL. The recommended reamer for the corrosion resisting steels is the spiral f luted type which is made from high speed steel/carbide tipped. These spiral f luted reamers are used to help alleviate chatter and chip removal that are associated with the straight f luted reamers. 2-102. Due to the work hardening characteristics of the corrosion resisting steel, it is advisable to leave sufficient stock to insure that cutting will occur behind the work hardening surface resulting from drilling. The recommended material to be lef t for reaming is 0.003-0.007 inch, and feed per revolution should be 0.003-0.005 for holes up to 1/2

2-70

T.O. 1-1A-9

inch and 0.005-0.010 for reamers up to 1 inch diameter. 2-103. Reamers for cutting stainless should have a 26o-30o starting chamfer with a slight lead angle behind the chamfer of 1o-2o for about 1/8-3/16 inch on the land to reduce initial shock of cutting. The land should be ground with a clearance of 4o-7o (and width should not be reduced below 0.0100.012 inch) to reduce rubbing and frictional heat. 2-104. Speeds for reaming will vary according to type of material being cut. The recommended speed for reaming types 301, 302, 304, 316, 321, 347, 403 and 410 is 20 - 75 surface feet per minute; for 430F, 420F, 416, 440F and 303 --35 - 100 SFPM; and for 309, 310, 430, 431, 440, 442, 426 20-60 SFPM. Trial should be conducted to determine best cutting for indivldua1 operations. 2-105. TAPPING CORROSION RESISTING STEEL. Conventional or standard type taps are used with stainless; however, better results can sometimes be obtained by modif ication of taps (in shop) as required and by use of two f luted type
Table 2-13.

taps for small holes. For instance modif ication of taps can be accomplished by grinding longitudinal grooves along the lands, omission of cutting edges on alternate threads and relieving cutting edges will reduce binding and frictional drag. These modifications will also aid in distribution of lubrication to cutting area, provide additional clearance for chips and compensate for the swelling which is encountered with the sof ter temper material. The modification is usually accomplished as follows: a. Longitudinal grooves are ground down the center of each land about 1/3 to 1/2 thread depth and 1/3 to 1/2 approximately of land width. b. Cutting edges are relieved by grinding a 2o5 radial taper on each land.
o

c. Lands are narrowed by removing about half the threading area from each land. The portion removed should trail the foremost cutting edge. Also, cutting edge should be ground to have positive hook/rake 15o-20o for sof ter material and 10o-15o for harder material.

Tapping Allowances (Hole Size to Screw Size)

THREAD/SCREW SIZE 4-40

MAJOR DIA. 0.1120

MINOR DIA. 0.08710.002

DRILL SIZE DECIMAL & NR 0.0810-46 0.827-45 0.0860-44 0.0890-43 0.0960-41

THREAD DEPTH PERCENT 95 90 80 71 49 95 83 72 54 97 77 65 96 87 69 57

6-32

0.1380

0.11000.004

0.0995-39 0.1040-37 0.1100-35 0.1160-32

6-40

0.1380

0.11440.0035

0.1065-36 0.1130-33 0.1200-31

8-32

0.1640

0.13420.004

0.1250-1/8 0.1285-30 0.1360-29 0.1405-28

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T.O. 1-1A-9

Table 2-13.

Tapping Allowances (Hole Size to Screw Size) - Continued

THREAD/SCREW SIZE 10-32

MAJOR DIA. 0.1900

MINOR DIA. 0.15930.003

DRILL SIZE DECIMAL & NR 0.1520-24 0.1562-5/32 0.1610-20 0.1660-19 0.1695-18

THREAD DEPTH PERCENT 93 83 71 59 50 100 96 87 78 63 100 86 75 68 88 80 67 95 86 75 65 86 70 66 86 57

1/4-20

0.2500

0.20100.005

0.1850-13 0.1875-3/16 0.1935-10 0.1990-8 0.2090-4

1/4-24

0.2500

0.21430.003

0.1960-9 2031-13/64 0.2090-4 0.2130-3

1/4-28

0.2500

0.21930.002

0.2090-4 0.2130-3 0.2187-7/32

5/16-24

0.3125

0.27080.0032

0.2610-G 0.2656-17/64 0.2720-1 0.2770-J

3/8-24

0.3750

0.32780.002

0.3281-2 1/64 0.3320-Q 0.3390-R

1/2-24

0.5000

0.45790.003

0.4531-29/64 0.4687-15/32

2-106. In addition to the above, the tap basically should have a taper/chamfer of about 9o with center line on the starting end to facilitate entry into hole. The taper should be held short (1st thread) for blind holes, and on through holes, it may extend over 3 or 4 threads

2-107. Due to high strength and poorer cutting quality of the stainless series steels, holes for tapping are usually made as large as possible consistent with f it specif ied by drawing or other data. Actually due to the higher strength of this material less thread area or engagement is required in comparison to most other metals. Due to the above and the fact that less cutting is required, 75% thread depth is generally used as maximum

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T.O. 1-1A-9

unless otherwise specif ied. Higher percentages of thread depth are necessary in material when stock is not thick enough to permit the required number of thread. For tapping allowances of some size screws/bolts see Table 2-13. 2-108. The decreased thread depth also reduces tendency to gall and seize, power required to drive tap, tap wear, and effect of swelling in sof t material. 2-109. Tapping Speeds Corrosion Resisting Steel. Tapping speeds used for stainless should be slower than those used for carbon steel. The 18-8 (300 series) are usually tapped at 10-25 SFPM except for the free machining types which are tapped at 15-30 SFPM. The straight-chromium 400 series generally is tapped at 15-25 SFPM, except the free machining grades, which are tapped at 15-35 SFPM. 2-110. Lubrication for Tapping. The lubrications recommended for tapping are sulphurized mineral oils with paraffin and lard oil. The lubricant serves to prevent overheating as well as lubrication, and if applied under pressure, aids in chip removal. Oil f low/application should be applied before tapping commences to prevent initial congestion of cuttings. 2-111. SAWING. 2-112. Hack saws (hand) for cutting corrosion resisting steel should be of high speed steel with approximately 32 teeth per inch for light work and approximately 24 teeth per inch for heavy work. The teeth area should be of wavy construction to increase width of cut area to prevent binding. As with cutting other metal, the blade should not be allowed to drag/ride on the return stroke, especially with the 300 series types to prevent work hardening. The hack saw blade should be lightly lubricated with lard oil/other cutting oil for best results. 2-113. Hack saws (mechanical drive). Power hack saws are used for heavy cross-cutting section

bars, tubing, etc. With the power hack saw, deeper cuts are made at relatively low speed. The deeper cuts are used to get under work hardened surface resulting from previous cut (stroke). The teeth per inch for saw blades average 8-12 and speed of saw travel usually ranges from 50-100 feet per minute depending on type and temper of material being cut. Coolant/lubrication is essential to prevent excess blade damage from heat. Lubrication recommended is soluble oil/water mixed about 1 part oil to 4 parts water for heavy work, and for light work, a light grade cutting oil. 2-114. Band Sawing. Band saws are well suited for low speed (straight line/contour) sawing of stainless/corrosion resisting steel within prescribed limitation. The saw manufacturers recommendations should be followed for cutting speed, saw selection, etc. However, speeds usually vary with the physical properties, temper, etc., of type/grade being cut. As general guide, speeds range from 100-125 feet per minute for material under 0.062 and 60-100 FPM for thickness over 0.062 inch. Saw blades must be kept in sharp condition for effective low speed sawing. 2-115. For faster cutting with the band saw, the friction cutting method may be employed. In utilizing the friction method, the band saw velocity ranges from 5000 FPM for cutting f lat 1/32 inch material to about 10,000 FPM for 1/2 inch and 14,000 for 1 inch material; tubing material is run at slightly higher speed. Feed for this method can be considerably higher than is used for slow speed cutting, rates range from about 100 FPM for light gauge to 15-18 FPM for 1/2 inch material. Saw teeth per inch varies from 18 for material below 1/ 8 inch thick to 10 per inch for thicknesses over 1/2 inch. 2-116. Heavy pressure to maintain cut is not usually necessary. Pressure should be just sufficient to create proper heating and sof tening at cut point without forcing the saw. Lubricants should not be used.

Paragraph 2-117 through 2-227 deleted. Tables 2-14 through 2-33 deleted. Figures 2-2 and 2-3 deleted. Pages 2-75 through 2-120 deleted.

Change 1

2-73/(2-74 blank)

T.O. 1-1A-9

2-228. 2-229. 2-230. 2-231. 2-232. 2-233.

(Deleted) (Deleted) (Deleted) (Deleted) (Deleted) (Deleted)

reading, assembly, etc., in accordance with scope of relation to fabrication process. Also, these personnel must keep constantly abreast of advancing processes for maximum efficiency/proficiency. 2-236. The section of steel for design or application to equipment and component is usually based on the following: a. Strength and weight requirement of part/ equipment to be fabricated. b. Method to be used for fabrication, i.e., welding, forming, machining, heat treat, etc. c. Corrosion resistance to certain chemicals/ environments. d. Temperatures to which part will be subjected. e. Fatigue properties under cyclic loads, etc. 2-237. The following general rules should be employed in handling and forming:

2-234. FABRICATION OF FERROUS ALLOYS. The information furnished in this section is provided as a guide to aid personnel engaged in the use and application of the ferrous alloys. Due to varied usage of steel products, details and rules related will not f it every application. In many instances, experimentation trial and further study will be required. 2-235. Personnel assigned to accomplish designs, application and fabrication must be well trained in fundamentals of metal forming practices, analysis, properties, corrosion control, machining, plating, welding, beat treat, riveting, painting, blue print

Change 1

2-121

T.O. 1-1A-9

a. Sheet, sheared/sawed strips and blank shall be handled with care to prevent cutting and other parts of the body. b. Sheared or cut edges shall be sanded, f iled, or polished prior to forming. The removal of rough and sharp edges is also recommended prior to accomplishing other machining operations to reduce hazards in handling. c. Form material across the grain when possible using correct or specif ied bend radii. Also provide bend relief in corner when required. d. Observe load capacity of equipment such as brakes, presses, rolls, drills, lathes, shears, mills, etc. CAUTION Machines rated for carbon steel shall not be used over 60% of rated capacity when cutting, forming or machining stainless steel unless approved by responsible engineering activity. When in doubt inquire. e. Tool and equipment shall be maintained smooth, free of nicks, rust, burrs and foreign material. In addition to above, dies, ways, etc., shall be checked for alignment tolerances, etc., periodically/ each set-up. f. Surfaces of material, especially f inished sheet, shall be protected from scratching, foreign particles, etc. These surfaces can be protected using non-corrosive paper, tape, other approved material and good cleaning procedures. Polished sheet material should be protected when forming to prevent die tool marking. g. After forming/machining is completed, remove all cutting lubrication, etc., by cleaning, degreasing, pickling, prior to any heat treat, plating or painting process. CAUTION Avoid handling parts, especially corrosion resistant steel, with bare hands after cleaning and subsequent to heat treating/ passivation because f inger prints will cause carburization and pitting of surface, when heated. 2-238. BENDING (SINGLE CURVATURE). The bending of most steel sheet and thin bar stock can be readily accomplished provided that equipment with adequate bending and cutting capacity is available and if the materials are formed in the

soft condition/lower temper range. The heat treatable alloys are usually formed in the annealed or normalized condition and heat treated if required/ specified af ter forming. Some difficulty will be encountered from warping due to treat treating and precautions must be taken when forming the material to prevent sporadic or uneven stress in the work piece. Also, parts will require jigs or close control during the heating and cooling phase of heat treatment. The use of heat treated formed sheet metal parts on aerospace craf t are usually an exception in part due to above and most materials are used in the normalized or annealed condition. 2-239. Springback allowance will vary according to the type and temper of material being formed. The use of sharp bend radii on parts for aeronautical application shall be avoided and other application where the parts will be subjected to f lexing (cycle) or concentrated stresses, due to possible fatigue or stress corrosion failure. For recommended General Bend Radii for use on Aerospace weapon/equipment (see Table 2-34 for Low Carbon/low alloy steel and Table 2-35 for Corrosion Resistant Steel.) 2-240. In utilizing Table 2-34 and Table 2-35 it is recommended that in practice bend area be checked for strain, grain, or bend cracking. If parts show presence of above, increase radius by one thickness or more until difficulty does not exist. Other details, inspection requirements, etc., shall be used when specif ied. 2-241. DRAW FORMING. Control of die design, and material from which dies are made, are essential to successfully draw form steel. For long production runs, high carbon, high chromium steel is recommended to manufacture drawing dies because of wear resistance and hardness. For medium and short production runs, Kirksite/case zinc alloy can be used with drop hammer hydraulic press if the draw is not severe. Hardwood and phenolic can be used in some cases for piece production where draws are shallow. 2-242. on: Successful drawing of steel will depend

a. Radii used for forming or bending. Use moderate radii, usually equal to 3-6 times thickness of material depending on specif ic requirements, and the severity of draw. b. Finish of die-all scratches and surface roughness should be removed. c. Blank hold down pressure and drawing rings. Hold down pressure should be sufficient to prevent wrinkling of material, but not to the extent that would prevent f low of the metal into

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the female portion of the die. Drawing rings radii should be 4-8 times metal thickness and smoothly polished. d. Clearance between punch and die - Generally punch clearance should be about 1 1/4 to 1 1/2 times thickness for the initial draws, and about 1 1/8 to 1 1/4 times for the following draws. If parts show signs of galling, clearance (drawing) should be increased when clearance is increased, size requirement must be considered. e. Temper-drawing should be started with annealed/normalized material and intermediate annealing accomplished as required. The requirement for annealing (intermediate) usually is needed af ter reduction exceeds 30-35% for stainless/20-25% carbon steel on the initial draw, and when reduction exceeds 8-15% on each following draw. Parts should be cleaned removing all lubrication and other contaminate prior to annealing and desealed af ter annealing. In instances where draws exceed 22-25% annealing is recommended after completion of the drawing operation followed by descaling and passivation (stainless). Restriking on f inal stage die to remove distortion af ter f inal anneal is permissible without further heat treatment. f. Drawing Speed - Generally a speed of 2055 feed per minute is satisfactory. Drawing using a hydraulic powered press in lieu of a cam operated or toggle type press is usually the most satisfactory, g. Lubricant - Compounds used should be of heavy consistency capable of withstanding high temperature and restating pressure necessary to form material. One heavy bodied lubricant used is lard oil, sulfur (one pound of sulfur to 1 gallon of oil) to which lithopone is added in equal parts until consistency equals 600W engine grease, or as desired. Other compounds such as tallow, mixture of mineral oil and sof t soap, powdered graphite mixed to thin paste with lightweight oil can be used. h. Blank size and preparation - A good practice is to use minimum size required to meet dimensional size of parts and for hold down. When trimming, consideration must be given to the fact that on rectangular parts, the majority of drawings will occur on wider portions of the rectangle away from the corners. To overcome this problem, the radius of the vertical corner should be approximately 10% of the width. Trial, using a very ductile material to determine blank size and stress areas prior to starting the forming operation is recommended. Af ter size is determined by trial, etc., the blank should be f iled/polished to prevent cracking in wrinkle/stress areas, handling hazard

and surface friction which hinders f low of metal into die. 2-243. The surface condition of the blank also has an effect on drawing. A slightly roughened surface, such as obtained by pickling (dull surface) improves control of metal under hold down pads and the holding lubricants. On the other hand, the roughened surface may be less desirable because of greater friction, especially where free f lowing drawing methods are used (without hold down). 2-244. Where facilities are available, cold forming of some steels (primarily straight chromium stainless such as 410, 416,430, 442, 446) can be improved by preheating dies and blanks. The preheating tends to reduce work hardening and the requirement for intermediate annealing during the drawing operation. 2-245. When forming involves more than one draw, the f irst operation should be a moderate draw with punch diameter equal to 60% of blanks diameter and reduction of 15-25%. The second and subsequent draws should be made with punches about 20%. It is recommended that part be cleaned and annealed following each draw. Excessive distortion may result from f inal annealing af ter last draw. This problem can be overcome in most instances, by reducing the severity of the last draw or restriking af ter f inal annealing on last stage die for the purpose of removing distortion.

CAUTION Parts shall be cleaned of all contaminates, lubrication, f iling, other foreign material, etc., before heating or annealing and upon completion of forming or drawing operation. Failure to clean the parts will result in pitting and carburization, which will damage the surface. 2-246. STRETCH FORMING. Stretch forming is a process where material, sheet or strip, is stretched beyond the elastic limit until permanent set will take with a minimum amount of springback. 2-247. The stretch forming is usually accomplished by gripping ends of material (blank) and applying force by a separate ram carrying the forming die. The ram pressure sufficient to cause the material to stretch and wrap to contour of the die form blank is applied perpendicular to the blank (see Figure 2-4). This method of forming is

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usually limited to parts with large radii of curvature and shallow depth, such as shallow dishing, reverse curves, and curved pan shaped parts containing f lat areas. 2-248. The trimming of edges and removal of nicks and scratches is important to prevent starting points for concentrated stress, which, under tension loads, would tear. The direction of major tension (stretch) and direction of grain is also important. It is recommended in forming that the major tension be transverse to the direction of grain. Lubrication aids in uniform distribution of stress and the lubricant shall be applied uniformly to work piece to avoid distortion which could result from unequal friction when material is sliding across the forming die during stretching. 2-249. Forming dics/blocks for general production are made from kirksite/zinc, alloy; for piece production from phenolic and hardwood. Some types and kinds of plastic with good hardness and high impact strengths are also used. The rubber pad hydraulic press is used to form relatively f lat parts having f langes, beads, lightening holes, and for very light drawing of pan shaped parts having large radii. 2-250. Form blocks are usually manufactured from steel, phenolic (mechanical grades), kirksite/ zinc cast alloy, and some types of hard molding plastic with high impact strength. The work is accomplished by setting the form block on the lower press plate or bed, and the blank is placed on the block. The blank is held in place on the block by locating pins (holes are drilled through the blank and into the form block for the insertion of the locating pins). These holes are referred to as tooling holes, which prevent slippage of blank when pressure is applied. If tooling holes are not allowed, another method of alignment and holding of blank must be utilized. The sheet metal blank should be cut to size (allow sufficient material to form f lange), deburred, and f iled prior to pressing. After the block is prepared and placed on the plate, the rubber pad f illed press head is lowered or closed over the block, and as the hydraulic pressure (applied by a ram to the head) increases, the rubber envelopes the form block forcing the blank to conform to the form block contour or shape. It is recommended that additional rubber be supplemented in the form of sheets (usuually l/2 - 1 inch, hardness of 70-80 durometers) over the form block and blank to prevent damaging the rubber press pad. The design of form blocks for hydropress forming requires compensation for springback. The form for forming f langes on ribs, stiffners, etc., should be undercut approximately 2-8 degrees depending on the alloy, hardness, and radius. In

some cases, it will be necessary to use a combination of hand forming shrinking/stretching using supplemental machinery and pressing to complete forming by this method. 2-251. DROP HAMMER FORMING. Dies for drop hammer forming are usually made by casting metals such as kirksite. These dies can be rapidly produced; are more economical than permanent dies; can be melted and recast; and can be reinforced at selected points of wear by facing with harder material, such as tool steel for long production runs. 2-252. Normally, drop hammer forming is accomplished without benef it of hold down. The metal is slowly forced in shape by controlling the impact of blows. In many instances, it is necessary to use drawings, rings, 2 or 3 stage dies, supplemental equipment, and hard forming such as bumping hammer, wooden mallet to remove wrinkles, etc. To successfully complete forming operations, another aid that may be necessary is to anneal material between die stages and intermediately for single stage die forming.

CAUTION Parts should be cleaned prior to annealing to protect f inish. Care should be taken to remove all traces of zinc that may be picked up from kirksite forming dies, as failure to remove the zinc will result in penetration of the steel (stainless) when treated and will cause cracking. 2-253. SPINNING. Those steels that have low yield strengths in the sof t/annealed condition, and low rates of work hardening are the best grades for spinning. To overcome work hardening problems, intermediate annealing and 2-3 or more stage spinning blocks are used. Annealing of the part at intervals also aids the operator when manual spinning, because less pressure is required to form metal and springback is lower. 2-254. Form blocks for spinning are usually made of phenolic, hard wood, or carbon steel. Manual spinning is usually accomplished on a lathe specif ically adapted and f itted for that purpose. The main requirements are that required speed be maintained without vibration; clamping pressure is sufficient to hold part; facilities are provided to apply pressure at a uniform rate; and tools are of proper design. Normally, spinning tools are the roller or round nose type designed in such a manner that high pressure can be applied without bending. Where local design of tools are

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required, raw material for manufacture is obtainable under QQ-T-570, Type D2, hardened to Rockwell C40-50. 2-255. SHEARING AND BLANKING. To prevent damage to shear, and to assure clean, accurate cuts, clearance between shear blades should be approximately one-twentieth (5%) thickness of material to be cut. Also, blades or knives must be maintained in sharp condition, clean, and free of nicks. Where only one shear is available, a clearance of 0.005 to 0.006 could be used for general shearing of sheet stock up to 0.125 inches thick. Excessive blade clearance should be avoided to prevent work hardening of cut area which increases susceptibility to stress corrosion and burring. Lubrication such as lightweight engine oil or soap should be applied at regular intervals to prevent galling and to clean blades for prolonged shear blade life. 2-256. BLANKING AND PUNCHING. Blanking and punching requires close control of die clearance, shearing action of punch/blanking die. Clearance for blanking and punching should be 5% of thickness and closely controlled for all gauges. In designing dies and punches, it is important that shear action be incorporated to equalize and reduce load. Double shear should be used when possible to minimize off balance condition and load. Punches and dies should be maintained in clean sharp condition and lubricated by swabbing or spraying material to be punched with lightweight lube oil to prevent galling and to aid in keeping punch/die clean. 2-257. GENERAL FABRICATING CHARACTERISTICS. 2-258. PLAIN CARBON AND ALLOY STEELS.

used for wire and rod for cold upsetting applications, such as bolts. The higher carbon groups, such as 1040 are of ten cold drawn to required physical properties for use without heat treatment. 2-262. Alloy Steels - 1055 through 1095. This alloy group is used where wear resistance resulting from high carbon content is needed, and is heat treated before use in partically every application. 2-263. 1100 Series Steel. Steels in this group are generally used where easy machining is the primary requirement. The main use of these steels is for screw stock. 2-264. 1300 Series Alloy Steel. The basic advantages of this group is high strength coupled with fair ductility and abrasion resistance. The major use is in the manufacture of forgings. 2-265. 2300 Series Nickel Alloy Steels. The addition of nickel has very little effect on machinability and greatly increases elasticity and strength. This material is normally machined in the forged, annealed, and normalized condition, and heat treated af ter fabrication. NOTE These grades not currently being produced. Listed for reference only. 2-266. 2500 Series Nickel Steel. This series almost without exception, is a carburizing grade with extremely high strength core. However, the case is not as hard as obtained with other carburizing steels. This steel is used for parts requiring a high strength core and good wear resistance. NOTE These grades not currently being produced. 2-267. 3100, 3200, and 3300 Series Nickel Chromium steels. This series of steels is characterized by good wear resistance and tough core and surface. The 3300 series is used primarily in the form of forgings and bars which are required to meet rigid mechanical properties. This steel is more difficult to handle in fabrication and heat treatment than lower nickel - chromium alloys. 2-268. 4000 Series Molybdenum Steels. This group of steels have good impact strength and require close control of heat treatment practices to obtain the required strength and ductility. 2-269. 4100 Series Chromium - Molybdenum Steels. This series has good working properties, response to heat treatment, and high wear resistance. This group is easily fabricated by forging

2-259. Plain Carbon Steel - 1006 through 1015. This group of steels is used where cold formability is the main requirement, and have good drawing qualities. This series is not used where great strength is required. The strength and hardness of these grades will vary according to carbon content and amount of cold work. 2-260. Plain Carbon Steels - SAE 1016 through lO30. This group of steels is commonly known as the carburizing or case hardening grades. The addition of manganese improves machining qualities but reduces the cold formability characteristics. This group is widely used for forged stock. 2-261. Plain Carbon Steels - 1030 through 1050. This group (medium carbon types) is used where higher mechanical properties are required. The lower carbon and manganese types are used for most cold formed parts. Alloys 1030 - 1035 are

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and rolling. Af ter welding and cold forming, internal stresses produced should be relieved and loss in strength regained by normalizing. 2-270. 4130 Grade Steel. This grade is used extensively in aircraf t construction in the form of sheet, bar, rod and tubing. This grade has very good cold forming characteristics. Forming and welding operations are accomplished utilizing annealed material, and heat treated or normalized after these operations are completed. 4130 sheet (MIL-S-18729 can be cold bent in the annealed condition to an angle of 180o with a radius equal to the thickness of the sheet. In the normalized condition, a radius equal to 3 times the thickness is recommended. 2-271. 4140 Series Steel. This steel is used for structural, machined and forged parts over 1/2 inch thick. It is usually obtained in the normalized condition. Forgings are always normalized or heat treated af ter fabrication. 2-272. 4300 Series Nickel - Chromium - Molybdenum Steels. These steels are used to meet conditions in which other alloy steels have insufficient strength. Preparation for machining or forming must be by a suitable annealing cycle. 2-273. 8000 Series Molybdemum Steels. These steels are characterized by their high impact strength and resistance to fatigue. They are easy to forge and machine, and are stable at high temperatures. 2-274. 8600, 8700, 9300, 9700, 9800, and 9900 Series Steels. These steels have approximately the same characteristics as the 4300 series steele. 2-275. CORROSION RESISTANT (STAINLESS) AND HEAT RESISTANT STEELS. 2-276. The fabrication of stainless steel requires the use of modif ied procedures in comparison to those used for carbon steels. 2-277. Forming Sheet Stock. The corrosion resisting series, i.e., types 301, 302, 304, 305, 316, 321, 347, 410, 430, 431, etc., generally have good forming and drawing qualities. Some types (302, 304 and 305) have forming characteristics superior to plain carbon steel because of the wide spread between tensile and yield strength, and higher elongation. However, more power is required to form these types than is required for carbon steel because of higher tensile strengths and the fact that yield strength increases rapidly during forming or bending.

2-278. The straight chromium grades such as 410, 416, 430, 442, and 446 react similar to carbon steel and are somewhat less ductile than the 300 series stainless. The tensile strength are higher than carbon steel and consequently will stand higher loads before rupture. Yield strengths are also higher which means that more power is required for bending and forming. Because of the ductility factor of this series drawing and forming should be limited to 20 -25% reduction. 2-279. The 301, 302, 304, 305 and 316 types can be drawn based on a reduction of 35 to 50%, i.e., a shape 8 inches in diameter and 4 inches in depth could be drawn in one operation, based on a 50% reduction. 2-280. The strains set up by severe reductions (above 45% with chromium-nickel types and 20% with straight chromium types) should be relieved by annealing immediately af ter the operation is completed, especially if using type 301. If this material is not relieved in 2 - 4 hours, it may crack. 2-281. Springback allowance should be about 2 to 3 times the amount allowed for carbon steel, and naturally will vary according to the type of material being formed. The use of sharp radii shall be avoided where parts are subjected to f lexing or concentrated stresses due to possible fatigue or stress corrosion failure. 2-282. Recommended bend radii for use with stainless is shown in Table 2-35. 2-283. Draw Forming. Stainless steels should be annealed for draw forming, and hardness should not exceed Rockwell B90. The beat drawing grades are of the 18-8 series. In selecting the type for drawing, welding of the f inished parts, if required, shall be considered. 2-284. Drop Hammer Forming. The most common types of corrosion resistant steel used for drop hammer forming are 301, 302, 304, 305, and stablized grades 321 and 347. 301 work hardens more rapidly and is subject to strain cracking. The condition of material for best forming should be annealed. It is possible to form some type (301 and 302) in 1/4 and 1/2 hard condition. However, the severity of the forming operation must be reduced to compensate for the prehardened material.

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Figure 2-4.

Stretch Forming

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Table 2-34.

Cold Bend Radii (Inside) Carbon/Low Alloy Steels

Temper, Sheet Thickness = T (Inches)

Alloy Temper 1020/1025 4130 Annealed 4130 Normalized 8630 Annealed 8630 Normalized

0.016 2T 2T 2T 3T 3T

0.020 2T 3T 3T 3T 3T Table 2-35.

0.025 2T 2 1/2T 2 1/2T 2 1/2T 2 1/2T

0.032 2T 2T 3T 3T 3T

0.040 2T 2 1/2T 3T 2 1/2T 3T

0.050 2T 2T 3T 2T 3T

0.063 2T 2T 3T 2T 3T

0.125 2T 2T 3T 2T 3T

0.187 2T 2T 3T 2T 3T

Cold Bend Radii (Inside) Corrosion Resistant Steel Alloys

Sheet Thickness = T (Inches)

Alloy 201, 202 301, 302 305, 304 309, 310 316, 321, 347 405, 410, 430 17-7PH

Temper Annealed 1/4 Hard 1/2 Hard 3/4 Hard Hard Annealed Annealed Table 2-36.

0.012 - 0.051 1-2T 1-2T 2T 2T 3-4T 1T 1T

0.051 - 0.090 1T 1 1/2T 2T 3T 4-5T 1T 1 1/2T

0.190 - 0.250 1 1/2T 2T 2T --1 1/2T 2T

Forging Temperature Ranges For Corrosion Resistant Steel

TYPE/GRADE 301 302 303 304 305 308 316 321 374

PREHEAT oF 1500-1600 1500-1600 1500-1600 1500-1600 1500-1600 1500-1600 1500-1600 1500-1600 1500-1600

FORGING TEMPERATURE oF STARTING FINISHING 2050-2200 2050-2200 2050-2200 2050-2200 2100-2200 2100-2200 2150-2250 2100-2200 2100-2200 1600-1700 1600-1700 1700-1800 1600-1700 1600-1700 1600-1700 1600-1700 1600-1700 1650-1750

HEAT TREATED

SEE HEAT TREAT DATA FOR ANNEALING AND STRESS RELIEF, SEE TABLE 2-3.

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Table 2-36.

Forging Temperature Ranges For Corrosion Resistant Steel - Continued

TYPE/GRADE

PREHEAT oF

FORGING TEMPERATURE oF STARTING FINISHING

HEAT TREATED

AIR HARDENING 403 410 414 416 420 431 440 NON-HARDENING 405 430 442 446 1400-1500 1400-1500 1400-1500 1400-1500 1900-2100 1900-2100 1900-2000 1800-2000 1750-1850 1350-1450 1300-1400 1300-1500 Post annealing required. See Heat Treat Data Table 2-3 for temperatures. 1400-1500 1400-1500 1400-1500 1400-1500 1400-1500 1400-1500 1400-1500 1900-2100 1900-2100 2050-2200 2100-2250 2000-2100 2050-2150 1950-2100 1600-1700 1600-1700 1600-1700 1600-1700 1600-1700 1600-1700 1950-2100 These grades shall be promptly annealed after forging because they air harden intently if allowed to cool from forging temperatures. See Heat Treat Data Table 2-3 for temperatures.

2-285. Spinning. Spinning procedures for stainless are similar to those used for other metals. Difficulty and variations depend on individual characteristics of grade to be worked, i.e., yield strength, ultimate strength, ductility, hardness and reaction to cold working. The best grades for spinning are those that have low yield strength in soft/annealed condition and low rate of work hardening such as 304, 305, 403, 410 and 416. The straight chromium grades respond to spinning similar to carbon steel, however, more power is required. Mild warming above 200oF improves performance of the straight chromium grades. 2-286. Shearing and Blanking. Shearing and blanking of corrosion resisting steels as with other fabrication processes requires more power in comparison to shearing carbon steel and most other metals. Shears and other equipment rated for carbon steel should not be used above 50 - 70% of rated capacity when cutting stainless. 2-287. Hot Forming. Hot forming is used to form shapes in stainless that cannot be accomplished by cold forming and for forging parts economically. In using heat for forming, it is important that temperature be closely controlled. Also, f inished parts should be relieved of residual stress and carbide precipitation which affects corrosion resistance. In

either case, this is accomplished by fully annealing.

CAUTION Difference in temper of raw material will result in variation of preheating, especially with the air hardening grades. The air hardening grades in tempers other than annealed may crack from thermal shock upon loading into a hot furnace. 2-288. Hot forming by methods other than forging is accomplished at somewhat lower temperatures. The unstabilized chromium-nickel grades may be formed at temperatures up to 800oF and the extra low carbon grades up to 1000oF. The use of temperatures higher than those cited above should be avoided to prevent subjection of material to the carbide precipitation heat zone. 2-289. The straight chromium (type 400 series) are more responsive to hot forming than the chromium-nickel grades. The reaction of these metals to hot forming in similar to carbon steels. Upon heating to 800o-900oF, their tensile strength is

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lowered considerably and at the same time ductility begins to increase. 2-290. Forming of the air hardening grades type 403, 410 is accomplished in two temperature ranges as follows: a. Low temperature forming up to 1400oF. The advantage of forming at this temperature is that parts can be stress relieved at 1350o - 1450oF to restore strength uniformity, and scaling is held at a minimum. b. High temperature forming at 1525o - 1575o F. Forming at this temperature is somewhat easier because strength is low and ductility is higher. Upon completion of forming at this temperature, parts shall be fully annealed under controlled conditions by heating to 1550oF and holding, slowly cooling to 1100oF (at approximately 50oF per hour) and then cooling in air. Grades 403, and 410 are not subject to loss of corrosion resistance due to the forming of intergranular carbides at grain boundaries. 2-291. When it is required that the non-hardening grades 430, 442, and 446 be hot formed, the recommended temperature for forming is 1400o 1500oF. This temperature is recommended in view of the following: a. Heating these grades above 1600oF promotes grain growth which can only be corrected by cold working. b. For types 442 and 446, the 1400o-1500oF temperature is below the scaling limit and very close to being below the scaling limit for type 430. 2-292. STEEL SURFACE FINISHES. 2-293. Metal plating is a process where an item is coated with one or more thin layers of some other metal. This is the type of f inishes generally used on ferrous parts, other than organic f inishes. It is usually specif ied when there is a need for surface characteristics that the basic metal does not possess. The most commonly used types of plating are: Cadmium plate; zinc plate; nickel plate; chromium plate; copper plate; tin plate; and phosphate coatings. The thickness of the plated coating is important since its protective value is primarily dependent on its thickness. The type of plated coatings is generally dependent on the characteristics desired. For protection against corrosion when appearance is unimportant, either cadmium or zinc coatings is usually used. For appearance, nickel, chromium, and silver plating are the most commonly used. For hardness, wear resistance, and buildup of worn parts, nickel and chromium plating are used. Effectiveness of most other metallic coatings depends on their ability to

provide envelope or anodic protection. Porous coatings of the more noble metals such as silver, copper, platinum and gold, tend to accelerate the corrosion of steel. For processing instructions, refer to T.O. 42C2-1-7. The following galvanic series table and dissimiliar metal def inition in accordance with MS33586 are for use as a guide in the selection of the most suitable plating for parts subject to uses where galvanic corrosion would be a prime factor. 2-294. DEFINITION OF DISSIMILIAR METALS. Dissimiliar metals and alloys, for the purpose of aircraf t and aircraf t parts construction are separated into four groups in accordance with MS33586. Metals classif ied in the same group are considered similar to one another and materials classified in different groups are considered dissimilar to one another. The metal/material referred to in the groups is the metal on the surface of the part; e.g., zinc includes all zinc parts such as castings as well as zinc coated parts, whether the zinc is electro deposited, applied by hot dipping, or by metal spraying over similar or dissimiliar metal parts. The four groups are as follows: a. GROUP I - Magnesium and its alloys. Aluminum alloys 5052, 5056, 5356, 6061 and 6063. b. GROUP II - Cadmium, zinc, and aluminum and their alloys (Including the aluminum alloys in Group I). c. GROUP III - Iron, lead, and tin and their alloys (except stainless steels). d. GROUP IV - Copper, chromium, nickel, silver, gold, platinum, titaniam, cobalt, rhodium and rhodium alloys; stainless steels; and graphite. NOTE The above groups do not apply to standard attaching parts such as rivets, bolts, nuts and washers which are component parts of assemblies, which will be painted prior to being placed in service unless other wise specif ied by specif ications MIL-F-7179, or other approved data. 2-295. TYPES OF PLATING.

2-296. CADMIUM PLATING (QQ-P-416). The primary purpose of cadmium plating is to retard or prevent surface corrosion of parts. Unless otherwise specif ied, the plating shall be applied af ter all machining, brazing, welding, forming and perforating of the item has been completed. Proper safety precautions should be observed in the event any welding or soldering operations are required

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on cadmium plated parts because of danger from toxic vapors during such operations. Cadmium coatings should not be used on parts subjected to temperatures of 450oF or higher. All steel parts having a hardness of Rockwell C40 (180,000 PSI) and higher shall be baked at 375o 25oF for 3 hours minimum af ter plating for hydrogen embrittlement relief. All steel parts having an ultimate tensile strength of 220,000 PSI or above shall not be plated, unless otherwise specif ied. When permission is granted, a low embrittlement cadmium plating bath shall be used. Federal Specif ications QQ-P-416 should be used for cadmium plate requirements. Critical parts should be magnaf luxed af ter plating. 2-297. Zinc Plating (QQ-Z-325). The primary purpose of zinc coatings is to retard or prevent the formation of corrosion products on exposed surfaces. Unless otherwise specif ied, the plating shall be applied af ter all machining, brazing, welding, forming and perforating have been completed. All parts having a hardness greater than Rockwell C40 and higher shall be baked at 375o 25oF for 3 hours af ter plating for hydrogen embrittlement relief. Zinc shall be deposited directly on the basic metal without a preliminary plating of other metal, except in the case of parts made from corrosion resisting steels on which a preliminary plating of nickel is permissible. Zinc plating (Type 1) should not be used in the following applications: a. Parts which in service are subjected to a temperature of 700oF or higher. b. Parts in contact with structural fabric structure. c. Parts in functional contact where gouging or binding may be a factor or where corrosion might interfere with normal functions. d. Grounding contacts where the increased electrical resistance of zinc plated surfaces would be objectional. e. Surfaces where free circulation of air does not exist and condensation of moisture is likely to occur. For additional information, refer to QQ-Z325.

addition high strength steels are susceptible to detrimental hydrogen embrittlement when electro plated. All steel having an ultimate strength of 220,000 PSI or above shall not be electro plated without specif ic approval of the procuring service or responsible engineering activity. 2-298. Nickel Plating (QQ-N-290). This coating is divided into two classes. Class I, plating is intended for decorative plating, and Class lI, plating is intended for wear and abrasion resistance. Unless otherwise specif ied, the plating shall be applied af ter all base metal heat treatments and mechanical operations such as machining, brazing, welding, forming and perforating on the article have been completed, all steel parts shall be given a stress relief at 375o 25F(191o 14C) for 3 hours or more prior to cleaning and plating, as required, to relieve residual tensile caused by machining, grinding or cold forming. Steel parts having a hardness of Rockwell C40 and higher shall be baked at 375o 25F for 3 hours or more and within eight (8) hours af ter plating to provide embrittlement relief. Parts shall not be reworked f lexed or subjected to any form of stress loads after placing and prior to the hydrogen embrittlement relief treatment. The general requirements for nickel plating are specif ied in QQ-N-290. Nickel shall be used for the following application only in accordance with MIL-S-5002: a. Where temperatures do not exceed 1,000oF and other coating would not be adequate or suitable. b. To minimize the effect of dissimilar metal contacts, such as mild steel with unplated corrosion resisting steel. c. As an undercoat for other functional coatings. d. To restore dimensions.

CAUTION Chromium and nickel electro deposits severely reduce the fatigue strength of high strength steels. All steel parts having a tensile strength of 180,000 PSI or above should be shotpeened prior to electro plating. In

2-299. Chromium Plating (QQ-C-320). This coating is of two classes; Class I, intended for use as a decorative coating; and Class II, for wear resistance and corrosion protection. Heavy chromium electro deposits (0-1-10 MILS) are of ten used to salvage under machine parts. Unless otherwise specified, the plating shall be applied af ter all basic metal heat treatments and mechanical operations such as machining, brazing, welding, forming and perforating have been completed. Hydrogen embrittlement relief shall be in accordance with blue prints and /or applicable specief ications. All plated parts which are designed for unlimited life under dynamic loads shall be shot peened in accordance with military Specif ication MIL-S-

2-131

T.O. 1-1A-9

13165 prior to plating. All parts with a hardness of Rockwell C40 (180,000 PSI), af ter shot peening and plating, shall be baked at 375o 25oF for 3 hours for hydrogen embrittlement relief. It is extensively used as an undercoating for nickel and chromium plating. 2-300. Tin Plating (QQ-T-425). Tin plating is used where a neat appearance, protective coating and easy solderability are of prime importance. The base metal for tinplate shall be low carbon cold steel. 2-301. Phosphate Coating (MIL-P-16232). The description of phosphate coatings herein is specified as heavycoatings. Light phosphate coatings used as a paint base are covered by specif ication TT-C-490. Type M (Manganese) coatings are resistant to alkaline environments and should not be exposed to temperatures in excess of 250oF. Except for special purpose applications, phosphate coatings should be used with a suitable supplementary treatment. Type Z (Zinc) coatings should not be used in contact with alkaline materials or temperature in excess of 200oF. For the different classes of coatings and required supplemental treatments, refer to MIL-P-16232. This coating should be applied af ter all machining, forming, welding and heat treatment have been completed. Parts having a hardness of Rockwell C40 or higher shall be given a suitable heat treat stress relief prior to plating and shall be baked subsequent to coating as follows: a. Type M shall be baked at 210 - 225 F for 1 hour. b. Type Z shall be baked at 200o - 210oF for 15 minutes (embrittlement relief). 2-302. Silver Plating (QQ-S-635). Silver plating (electro deposits) has high chemical and oxidation resistance, high electrical conductivity and good bearing properties. Silver is of ten used as an antisieze and for preventing fretting corrosion at elevated temperatures. Silver plating shall be of the following types and grades: a. Type I, Matte. Deposits without luster, normally obtained from silver-cyanide plating solutions operated without the use of brighteners. b. Type II, Semi-Bright. Semi-lustrous deposits normally obtained from silver-cyanide plating solutions operated with brightener. c. Type m, Bright. Sometimes obtained by polishing or by use of brighteners. d. Grade A. With supplementary tarnish resistant treatment (chromate treated).
o o

e. Grade B. Without supplementary tarnishresistant treatment. 2-303. Intended Use. The following applications of thicknesses are for information purposes only: a. 0.0005 - for corrosion protection of nonferrous base metal. b. 0.0003 - for articles such as terminals which are to be soldered. c. 0.0005 to 0.010 - for electrical contacts, depending on pressure, friction and electrical load. d. 0.0005 - for increasing the electrical conductivity of base metals. e. On ferrous surfaces, the total plated thickness shall not be less than 0.001inch. Af ter all base-metal heat treatments and mechanical operations such as machining, brazing, welding, forming and perforating of the article have been completed,if the type is not specif ied, any type is acceptable. All steel parts subject to constant f lexure or impact having a Rockwell hardness of RC40 or greater shall be heated at 375o 25oF for 3 hours for stress relief prior to cleaning and plating. 2-304. Hardened parts which have been heat treated at less than 375oF shall not be heated as noted above, but shall be treated by any method approved by the contracting agency. 2-305. For complete information pertaining to silver plating, refer to Federal Specif ication QQ-S365. 2-306. SURFACE TREATMENTS FOR CORROSION AND HEAT-RESISTING STEELS AND ALLOYS. Normally the corrosion-resisting and heat resisting alloys are unplated unless a coating is necessary to minimize the effect of dissimiliar metal contacts. When a plating is required it shall be in accordance with specif ication MIL-S-5002A or other approved technical engineering data. Where a plating is required, steel parts plated with hard coating, such as nickel and chromium or combinations thereof, shall be processed as follows in accordance with MIL-S-5002A: a. Plated parts below Rockwell C40 hardness and subject to static loads or designed for limited life under dynamic loads, or combinations thereof, need not be shot peened prior to plating or baked after plating. b. Plated parts below Rockwell C40 hardness which are designed for unlimited life under dynamic loads shall be shot peened in accordance with specif ication MIL-S-13165 prior to plating. Unless otherwise specif ied, the shot peening shall

2-132

T.O. 1-1A-9

be accomplished on all surfaces for which the coating is required and on all immediately adjacent surfaces when they contain notches, f illets or other abrupt changes of section size where stresses will be concentrated. c. Plated parts which have a hardness of Rockwell C40, or above, and are subject to static loads or designed for limited life under dynamic loads or combination thereof, shall be baked at 375o 25oF for not less than three (3) hours af ter plating. d. Plated parts which have a hardness of Rockwell C40, or above, and are designed for unlimited life under dynamic loads, shall be shot peened in accordance with specif ication MIL-S13165 prior to plating. Unless otherwise specif ied, the shot peening shall be accomplished on all surfaces for which the coating is required and all immediately adjacent surfaces when they contain notches, f illets, or other abrupt changes of section size where stresses will be concentrated. Af ter plating, the parts shall be baked at 375o 25oF for not less than three (3) hours. 2-307. PASSIVATION OF STAINLESS STEELS. The stainless steels are usually passivated af ter fabricating into parts to remove surface contaminates, which may cause discoloration or corrosive attack af ter the parts are placed in use. The process is primarily a cleaning operation which removes the contamination and speeds up the formation of the protective (invisible) oxide f ilm which would occur naturally but slower in the presence of oxygen in a normal atmosphere. The protective f ilm formation is inherent with the stainless steels in normal air when they are clean. 2-308. The foreign materials are removed from stainless to provide for uniform surface contact with oxidizing agents (Air or Acid) which forms the protective f ilm or passive surface. In this case after the f ilm has formed the material is placed in a condition approaching that of maximum corrosion resistance. Any areas to which oxygen contact is prevented by contaminants or other means tends to remain activated and subject to corrosion attack. 2-309. Prior to accomplishing the passivation treatments the parts shall be cleaned, all grease, oil, wax, which might contaminate the passivation solution and be a detriment to the passivation treatment shall be removed. Surfaces will be considered sufficiently clean when a wetted surface is free of water breaks. Af ter cleaning the parts will be passivated by immersing in a solution of 2025% (Volume) nitric acid (Sp.gr 1.42) plus 1.5 2.5% (Weight) sodium dichromate with process times and temperatures as follows:

CAUTION Excessive time shall not be used, as damage to parts may occur. In addition the times and temperatures shall be selected according to the alloy involved.
TYPES OF PROCESS I II III TEMPERATURE TIME (Minutes Minimum) 30 20 10

70-90 120-130 145-155

For parts made of ferritic or austenitic stainless use process Type I, II or III. For parts made of martensitic stainless steel, use process Type II or III. Within 15 minutes af ter above treatment, thoroughly rinse in hot water (140oF - 160oF). Within 1 hour af ter hot water rinse, immerse in an agueous solution containing 4 - 6% sodium dichromate (by weight) at 140 - 160oF for 30 minutes, and rinse thoroughly with water and dry. NOTE After the parts are passivated they shall be handled the minimum necessary consistant with packaging, assembly/installation. Parts for installations in high temperature areas shall not be handled with bare hands because f inger prints will cause carburization and pitting of surface when heated. 2-310. VAPOR DEPOSITED COATING. Vapor deposited coatings are applied by exposing the base metal to a heated vaporized metallic coating such as cadmium and aluminum in a high vacuum. The metal coating forms by condensation of the vaporized coating metal on all exposed surfaces of the base metal. Vapor-deposited coatings can be obtained by processes in which a volatile compound of the coating is reduced or thermally decomposed upon the heated surface of the base metal. Vapor deposited coatings are used to provide good corrosion resistance for steel and eliminate sources of hydrogen embrittlement. Specif ic requirements for coating, aluminum vacuum deposited, are cited in specif ication MIL-C23217A; and for coating, cadmium vacuum deposited, in specif ication MIL-C-8837. 2-311. MECHANICAL-SURFACE FINISH. The following paragraphs are concerned with mechanical surface f inish of the geometrical irregularities of surfaces of solid materials and established classification for various degrees of roughness and

2-133

T.O. 1-1A-9

waviness. The surface roughness of a part is a measurement rating of the f inely spaced irregularities, such as the surfaces produced by machining and abrading (abrasive honing, grinding, f iling, sanding, etc.) The roughness height ratings are specified in microinches as the arithmetic average of the absolute deviations from the mean surface. Profilometers and other instruments used to measure surface height if calibrated in RMS (Root Mean Square) average will read approximately 11% higher on a given surface than those calibrated for arithmetic average. Also associated with roughness high is roughness width, usually specified in inches and the maximum permissible spacing of surface irregularities. As the arithmetic average of the absolute diviations from the mean surface. Waviness height rating (when required) may be specif ied in inches as the vertical distance from peaks to valleys of the waves, whereas waviness width is the distance in inches from peak to peak of the waves. Figure 2-5 shows the meaning of each symbol def ined. 2-312. The symbol used to designate surface irregularities is the check mark as shown below. *When waviness width value is required, the value may be placed to the right of the waviness height value. **Roughness width cutoff value, when required, is placed immediately below the right-hand extension.
Table 2-37.

2-313. Designation of Surface Finish. Surface finish should be specif ied for production parts only on those surfaces which must be under functional control. For all other surfaces the f inish resulting from the machining method required to obtain dimensional accuracy is generally satisfactory. The surface chosen (unless already designated) for a specif ic application will be determined by its required function. Table 2-38 gives the typical normal ranges of surface roughness of functional parts. The values cited are microinches, for example 63 = 63 Microinches or 0.000063 inches average deviation from mean.

Galvanic Series of Metals and Alloys

CORRODED END - ANODIC (LEAST NOBLE) Magnesium Magnesium Alloys Zinc Aluminum - 7075 Clad Aluminum - 6061 Clad Aluminum - 5052 Aluminum - 2024 Clad Aluminum - 3003 Aluminum - 6061 - T6 Aluminum - 7075 - T6 Aluminum - 7178 Cadmium Aluminum - 2017 - T4 Aluminum - 2024 - T6 Aluminum - 2014 - T6 Steel or Iron Lead Tin Nickel (active) Inconel (active) Brass Copper Bronze Titanium Monel Silver Solder Nickel (Passive) Inconel (Passive) Silver Graphite Gold Platinum Protected End - Cathodic (Most Noble)

2-134

T.O. 1-1A-9

Figure 2-5.

Surface Roughness

2-135

T.O. 1-1A-9

Table 2-38.

Surface Roughness and Lay Symbols

2-136

T.O. 1-1A-9

SECTION III ALUMINUM ALLOYS

3-1. CLASSIFICATION. assigned consecutively as needed indicates special control of one individual impurity. Thus 1040 indicates 99.40% minimum aluminum without special control on individual impurities and 1140, 1240 etc. indicate same purity with special control on one or more impurities. 3-5. The last two of the four digits in alloy groups 2XXX through 8XXX have no special significance except that they serve to designate the alloy by its former number, i.e., 243, 525, 758, etc. 3-6. Experimental alloys are, also, designated by this system except that the 4 digit number is prefixed by an X.
Table 3-2. Aluminum Alloy Designation and Conversions to 4 Digit System

3-2. Aluminum alloys are produced and used in many shapes and forms. The common forms are casting, sheet, plate, bar, rod (round, hex, etc.), angles (extruded and rolled or drawn), channels and forgings. The inherent advantages of this material are lightweight, corrosion resistance to the atmosphere and many varieties of chemicals, thermal and electrical conductivity, ref lectivity for radiant energy of all wave lengths and ease of fabrication. 3-3. The above factors plus the fact that some alloys of this material can be formed in a sof t condition and heat treated to a temper comparable to structural steel make it very adaptable for fabricating various aircraf t and missile parts. 3-4. COMMERCIAL AND MILITARY DESIGNATIONS. The present system utilized to identify aluminum alloys is the 4 digit designation system. The major alloy element for each type is indicated by the f irst digit (see Table 3-1) i.e., 1XXX indicates aluminum of 99.00% minimum, 2XXX indicates an aluminum alloy in which copper is the main alloying element, etc. Although most aluminum alloys contain several alloying elements only one group the 6XXX designate more than one alloying element. See Table 3-1 for complete listing.
Table 3-1. Designations for Alloy Groups

OLD 2S 3S 4S 11S 14S R301 Core 17S A17S 18S 24S 19S 32S 50S 52S 56S 61S 62S 63S MA15 -72S 75S 78S 79S

NEW 1100 3003 3004 2011 2014 2017 2117 2018 2024 2219 4032 5050 5052 5056 6061 6062 6063 7050 7475 7072 7075 7178 7079

MAJOR ALLOYING ELEMENT None (Aluminum 99.00X) Manganese Manganese Copper Copper Copper Copper (Special control of impurities) Copper Copper Copper Silicon Magnesium Magnesium Magnesium Magnesium & Silicon Magnesium & Silicon Magnesium & Silicon Zinc Zinc Zinc Zinc Zinc Zinc

1XXX - - - Aluminum 99.00% of minimum and greater 2XXX - - - Copper 3XXX - - - Mangenese 4XXX - - - Silicon 5XXX - - - Magnesium 6XXX - - - Magnesium and Silicon 7XXX - - - Zinc 8XXX - - - Other element 9XXX - - - Unused series The second digit of the destination indicates modification in impurity limits. If the second digit is 0 it indicates that there is no special control on the impurities, while numbers 1 - 9 which are

3-1

T.O. 1-1A-9

NOTE Cladding which is a sacrif icial aluminum coating applied to an aluminum alloy core for the purpose of increasing corrosion resistance is designated as alclad 2024, alclad 2014, alclad 7075, etc. 3-7. Aluminum alloys for military use are identified by military and federal specif ications which are comparable to commercial specif ications and designations. The following table is a general list of the commonly used military and federal specif ications according to the commercial designation and forms of material. 3-8. MECHANICAL PROPERTIES. Prior to presenting factual data on mechanical properties the tempers (hardness) and methods of designation should be explained. For nominal mechanical properties see Table 3-4. 3-9. The tempers of aluminum alloys are produced essentially by three methods. These methods are cold working (strain hardening), heat treatment and a combination of the two. The various alloys of aluminum are either classed as heattreatable or non-heat-treatable. Alloys 1100, 3003, alclad 3003, 3004, alclad 3004, 5050 and 5052 are classed as nonheat-treatable. The tempers of these alloys are designated by symbols H1, H2, H3, H4, F & O. 3-10. A second number added to the above indicates the degree of strain hardening-actual temper. Example: 2=1/4 hard (2/8) - H12, H22, H32 4=1/2 hard (4/8) - H14, H24, H34 6=3/4 hard (6/8) - H16, H26, H36 8=Full Hard (8/8) - H18, H28, H38 As previously pointed out the above tempers designation symbols are hyphen (-dash) suffixed to the 4 digit alloy designation. Example: 1000-H12, 5052-H24, 3004-H34 etc. The general symbols used for the nonheat-treatable alloys are as follows: -F As fabricated -O Annealed -H21 Strain hardened only -H2 Strain hardened then partial annealed -H3 Strain hardened then stabilized NOTE Attempt should not be made to alter the temper characteristics of the H series of aluminum alloys other than in emergencies. This shall be limited to annealing operation only.

3-11. Alloys alclad 2014, 2024, alclad 2024, 6061, 7075, alclad 7075 and 7178 are classed as heat treatable. The mechanical properties of these alloys is improved by heat treatment or by a combination of heat treatment and strain hardening. The tempers for these alloys is designated by symbols, W, T, T2, T3, T4, T5, T6, T7, T8, T9, T10, F and O. Following is a summary of these symbols. -F As fabricated -O Annealed -W Solution heat treated - unstable temper -T Treated to produce stable tempers other than -F or -O -T2 Annealed (cast products only) -T3 Solution heat treated and then cold worked -T4 Solution heat treated -T5 Artif icially aged only -T6 Solution heat treated and then artif icially aged -T7 Solution heat treated and stabilized -T8 Solution heat treated, cold worked and then artificially aged -T9 Solution heat treated, artif icially aged, and then cold worked -T10 Artif icially aged and then cold worked Added numbers to the above denotes a modif ication of standard tempers. Example: The numeral 6 following T3 indicates a different amount of cold work then used in T3 such as 2024-T36. The numbers added to indicate modif ication or significant alternation of the standard temper are arbitrarily assigned and specif ication for the alloy should be utilized to determine specif ic data. 3-12. The following standard modif ication digits have been assigned for wrought products in all alloys: TX-51 - Stress-Relieved by Stretching: Applies to products which are stress-relieved by stretching the following amounts af ter solution heat treatment: Plate Rod, Bar and Shapes 1 1/2 to 3% permanent set 1 to 3% permanent set

Applies directly to plate and rolled or cold f inishes rod and bar. These products receive no further straightening af ter stretching. Applies to extruded rod, bar and shapes which receive minor straightening af ter stretching to comply with standard tolerances. -TX510 - Applies to extruded rod, bar and shapes which receive no further straightening after stretching. -TX511 - Applies to extruded rod, bar and shapes which receive minor straightening af ter stretching to comply with standard tolerances.

3-2

T.O. 1-1A-9

Table 3-3.

Federal and Military Specifications

ALLOY 1100

FORM (COMMODITY) Bars Rolled Bar, rod, wire and shapes, rolled or drawn Sheet and Plate Tubing

AMS 4102 4001B,4003B 4062C -

FEDERAL QQ-A-411, QQ-A-225/1 QQ-A-411, QQ-A-225/1 QQ-A-561, QQ-A-250/1 WW-T-783 (Old), WW-T700/1 QQ-A-365, QQ-A-225/3 QQ-A-261, QQ-A-200/2 QQ-A-266, QQ-A-225/4 QQ-A-367 (See QQ-A-367 & 367-1) QQ-A-255, QQ-A-250/3

MILITARY MIL-A-148 MIL-A-12545 MIL-A-799 -

* Extrusion (Impact) 1360 2011 2014 Wrought Product Bar and Rod Bar, Rod and Shapes Extruded Bar, Rod and Shapes Rolled or Drawn Forgings Extrusions (Impact) Alclad 2014 2017 Plate and Sheet Bar, Rod, Wire and Shapes, Rolled or Drawn WIRE - ROD FORGINGS 2018 2020 2024 Forgings Sheet and Plate Bar, Rod and Shapes Extruded Bar, Rod and Shapes Rolled or Drawn 2024 Plate and Sheet

4153A 4121B 4134A,4135H

MIL-A-12545

4118

QQ-A-351, QQ-A-225/5 QQ-A-430 QQ-A-367 MIL-W-7986

4140

QQ-A-367 QQ-A-250/16 MIL-A-8882

4152

QQ-A-267, QQ-A-200/3

4120 4035 4037

QQ-A-225/6, QQ-A-268 QQ-A-355, QQ-A-250/4

3-3

T.O. 1-1A-9

Table 3-3.

Federal and Military Specifications - Continued

ALLOY Alclad 2024

FORM (COMMODITY) Sheet and Plate

AMS 4040 4041 4042 4086 4087 4088 4130 4142

FEDERAL QQ-A-362, QQ-A-250/5

MILITARY

2024

Tube Drawn

WW-T-785 (Old), WW-T-700/3 QQ-A-367 QQ-A-367 MIL-A-8720

2025 2218 2219

Forgings Forgings Plate and Sheet Sheet and Plate Sheet and Plate, Alclad Extrusions

4031 4090 4094 4095 4096 4162 4163

QQ-A-250/30

3003

Bar, Rod, Shapes Extruded Bar, Rod, Wire and Shapes Rolled or Drawn Plate and Sheet Tube Drawn 4006 4008 4065 4067 4145 4114 4015 4016 4017 4070 4071 4182

QQ-A-200/1, New QQ-A-357, Old QQ-A-225/2 (New) QQ-A-356 (Old) QQ-A-359, QQ-A-250/2 WW-T-786 (Old) WW-T-700/3 QQ-A-367 QQ-A-225/7 (New) QQ-A-315 (Old) QQ-A-318 QQ-A-250/8 WW-T-787 (Old), WW-T-700/4 MIL-C-915 (Ships)

4032 5052 5052

Forgings Bar, Rod, Wire and Shapes Drawn Plate and Sheet

Tube, Drawn 5056 Bar, Rod and Wire Rolled or Drawn

3-4

T.O. 1-1A-9

Table 3-3.

Federal and Military Specifications - Continued

ALLOY 5056 (Cont)

FORM (COMMODITY) Bar, Rod, ShapesExtruded Plate Sheet Wire Rod Welding Rod

AMS

FEDERAL QQ-A-200/7 QQ-A-250/9

MILITARY MIL-C-6136

MIL-W-7986 QQ-R-566 C1 FS-RA156 QQ-A-200/4 (New) QQ-A-250/8 (New) QQ-A-250/7 (New) 4018 4019 4150 QQ-A-270 QQ-A-225/8 (New) QQ-A-325 (Old) 4127 4025 4026 4027 4080 4082 4081 4021 4022 4023 4155 4091 4092 4093 MIL-T-7081 4156 QQ-A-200/9 (New) QQ-A-274 (Old) QQ-A-270 (Old) QQ-A-200/8 (New) QQ-A-367d-1 QQ-A-327 QQ-A-250/11 (New) WW-T-789/WW-T-700/6 MIL-T-7081 MIL-A-19005 MIL-A-87001 MIL-A-17358 MIL-A-19070 MIL-A-17357

5083

Bar, Rod and Shapes Plate and Sheet

5086 5154 6061

Plate and Sheet Plate and Sheet Bar, Rod and Shapes Extruded Bar, Rod and Shapes Rolled or Drawn

6061

Forgings Plate and Sheet

Tube, Drawn Tube, Hydraulic Alclad 6061 Sheet and Plate

6062

Bar, Rod and Shapes Extruded Tube, Drawn

Tube, Hydraulic 6063 6066 Bar, Rod and Shapes Extruded Bar, Rod and Shapes Extruded

3-5

T.O. 1-1A-9

Table 3-3.

Federal and Military Specifications - Continued

ALLOY 6151 7050

FORM (COMMODITY) Forgings Plate Extrusion

AMS 4125 4050 4201 4340 4341 4342 4107 4108 4154

FEDERAL QQ-A-367

MILITARY

Die Forging Hand Forging 7075 Bar, Rod and Shapes Extruded Bar, Rod, Shapes and Wire, Rolled or Drawn Forgings Extrusions (Impact) Plate and Sheet Alclad 7075

MIL-A-46118D (Armor)

QQ-A-225/11 QQ-A-277 QQ-A-225/9 QQ-A-282 QQ-A-367 MIL-A-12545 QQ-A-283 QQ-A-250/12 QQ-A-287 QQ-A-250/13 QQ-A-250/13 MIL-A-8902 MIL-A-11352

4122 4139 4170 4044 4045 4048 4049

Plate and Sheet Plate and Sheet Alclad one side

7076 7079

Forgings Forgings Plate and Sheet Plate and Sheet Alclad one side

4137 4138

QQ-A-367 QQ-A-367 QQ-A-250/17 QQ-A-250/18

7475

Sheet and Plate Rod

4207 4202 MIL-A-63547 4158 4051 4052 QQ-A-250/14 MIL-A-9186 MIL-A-9180 MIL-A-11267 (ORD)

7178

Bar and Shapes Extruded Plate and Sheet

8280

Sheet

3-6

T.O. 1-1A-9

Table 3-3.

Federal and Military Specifications - Continued

ALLOY 99.75% 99.5% 99.3% 99.0% 43 108 A108 113 122 A132 142 195 B195 214 220 319 355 356 XB216 43 108 113 122 142 195 B214 XB216 220 319 355

FORM (COMMODITY) Ingot

AMS

FEDERAL QQ-A-451

MILITARY

Foundry Ingot

QQ-A-371

Foundry Ingot

QQ-A-371

Foundry Ingot Sand Castings Sand Castings Sand Castings Sand Castings Sand Castings Sand Castings Sand Castings Sand Castings Sand Castings Sand Castings Sand Castings 4240 4210 4212 4214 4217 QQ-A-601 QQ-A-601 QQ-A-601 4222 4230 4231 QQ-A-601 QQ-A-601 QQ-A-601 QQ-A-601 QQ-A-601 QQ-A-601 QQ-A-601

MIL-A-10937 (ORD)

MIL-A-10936 (ORD)

356 A612 ML 43 A108

Sand Castings Sand Castings Sand Castings Permanent Mold Castings Permanent Mold Castings

MIL-A-10936 (ORD) MIL-A-25450 USAF QQ-A-596 QQ-A-596

3-7

T.O. 1-1A-9

Table 3-3.

Federal and Military Specifications - Continued

ALLOY 113 122 A132 B195 XB216 319 355 356 750 ML 13 43 218 360 A360 380 A380

FORM (COMMODITY) Permanent Mold Castings Permanent Mold Castings Permanent Mold Castings Permanent Mold Castings Permanent Mold Castings Permanent Mold Castings Permanent Mold Castings Permanent Mold Castings Permanent Mold Castings Permanent Mold Castings Die Castings Die Castings Die Castings Die Castings Die Castings Die Castings Die Castings

AMS

FEDERAL QQ-A-596 QQ-A-596 QQ-A-596

MILITARY

4282 4283

QQ-A-596 MIL-A-10935 (ORD) QQ-A-596

4280 4281 4284 4286 4275 4290

QQ-A-596 QQ-A-596 QQ-A-596 QQ-A-591 QQ-A-591 QQ-A-591 MIL-A-15153 Ships MIL-A-15153 Ships MIL-A-15153 Ships MIL-A-15153 Ships MIL-A-15153 Ships

4290

QQ-A-591 QQ-A-591 QQ-A-591

4291

QQ-A-591

Misc STANDARD/SPECIFICATIONS -TX52 - Stress-Relieved by Compressing: Applies to products which are stress-relieved by compressing af ter solution heat treatment. -TX53 - Stress-Relieved by Thermal Treatment. 3-13. The following two digit - T temper designations have been assigned for wrought products in all alloys: -T42 - Applies to products solution heat treated by the user which attain mechanical properties different from those of the -T4 temper.* -T62 - Applies to products solution heat-treated and artif icially aged by the user which attain mechanical properties different from those of the -T6 temper.* *Exceptions not conforming to these def initions are 4032-T62, 6101-T62, 6062-T62, 6063-T42 and 6463-T42. 3-14. For additional information on heat treating aluminum alloys, see paragraph 3-22. 3-15. Chemical composition nominal plus general use data are given in Table 3-4 and nominal mechanical properties at room temperature are given in Table 3-5. The values cited are general and intended for use as comparisons values. For specific values the specif ication for the alloy should be utilized.

3-8

Table 3-4.

Chemical Composition Nominal and General Use Data 1/

1 NOMINAL COMPOSITION - % ALLOY SI CU MN MG CR ZN AL FLAT AND COILED SHEET

PLATE

SHAPES RODS AND BARS

TUBE

PIPE

CHARACTERISTICS

EC 1060

-0.25

-0.05

-0.03

-0.03

---

-0.05

99.45 99.60

X X

Electrical conductor Good corrosion resistance, electrical conductivity, formability and weldability. X X Excellent formability, readily welded and brazed, corrosion resistant. Excellent formability combined with high electrical and thermal conductivity and corrosion resistant.

1100

1.0

0.20

0.05

--

0.10

0.10

99.0

1145

0.55

0.05

0.05

--

--

--

99.45

2014

0.8

4.5

0.8

0.4

0.10

0.25

REM

High strength alloy. Electric resistance weldability excellent fusion weldability limited. Popular sheet alloy for aircraf t similar to 2014. T.O. 1-1A-9

2024

0.5

4.5

0.6

1.5

0.10

0.25

REM

3-9

3-10 ALLOY SI CU MN 2219 0.1 6.2 0.3 3003 0.6 0.20 1.2 -3004 0.30 0.25 1.2 5005 0.40 0.20 0.20 5050 0.40 0.20 0.10

T.O. 1-1A-9

Table 3-4.

Chemical Composition Nominal and General Use Data 1/ - Continued

1 NOMINAL COMPOSITION - % MG CR ZN AL FLAT AND COILED SHEET

PLATE

SHAPES RODS AND BARS X

TUBE

PIPE

CHARACTERISTICS

0.01

0.05

REM

Strutural uses requiring high strength up to 600 degrees F; high strength weldments. Stronger than 1100 with good weldability and formability, high resistance to corrosion. Stronger than 1100 and 3003 with fair workability and good corrosion resistance. Similar to 3003 in strength. Good anodizing characteristics, formability and resistance to corrosion. Good anodizing strength, formability, weldability, and corrosion resistance.

--

0.10

REM

1.0

--

0.25

REM

0.8

0.10

0.25

REM

1.4

0.10

0.25

REM

Table 3-4.

Chemical Composition Nominal and General Use Data 1/ - Continued

1 NOMINAL COMPOSITION - % ALLOY SI CU MN MG CR ZN AL FLAT AND COILED SHEET

PLATE

SHAPES RODS AND BARS

TUBE

PIPE

CHARACTERISTICS

5052

0.45

0.10

0.10

2.5

0.25

0.10

REM

Highest strength of non-heat-treatable alloys. Good corrosion resistance and finishing characteristics. X High weld joint efficiency with basic good strength and resistance combined with good formability. Good strength and excellent weldability. Good strength, weldability and corrosion resistance. Excellent bright f inishing characteristics.

5083

0.40

0.10

0.8

4.5

0.15

0.25

REM

5154 5254

0.45 0.45

0.10 0.05

0.10 0.01

3.5 3.5

0.25 0.25

0.20 0.20

REM REM

X X

5357

0.12

0.07

0.3

1.0

--

--

REM

5454

0.40

0.10

0.8

2.7

0.2

0.25

REM

Excellent strength at elevated temperature (150 -300 F) plus weldability. T.O. 1-1A-9 High strength and corrosion resistance, weldable.

5456 3-11

0.40

0.20

0.8

5.3

--

--

REM

3-12 ALLOY SI CU MN 5457 5557 0.08 0.20 0.3 0.25 5652 6061 0.6 .25 0.15 6062 0.6 .25 0.15 6063 0.4 0.10 0.10

T.O. 1-1A-9

Table 3-4.

Chemical Composition Nominal and General Use Data 1/ - Continued

1 NOMINAL COMPOSITION - % MG CR ZN AL FLAT AND COILED SHEET

PLATE

SHAPES RODS AND BARS

TUBE

PIPE

CHARACTERISTICS

1.0 0.6

--

--

REM REM

X X

Superior bright f inish when anodized. Good bright f inishing characteristics. Good weldability and formability. X Excellent strength with good f inishing characteristics and corrosion resistance. X X X Best weldability of heat treatable alloys, good formability and corrosion resistance. Good weldability with formability better than 6061. X Good f inishing characteristics and resistance to corrosion. Good workability with moderate strength.

2.5

0.25

REM

1.0

.25

0.25

REM

1.0

.06

0.25

REM

0.7

0.10

0.25

REM

Table 3-4.

Chemical Composition Nominal and General Use Data 1/ - Continued

1 NOMINAL COMPOSITION - % ALLOY SI CU MN MG CR ZN AL FLAT AND COILED SHEET

PLATE

SHAPES RODS AND BARS X

TUBE

PIPE

CHARACTERISTICS

7050

2.3

2.25

6.2

REM

High tensile properties, good exfoliation corrosion resistance good stress-corrosion cracking resistance. 2/ Extra high strength and hardness. Electric resistance weldability but limited fusion weldability. Similar to 7075 but maximum strength in thick sections. High strength alloy for a/c applications, however it is notch sensitive. Aerospace applications requiring high strength, toughness up to 300 degrees F resistance to stresscorrosion cracking.

7075

0.50

1.6

0.30

2.5

.3

5.6

REM

7079

0.30

.6

.2

3.3

.2

4.3

REM

7178

2.0

0.30

2.7

.3

6.8

REM

7475

0.05

1.5

0.03

2.25

2.1

5.7

REM

SI = Silicon MN = Manganese CR = Chromium AL = Aluminum CU = Copper MG = Magnesium ZN = Zinc T.O. 1-1A-9 1/ Nominal Composition Does Not Include All Alloying Elements That May Pertain, Specif ication Should Be Utilized When Specif ic Data Required. 3-13 2/ 7075 - T73 Is Completely Resistant To Stress Corrosion Cracking.

T.O. 1-1A-9

Table 3-5.

Mechanical Properties - Typical

Alloy and Temper 1100-0 1100-H12 1100-H14 1100-H16 1100-H18 3003-0 3003-H12 3003-H14 3003-H16 3003-H18 Alclad 3003 3004-0 3004-H32 3004-H34 3004-H36 3004-H38 Alclad 3004 Alclad Alclad Alclad Alclad 2014-0 2014-T3 2014-T4 2014-T6

Tensile Strength PSI 13,000 16,000 18,000 21,000 24,000 16,000 19,000 22,000 26,000 29,000 26,000 31,000 35,000 38,000 41,000 25,000 63,000 61,000 68,000 27,000 70,000 72,000 68,000 26,000 65,000 67,000 64,000 65,000 70,000 25,000 52,000 52,000 57,000 60,000 66,000 69,000 18,000 20,000 23,000 26,000 29,000

Yield Strength (Offset= 0.2%) PSI 5,000 15,000 17,000 20,000 22,000 6,000 18,000 21,000 25,000 27,000 10,000 25,000 29,000 33,000 36,000 10,000 40,000 37,000 60,000 11,000 50,000 57,000 47,000 11,000 45,000 53,000 42,000 60,000 66,000 11,000 27,000 36,000 46,000 42,000 51,000 57,000 6,000 17,000 20,000 24,000 27,000

Elongation, Per Cent in 2 in. Sheet Specimen (1/16 in. Thick) 35 12 9 6 5 30 10 8 5 4 20 10 9 5 5 21 20 22 10 20 18 13 20 20 18 11 19 6 6 18 20 17 11 10 1 10 30 11 8 6 5

Brinell Hardness 500-kg Load 10 MMM Ball 23 28 32 38 44 28 35 40 47 55 45 52 63 70 77 ----47 120 130 120 --------96 110 113 123 128 28 36 41 46 51

Shearing Strength PSI 9,000 10,000 11,000 12,000 13,000 11,000 12,000 14,000 15,000 16,000 16,000 17,000 18,000 20,000 21,000 18,000 37,000 37,000 41,000 18,000 41,000 42,000 41,000 18,000 40,000 41,000 40,000 40,000 42,000 --33,000 37,000 37,000 41,000 40,000 11,000 14,000 14,000 15,000 16,000

2024-0 2024-T3 2024-T36 2024-T4 Alclad 2024-0 Alclad 2024-T3 Alclad 2024-T36 Alclad 2024-T4 Alclad 2024-T81 Alclad 2024-T86 2219-0 2219-T42 2219T31,T351 2219-T37 2219-T62 2219T81,T851 2219-T87 5005-0 5005-H32 5005-H34 5005-H36 5005-H38

3-14

T.O. 1-1A-9

Table 3-5.

Mechanical Properties - Typical - Continued

Alloy and Temper 5050-0 5050-H32 5050-H34 5050-H36 5050-H38 5052-0 5052-H32 5052-H34 5052-H36 5052-H38 5154-0 5154-H112 5154-H32 5154-H34 5154-H36 5154-H38 5357-0 5357-H32 5357-H34 5357-H36 5357-H38 6061-0 6061-T4 6061-T6 7050-T74, T7451,T7452 7075-0 7075-T6 Alclad 7075-0 Alclad 7075-T6 A1clad 7079-T6 7178-0 7178-T6 7079-T6 7475-T7351

Tensile Strength PSI 21,000 25,000 28,000 30,000 32,000 28,000 33,000 38,000 40,000 42,000 35,000 35,000 39,000 42,000 45,000 48,000 19,000 22,000 25,000 28,000 32,000 18,000 35,000 45,000 74,000 33,000 83,000 32,000 76,000 70,000 40,000 83,000 72,000 73,000

Yield Strength (Offset= 0.2%) PSI 8,000 21,000 24,000 26,000 29,000 13,000 28,000 31,000 35,000 37,000 17,000 17,000 30,000 33,000 36,000 39,000 7,000 19,000 22,000 26,000 30,000 8,000 21,000 35,000 65,000 15,000 73,000 14,000 67,000 60,000 21,000 72,000 62,000 63,000

Elongation, Per Cent in 2 in. Sheet Specimen (1/16 in. Thick) 24 9 8 7 6 25 12 10 8 7 27 25 15 13 12 10 25 9 8 7 6 25 22 12 13 17 11 17 11 10 6 14

Brinell Hardness 500-kg Load 10 MMM Ball 36 46 53 58 63 47 60 68 73 77 58 63 67 78 83 87 32 40 45 51 55 30 65 95 142 60 150 ---

Shearing Strength PSI 15,000 17,000 18,000 19,000 20,000 18,000 20,000 21,000 23,000 24,000 22,000 --22,000 24,000 26,000 28,000 12,000 13,000 15,000 17,000 18,000 12,000 24,000 30,000 --22,000 48,000 22,000 46,000

--

--

3-15

T.O. 1-1A-9

Table 3-6.

Physical Properties-Standard Alloys

ALLOY

SPECIFIC GRAVITY

WEIGHTS PER CU.IN.

APPROX MELTING RANGE DEGREES F

ELECTRICAL CONDUCTIVITY % COMPARE TO COPPER STANDARD 59 57 50

1100-0 1100-H18 3003-0 3003-H12 3003-H14 3003-H18 3004-0 3004-H38 2014-0 2024-0 2024-T3 2219 5050-0 5050-H38 5052-0 5052-H38 5357-0 5357-H38 6061-0 6061-T4,T6 7050 7075-0 7075-T6 7475 BRASS Copper Monel Nickel Steel(low alloy) Steel(18.8 stainless) Tin Zinc

2.71

0.098

1,190-1,215

2.73

0.099

1,190-1,210

42 41 40

2.72

0.098

1,165-1,205

42 42 50

2.80 2.77 2.84 2.69 2.68 2.70 2.70 2.83 2.80 2.80 8.4-8.8 8.94 8.8 8.84 7.6-7.8 7.92 7.3 7.1

0.101 0.100 0.102 0.097 0.097 0.098 0.098 0.102 0.101 0.101 0.304-0.319 0.322 0.318 0.319 0.276-0.282 0.283 0.265 0.258

950-1,180 935-1,810 1010-1190 1,160-1,205 1,100-1,200 1,165-1,210 1,080-1,200 890-1175 890-1,180 890-1175 -1981 --2645 2800 2500-2650 449 787

40 30 50 30 44 50 50 35 35 43 43 45 40 45 -30 46 26-43 100 4 16 3-15 2-4 15 30

3-16

T.O. 1-1A-9

Table 3-7.

Heat Treating (Soaking) Temperatures

ALLOY DESIGNATION WROUGHT ALLOYS Except forgings alloys 2014 2017 2117 2024 2219 6061 6062 6066 7050 7075 (rolled or drawn) 7075 (Extruded) 7075 (Sheet .051 in thickness or less) 7178 (rolled or drawn) 7178 (Extruded) *7079

SOLUTION HEAT TREAT TEMPERATURE (DEGREES F)

TEMPER

925-945 925-945 925-950 910-930 985-1005 960-1010 960-1010 960-980 880-900 860-930 860-880 910-930 860-930 860-880 820-840

2014-T4 2017-T4 2117-T4 2024-W 2219-T4 6061-T4 6062-T4 6066-T4 7050-W 7075-W 7075-W 7075-W 7178-W 7178-W 7079-W 7475-W 2014-T4 2017-T4 2018-T4 2025-T4 4032-T4 6151-T4 6061-T4 7075-W

*7079 Other temperature may be required for certain sections and conditions. 7475 880-970 FORGINGS ALLOYS 2014 2017 2018 FORGINGS 2025 4032 6151 6061 7075 925-950 925-950 940-970 950-970 940-970 950-980 960-1010 360-890

7075 Other temperatures may be required for certain sections and conditions. 7079 820-840 7079-W

7079 Other temperatures may be required for certain sections and conditions. SAND CAST ALLOYS 122 142 195 220 319 355 356 930-960 950-980 940-970 800-820 920-950 960-990 980-1010 T4 T4 T4 T4 T4 T4 T4

3-17

T.O. 1-1A-9

Table 3-7.

Heat Treating (Soaking) Temperatures - Continued

ALLOY DESIGNATION 40E Solution heat treatment not required. PERMANENT MOLD CAST ALLOYS 122 A132 142 B195 355 356

SOLUTION HEAT TREAT TEMPERATURE (DEGREES F)

TEMPER

930-960 940-970 950-980 935-965 960-990 980-1010

T4 T4 T4 T4 T4 T4 low. To complete the solution of ten the metal is held at high temperatures for suff icient time; it is then quenched rapidly in cold water to retain this condition. Immediately af ter quenching, the alloy is in an unstable condition, because it consists of a supersaturated solid solution of the hardening agent. Upon standing at room temperature the hardening constituent in excess of that which is soluble at room temperature precipitates. The precipitate is in the form of extremely f ine particles which due to their keying action, greatly increase their strength. This is in effect a method where the molecules of the aluminum and alloying elements are realigned to increase the strength and hardness of some aluminum alloys. 3-20. PRECIPITATION (AGE) HARDENING. This phase of heat treatment consists of aging material previously subjected to solution heat treatments by natural (occurs at room temperature) or artif icial aging. Artif icial aging consists of heating aluminum alloy to a specif ic temperature and holding for a specif ied length of time. During this hardening and strengthening operation the alloying constituents in solid solution precipitate out. As precipitation progresses, the strength of the material increases until the maximum is reached. Further aging (overaging) causes the strength to decline until a stable condition is obtained. The strengthening of the material is due to the uniform alignment or formation of the molecule structure of the aluminum and alloying element. 3-21. Artif icial aged alloys are usually slightly overages to increase their resistance to corrosion, especially the high copper content alloys. This is done to reduce their susceptibility to intergranular corrosion caused by under-aging. 3-22. Natural aging alloys can be artif icially aged, however, it increases the susceptibility of the material to intergranular corrosion. If utilized it should be limited to clad sheet, extrusions and

3-16. PHYSICAL PROPERTIES. Commercially pure aluminum weights 0.098 pounds per cubic inch, corresponding to a specif ic gravity of 271. Data for standard alloys are shown in Table 3-6. The approximate weight for aluminum, including its alloys, is one-tenth of a pound per cubic inch (see Table 3-6). 3-17. HEAT TREATMENT OF ALUMINUM ALLOYS. NOTE SAE-AMS-2772, Heat Treatment of Aluminum Alloys, will be the control document for heat treatment of Aluminum Alloys used on aerospace equipment. For complete description of aluminum heat treat requirements, refer to latest issue of SAE-AMS2772. 3-18. GENERAL. There are two types of heat treatment applicable to aluminum alloys. They are known as solution and precipitation heat treatment. Some alloys such as 2017 and 2024 develop their full mechanical properties as a result of solution heat treatment followed by 96 hours (natural precipitation) aging at room temperature. Other alloys, such as 2014, 7075, and 7178 require solution heat treatment and aging (precipitation heat treatment) for specif ic length of time at a def inite temperature (see Table 3-11). NOTE Additional Heat Treatment information is discussed in Section IX. 3-19. Solution heat treatment is a process where the alloying elements enter into solid solution in the aluminum at critical temperatures. It has been found that those alloying elements which increase the strength and hardness are more soluble in solid aluminum at high temperature than at

3-18

Change 4

T.O. 1-1A-9

similar items. For aging treatment, temperature and times see Table 3-11. 3-23. SOLUTION HEAT TREATMENT. As previously pointed out it is necessary that solution heat treatment of aluminum alloys be accomplished within close limits in reference to temperature control and quenching. The temperature for heat treating is usually chosen as high as possible without danger of exceeding the melting point of any element of the alloy. This is necessary to obtain the maximum improvement in mechanical properties. 3-24. If the maximum specif ied temperature is exceeded eutectic melting will occur. The consequence will be inferior physical properties, and usually a severely blistered surface. If the temperature of heat treatment is low, maximum strength will not be obtained. 3-25. Heating Time. The heating time commonly called the soaking time required to bring about solution increases with the thickness of the section or part to be heat treated. Solution heat treatment should be held to the minimum time required to obtain the desired physical properties. In many instances the above will require sample testing to determine the exact solution time. For the recommended approximate soaking time for various alloys see Table 3-8. 3-26. The time at temperature (soaking time) is measured from the time the metal reaches the minimum limit of the temperature range. In the case of thick material the controlling factor would be when the center (core) reached the minimum temperature. The soaking period will vary from 10 minutes for thin sheet to approximately 12 hours for the thicker materials, such as heavy forgings. A general guide to use is approximately one hour for each inch of cross-sectional thickness. It is recommended that thermocouple be placed in the coldest part of the load to determine the period required to bring the load to the correct temperature (soaking temperature). 3-27. The soaking temperature required is selected to put all of the soluble elements into solid solution. With clad materials, prolonged heating may defeat the purpose of the cladding by excessive diffusion of copper and other soluble elements into the cladding. 3-28. RE-SOLUTION HEAT TREATMENT. The bare heat-treatable alloys can be solution heat treated repeatedly without harmful effects other than high temperature oxidation. The oxidation can be retarded by using either sodium or potassium f luoborate during the heating cycle.

3-29. For clad sheet the number of solution heattreatment is limited due to the increased diffusion of the core and cladding. See Table 3-12 for the recommended reheat-treatment times. 3-30. QUENCHING. The basic purpose for quenching is to prevent the immediate re-precipitation of the soluble constituents af ter heating to solid solution. 3-31. To obtain optimum physical properties of aluminum alloys, rapid quenching is required. The recommended time interval between removal from the heat and immersion is 10 seconds or less. Allowing the metal to cool before quenching promotes intergranular corrosion and slighty affects the hardness. This is caused by re-precipitation along grain boundaries and in certain slip planes. For specif ic quench delay see Table 3-10. 3-32. There are three methods employed for quenching. The one used depends upon the item, alloy and properties desired. 3-33. Cold Water Quenching. Small articles made from sheet, extrusions, tubing and small fairing are normally quenched in cold water. The temperature before quenching should be 85oF or less. Suff icient cold water should be circulated within the quenching tanks to keep the temperature rise under 20oF. This type of quench will insure good resistance to corrosion and particularly important when heat-treating 2017 and 2024. 3-34. Hot Water Quenching. Large forgings and heavy sections can be quenched in (150o - 180oF) or boiling water. This type of quench is used to minimize distortion and cracking which are produced by the unequal temperatures obtained during the quenching operation. The hot water quench will also reduce residual stresses which improves resistance to stress corrosion cracking. 3-35. Spray Quenching. Water sprays are used to quench parts formed from alclad sheet and large sections of most alloys. Principal reasons for using this method is to minimize distortion and to alleviate quench cracking. This system is not usually used to quench bare 2017 and 2024 due to the effect on their corrosion resistance. The parts quenched by this media should pass the corrosion test required for the item involved; (see specif ication SAE-AMS-2772). 3-36. STRAIGHTENING OF PARTS AFTER SOLUTION HEAT TREATMENTS. It will be necessary to straighten some parts af ter heat treating due to warping produced by the process. These

Change 4

3-19

T.O. 1-1A-9

parts are usually straightened by restriking or forming. It is desirable to place these parts in refrigeration immediately af ter quenching to retard natural aging until such time straightening

is accomplished. A temperature of 32oF or below will delay or retard natural aging for approximately 24 hours, lower temperatures will delay the aging longer.

Figure 3-1.

Head to Alloy Identification Method

3-37. HEAT TREATMENT OF RIVETS. The heat-treatable alloys commonly used for rivets are 2117, 2017, and 2024. a. 2117 Rivets. If supplied in T-4 temper no further treatment is required. The rivet is identified by a dimple in the center of the head (see Figure 3-1, item AD for head identif ication). b. 2017 or 2017-T4 (D) Rivets. Heat treat prior to installation by heating to 940oF 10oF for 30 minutes in a circulating air furnace, 1 hour in still air furnace, or 30 minutes in a molten salt bath and quench in water. These rivets must be driven within 20 minutes af ter quenching or refrigerate at 32oF or lower which will delay the aging time 24 hours. If either time is exceeded reheat treatment is required. See Figure 3-1, item D for head identif ication. It is noted the D rivets may also be used in the age hardened condition. c. 2024-0 or 2024-T4 (DD) Rivets. The same conditions apply for these rivets as for the 2017 (D) except heat treat at 920oF 10oF. See Figure 3-1, item DD for head identif ication.

d. 1100 and 5056 Rivets. These do not require heat treatment, install as received. See Figure 3-1, item A and 3-1, item B for identif ication. CAUTION Rivets which have been anodically oxide coated should not be reheattreated in direct contact with molten salts more than 5 times. e. 7050 (E) Rivets. These do not require heat treatment, install as received. See Figure 3-1, item E for head identif ication. f. D/DD Rivets. These may be stored in refrigerators which ensure that the rivet temperature does not rise above minus 10oF. Rivets held at minus 10oF or below can be retained for use indefinitely. When the rivets are transported, their temperature will be maintained at minus 10oF or below by being carried in refrigerated boxes.

3-20 Change 2

T.O. 1-1A-9

(1) Quality control shall be responsible for periodically checking the temperature of each refrigerator and for prohibiting the use of rivets in any box when the temperature becomes excessive. (2) Each refrigerator shall have the rivets removed and be thoroughly cleaned at least once every six months. A tag or placard that denotes the next cleaning date shall be attached to each refrigerator. (3) Rivets which remain out of refrigeration for 30 minutes or more shall be reheat treated. These rivets can be reheat treated a maximum of three times. 3-38. ANNEALING. Aluminum alloys are annealed to remove the effects of solution heat treatment and strain hardening. Annealing is utilized to help facilitate cold working. Parts work hardened during fabrication are annealed at various stages of the forming operation so that complicated shapes can be formed. During prolonged forming or stamping operations the metal becomes strain hardened (commonly called work hardened and upon the performance of additional work it will split or crack.) When the above is encountered it is usually necessary to anneal the part one or more times at progressive stages of the forming operation, if the part is to be successfully completed. CAUTION Annealed aluminum parts shall not be used for parts or f ittings on aircraft or missiles unless specif ied by drawings or other approved engineering data. 3-39. Time at temperature. This factor will vary depending upon the type of anneal (partial or full), metal, thickness, method of furnace charging and similar factors. Avoid excessive time at temperature to prevent growth, diffusion and discoloration, especially when annealing clad alloys. 3-40. When fully annealing, no attempt should be made to shorten the annealing cycle because the soluble constituents go into solution as the temperature is increased. If the material is then cooled rapidly the soluble constituents remain in solution and the material does not attain fully annealed mechanical properties. 3-41. Annealing and subsequent forming of material previously heat treated should be avoided if conditions and time permit. The recommended method is to repeat the solution heat treatment

and immediately perform the forming or drawing operation. 3-42. Recommended times and temperatures for annealing various alloys are as follows: a. Annealing of Work-Hardened Alloys. All of these alloys except 3003 are annealed by heating to 650oF and no higher than 775oF, holding at temperature until uniform temperature has been established throughout the furnace load, and cooling in air or in the furnace. Annealing temperature shall not exceed 775oF to prevent excess oxidation and grain growth. The 3003 alloy is annealed by heating to 775oF at a relatively rapid rate and holding at the minimum soaking period necessary to attain temperature uniformity and then cool as cited above. b. Annealing of heat-treated alloys (wrought). These alloys (except 7075) are annealed by heating to 775oF for not less than 1 hour and most instances 2-3 hours. Material is then cooled at a rate of no greater than 50oF per hour until the temperature is 500oF or below. Rate of cooling below 500oF is not restricted; cool as desired. Alloy 7075 is fully annealed by heating to 775oF 850oF (higher temperature utilized for material having smaller amount of cold work), soaking for 2 hours at temperature, cooling in air, reheating to 450oF, holding at this temperature for 6 hours and then cooling to room temperature. Alternate 7075 annealing methods: (1) If forming is to be accomplished immediately af ter annealing, heat to 775oF, 2-3 hours; air cool. (2) If alloy is to be stored for an extended period before forming, heat to 670oF - 775oF, 2 hours; cool in air; reheat to 450oF; hold at this temperature for 4 hours and then cool in air. (3) Intermediate anneal during cold working of O condition material; heat to 670o - 700oF, 1/2 hour maximum, or heat to 910o - 930oF until uniform temperature is attained; cool in air. A part shall not be annealed using the 910o - 930oF temperature more than 3 times. c. Annealing of cast alloys. Castings are annealed by heating to 650o - 750oF holding for approximately 2 hours, and cooling to room temperature. The purpose of such annealing are for the relief of stresses and attainment of dimensional stability. d. Partial annealing of heat-treated material. When heat-treated materials are annealed as specified for annealing of the work-hardened alloys, the effect of heat-treatment is reduced considerably, but not completely. The partially annealed

Change 1

3-21

T.O. 1-1A-9

material is only to be utilized when moderate but not secure operations are to be performed. If diff iculty is experienced with forming partially annealed material, recommend that O fully annealed material be utilized. 3-43. Heat treating temperatures and times. Aluminum alloy should be heat treated at the temperature given in Table 3-7. The load should be held within the heat-treatment range (af ter the coldest part has reached the minimum of the range) for a suff icient time to insure that specif ied properties will be developed. In some cases sample testing will be required to ascertain that specif ied properties are developed. Suggested soaking periods are given in Tables 3-8 and 3-9 for the common alloys. In instances where new alloys are involved it will be necessary to consult the specif ication for the alloys, Specif ication SAE-AMS-2772 or the manufacturer for the appropriate heat treat data. In case of conf lict the correct Military/Federal specif ication will be the governing factor. 3-44. QUENCHING. To effectively obtain the desired qualities in aluminum alloys it is necessary that the interval between removing the charge from the furnace and immersion in the quenching water be maintained at the absolute minimum (See Table 3-10). 3-45. Wrought alloy products must be quenched by total immersion in water or by a drastic spray quench. Forgings of 2014, 2017, 2117 and 7075 are quenched in water at temperatures in excess; of 100oF. 7079 forgings are generally quenched in water at temperatures less than 100oF to obtain optimum mechanical properties, however a hot water quench (180oF) should be used whenever possible providing the lower strength associated with the quench is satisfactory. The hot water quench lowers the residual stresses considerably. This is desirable from the point of view of reducing stress corrosion susceptibility. 3-46. Charging of furnace and baths. Individual pieces of materials or parts should be racked or supported to prevent distorting if possible and permit free access to the heating and quenching

medium. The above is necessary to maintain the form of the material involved and to facilitate heating to the specif ied temperature and quenching rapidly. To prevent distortion it is necessary in some cases to provide jig and f ixture support for complex contoured (formed) parts. However, the jig used shall be so constructed that is will not restrict the contact required with the heating medium of the part being treated. NOTE Parts formed that are unavoidably distorted should be reformed immediately af ter quenching. 3-47. When heat treating clad sheet material, the size and spacing of the load will be arranged to permit raising to the heat treatment temperature range in the minimum time. The mixing of different thicknesses of clad material when charging heat-treatment furnaces will be avoided, in order to help prevent diffusion of the cladding, especially in the case where very thin to thick materials are involved. CAUTION Heat-treating operations will be performed on the complete individual part or piece of material never on a portion only. This should be accomplished in such a manner that will produce the utmost uniformity. Maximum quench delay for immersion quenching is shown by Table 3-10. 3-48. Wrought alloy products may be quenched using high velocity, high volume jets of cold water where the parts are effectively f lushed in a specially constructed chamber, provided that the parts will pass the corrosion test set forth in Specif ication SAE-AMS-2772, Metal Specification and the mechanical property requirements of the applicable material specif ication.

3-22

Change 4

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Table 3-8.

Soaking Time for Solution Heat Treatment of All Wrought Products

THICKNESS (INCHES) (MIN. THICKNESS OF THE HEAVIEST SECTION) 0.016 0.017 0.021 0.033 0.064 0.091 0.126 0.251 0.501 1.001 1.501 2.001 2.501 3.001 3.501 and under - 0.020 - 0.032 - 0.063 - 0.090 - 0.125 - 0.250 - 0.500 - 1.000 - 1.500 - 2.000 - 2.500 - 3.000 - 3.500 - 4.000

SALT MIN 10 10 15 20 25 30 35 45 60 90 105 120 150 165 180

SOAKING TIME (MINUTES) BATH AIR FURNACE MAX (Alclad Only) MIN MAX (Alclad) 15 20 25 30 45 40 45 55 70 100 115 130 160 175 190 20 20 25 30 35 40 50 60 90 120 150 180 210 240 270 25 30 35 40 45 50 60 70 100 130 160 190 220 250 280

3-49. Castings and forgings quenching. Casting should be quenched by total immersion in water at 150o to 212oF. Forgings should be quenched by total immersion in water at no more than 180oF. Forgings and impact extrusion supplied in T41 or T61 should be quenched in boiling water. However, if conditions warrant castings or forgings may be quenched by complete immersion in cold water. 3-50. Small parts such as rivets, fasteners, washers, spacers, etc., should be quenched by dumping into cold water. CAUTION Rivets, fasteners, washers and other small parts which have been anodically oxidecoated should not be heat treated indirect contact with molten salts or more than 5 times by this medium. NOTE Quench delay time begins at the instant furnace door begins to open or at the instant any portion of a load emerges from a salt bath and when

last portion of the load is immersed in the (water) quench tank. The maximum quench delay may be exceeded (usually conf ined to large sections or loads) if temperature will be above 775oF when quenched.
Table 3-9. Soaking Time for Solution Treatment of Cast Alloys

ALLOY SAND CAST ALLOYS 122 142 195 S195 (105) 220 319 355 356 PERMANENT MOLD CAST ALLOYS 122 A132 142 B195 355 356

TIME (HOURS) 6-18 2-10 6-18 6-24 12-24 6-18 6-18 6-18

6-18 6-18 2-10 4-12 6-18 6-18

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T.O. 1-1A-9

Table 3-10.

Recommended Maximum Quench Delay, Wrought Alloys (For Immersion Type Quenching)

stretch or roll the material in order to produce these conditions. 3-56. HEAT TREATING EQUIPMENT. Equipment and heating media used are divided into two distinct groups. They are liquid baths and controlled atmosphere. Either method has certain advantages over the other and it generally is advisable to weigh the advantages desired and consider environmental conditions. 3-57. The above are heated by gas, electricity and oil regardless of the method utilized it must be demonstrated that satisfactory results are obtained and the material is not injured. 3-58. AIR FURNACES. Air furnaces are ideal for precipitation (aging), thermal treatments and annealing. These furnaces are also used for solution heat treating. The initial cost of these type furnaces is higher than for the salt bath types, but they are usually more economical to operate, safer, cleaner and more f lexible. Air furnaces used for heat treatment of aluminum alloy should be of the recirculating air type. The heated air in this type furnace is recirculated at high velocities to obtain a rapid heating cycle and uniform temperatures. The products of combustion must be excluded from the furnace atmosphere to help avoid high temp oxidation and atmosphere contamination. 3-59. SALT BATHS. The salt bathe method has certain advantages over the air furnace. However, the advantages are usually conf ined to solution heat treatment only. Associated advantages are uniform temperature without excess danger of high temperature oxidation and faster heating which reduces the time required to bring the load to temperature. This method is adaptable for solution heat treating small parts, large thin sections and missed loads. The above advantages may be completely nullif ied by the slower quench caused by the necessary arrangement of equipment, f ire and explosion hazards, and decomposition of the sodium nitrate which when dissolved in quenching water forms a compound that attacks aluminum alloys. The addition of potassium dichromate (approximately 1/2 ounce per hundred pounds of nitrate) tends to inhibit the attack. 3-60. Hollow core casting or parts where the salts are likely to be difficult or impossible to remove should not be treated by bath salt.

NOMINAL THICKNESS (INCHES) up to 0.016 0.017 to 0.031 0.032 to 0.091 0.091 and over 3-51. HEAT TREATMENT.

MAXIMUM TIME (SECONDS) 5 7 10 15

3-52. PRECIPITATION (ARTIFICIAL AGE) HEAT TREATMENT. Precipitation heat treatment of many aluminum alloys is necessary to obtain the required properties. Heating of some aluminum alloys bare or alclad at an elevated temperature, but well below the annealing temperature, after solution heat treatment will result in tensile and yield strength well above those obtained by room temperature aging. The above will also apply to alloy 2024. However, this process will reduce the elongation factor of the material and increase resistance to forming. Therefore, most forming operations should be performed prior to this stage of treatment. 3-53. Mechanical properties obtained from precipitation (aging) are dependent on the amount of cold work present in the material at the time of aging. The selection of material for various uses will therefore be governed by, the severity of the cold work to be performed, strength and condition of the material required. 3-54. Annealing or solution heat treating will remove any properties developed as a result of cold working the material. Subsequent heat treatment and aging of annealed material or aging of solution heat treated material will result in T-6 condition, provided the material is not cold worked prior to aging. The higher strength conditions can only be obtained by a controlled amount of cold work prior to aging. Conditions T-81 or T-86 would necessitate a cold work percentage of approximately 1% for T-81 and 6% for T-86 af ter solution heat treated and prior to aging. 3-55. Field accomplishment of the cold work required to produce the higher strength conditions is considered impractical. This is due to the amount and types of equipment necessary to

3-24

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Table 3-11.

Precipitation (Aging) Treating Temperatures, Times and Conditions

ALLOY & TEMPER OR COND BEFORE AGING WROUGHT ALLOYS (EXCLUDING FORGINGS) 2017 - as quenched(w) 2117 - as quenched(w) 2024 - as quenched(w) 3/ 6061 - as quenched(w) 6061-T4 2020-W 2024-T4 1-T42 2024-T4 (Alternate for sheet) 2024-T3 2024-T36 2014-T4 1-T42 2014-T4 (Alternate for Plate) 2219-T31/T351 2219-T4 2219-W 6066-T4 6061-T4 7050-W 7075-W 1/ 7178-W 6063-F 7079 - as quenched(w) 96 96 96 96

AGING TIME (HOURS)2/

AGING TEMP (DEGREES F)2/

TEMPER AFTER AGING

room room room room 340-360 310-360 370-380 370-380 370-380 370-380 305-330 305-330 350 375 room 340-360 340-360 250 followed by 350, 6-8 hours 240-260 240-260 440-460

2017-T4 2117-T4 2024-T4 6061-T4 6061-T6 2020-T6 2024-T6 1-T62 2024-T6 2024-T81 2024-T86 2014-T6 1-T62 2014-T6 2219-T81/T851 2219-T62 2219-T4 6066-T6 6061-T6 7050-T74 7075-T6 7178-T6 6063-T5

71/2 - 81/2 18 16 11-13 11-13 7-9 8 - 12 17-20 17-19 35-37 96 71/2 - 81/2 71/2 - 81/2 6-8 22 Minimum 22 Minimum 1-2 5 days at room temperature following 48 hours at 230250 degrees F 24-25 3-5

7475-W, Plate 7475-W, Sheet FORGING ALLOYS 2014-T4 2014 - as quenched 2017 - as quenched

250 250 followed by 315, 3-3.25 hours 340-360 room room

7475-T6 7475-T61

5-14 96 Minimum 96 Minimum

2014-T6 2014-T4 2017-T6

Change 1

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Table 3-11.

Precipitation (Aging) Treating Temperatures, Times and Conditions - Continued

ALLOY & TEMPER OR COND BEFORE AGING 2018-T4 2025-T4 4032-T4 6151-T4 7075-W X7079

AGING TIME (HOURS)2/ 4-12 6-14 4-12 4-12 22 Minimum 5 days at room temperature followed by 48 hours at 230-250 degrees F 1-3 1-3 1-4 96 Minimum 1-6 1-6 1-6 6-12 9-11 21 days 1-3 1-8 1-6 1-6 1-6 14-18

AGING TEMP (DEGREES F)2/ 330-350 330-350 330-350 330-350 230-260

TEMPER AFTER AGING 2018-T6 2025-T6 4032-T6 6151-T6 7075-T6 X7079-T6

SAND CAST ALLOYS 142-T41 195-T4 S195-T4 220-W 319-T4 335-T4 356-T4 356-F 40 40PERMANENT MOLD CAST ALLOYS 142-T41 B195-T4 319-T4 355-T4 356-T4 A132-T45 400-450 300-320 300-330 300-320 300-320 300-350 142-T61 B195-T6 319-T6 355-T6 356-T6 A132-T65 400-450 300-320 300-320 room 300-320 300-320 300-320 430-450 345-365 room 142-T61 142-T6 S195-T6 220-T4 319-T6 335-T6 356-T6 356-T6 40-E 40-E

1/ Alternate aging treatment for 7075-W sheet only; in thicknesses less than 0.500 inch: Heat at 230o250oF for 3-4 hours, then heat 315o-335oF for 3-4 hours. The temperature may be raised directly from the lower to the higher temperature, or load may be allowed to cool between the two steps of the treatment. 2/ Time is soak time af ter recorder is at temperature, for 0.500 inch thickness or less. Add 1/2 hour for each additional 1/2 inch of thickness. 3/ The 96 hour minimum aging time required for each alloy listed with temper designation W is not necessary if artif icial aging is to be employed to obtain tempers other than that derived from room temperature aging. (For example, natural aging (96 hours) to achieve the -T4 or -T42 temper for 2014 alloy is not necessary prior to artif icial aging to obtain a -T6 or -T62 temper.)

3-26 Change 1

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Table 3-12.

Reheat Treatment of Alclad Alloys

THICKNESS (INCHES)

MAXIMUM NO. OF REHEAT TREATMENT PERMISSIBLE 1 2

0.125 and less over 0.125

NOTE Heat treatment of a previously heattreated material is classif ied as a reheat treatment. Therefore, the f irst heat treatment of material purchased in the heat treated condition is a reheat treatment. Insofar as this chart is concerned annealing and precipitation treatments are not considered heat treatments. 3-61. Salt baths must be operated with caution to prevent explosions as any water on the material being treated is instantly transformed to steam upon imersion in the salt bath. 3-62. Nitrate charged salt baths should not be used to heat-treat aluminum alloys types 5056 and 220 due to the fact that the bath compound will attack the alloy. 3-63. Temperature Control and Uniformity. Good temperature control is essential to produce the exacting temper requirements for superior quality material. Upon bringing a change to temperature, the furnace and the load should be controllable with 5oF of the required temperature range. The design and construction of the furnaces and baths should be such that during the recovery and soaking period, the air and metal (load) temperature at any point in the working or soaking area shall not exceed the maximum soaking temperature (see Table 3-7) for the specif ic alloy being heat treated. 3-64. Furnace temperature survey. Furnace equipment shall be installed with the necessary furnace control, temperature measuring, and recording instruments to assure and maintain accurate control. 3-65. Upon the initial installation and af ter each change is made in the furnace which might affect the operational characteristics a temperature survey should be made. The temperatures should be checked at the maximum and minimum required for solution and precipitation heat treatment for which the furnace is to be used. A minimum of 9

test locations within the furnace load area should be checked, one in each corner, one in the center and one for each 25 cubic feet of air furnace volume up to the maximum of 400 cubic feet. For salt bath the same as above except one test location for each 40 cubic feet of air volume, 40 test locations are recommended. Other size furnaces should be checked with a ratio of test locations in accordance with those previously cited. A monthly survey should be made af ter the initial survey, unless separate load thermocouples are employed, to record actual metal temperatures. However, periodic surveys shall be made as outlined for the initial survey. The monthly survey should be made at one operating temperature for solution treatment and one for precipitation heat treatment. There should be a minimum of 9 test locations with at least one for each 40 cubic feet of heat treating volume. For all surveys, the furnaces should be allowed to heat to point of stabilization before commencing the survey. The temperature of all test locations should be determined at 5 to 10 minute intervals af ter insertion of the temperature sensing elements in the furnace. Temperature readings should be taken for a sufficient length of time af ter thermal equilibrium to determine the recurring temperature pattern. After all temperature sensing elements have reached equilibrium, the maximum temperature variation of all elements shall not exceed 20oF and at no time af ter equilibrium is reached should the temperature readings be outside the solution heat treating or precipitation range being surveyed. 3-66. Temperature measuring instruments used for furnace control shall not be used to read the temperature of the test temperature sensing elements. 3-67. Furnace thermocouple and sensing element should be replaced periodically. This is necessary due to oxidation and deterioration of the elements. 3-68. Salt Bath Testing - Temperature uniformity in a salt bath may be determined by use of a temperature sensing element enclosed in a suitable protected tube. The temperature sensing element should be held in one position until thermal equilibrium has been substantially reached and reading made. The temperature sensing element should then be placed in a new location and the procedure repeated. These operations should be repeated until the temperature in all parts of the bath have been determined. The maximum variation indicated by reading from the various locations in the load zone shall not exceed 20oF and no reading shall be outside the heat treating range specified for the materials involved.

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T.O. 1-1A-9

3-69. At this point it should be explained that a substantial amount of the diff iculties encountered in heating aluminum alloys is due to improper or inadequate temperature control and circulation of heating medium. When diff iculties arise the function of these units should be checked prior to performing other system test. 3-70. FABRICATION.

b. Provide clean smooth (rust free) and adaptable forming equipment. c. Sheared or cut edges shall be sanded and f iled or polished, prior to bending or forming. d. Use only straight and smooth forming dies or brake leafs of the correct radius which are free of nicks, burrs and sharp edges. e. Form material across the direction of grain f low when possible. f. Material should be of the correct temper, thickness and alloy in the range of formable material. 3-77. For intricate forming operations it is necessary to use annealed (ConO) material and f inal strength developed by heat treating af ter the forming has been accomplished. Heat-treated alloys can also be formed at room temperature immediately af ter quenching (Wtemper), which is much more formable than the fully heat-treated temper. The part is then aged to develop full strength. The forming operation should be performed as soon af ter quenching as possible, in view of the natural aging that occurs at room temperature on all the heat treatable alloys. The natural aging can be delayed to a certain extent by placing the part in a cold storage area of 32o or lower. The lower the temperature the longer the delay to a point where maximum delay is obtained. 3-78. BENDING. Bending is classif ied as single curvature forming. Upon bending sheet metal, bar or rod, the material at the bends f lows or deforms i.e., the material adjacent to the other surface of the bend is under tension and the length is increased due to stretching and the material adjacent to and on the inner surface is under compression and the length is decreased. 3-79. The most common problems encountered in practice are springback and cracking within the bend area. Problems associated with bend cracking are usually a result of improper bend radii, rough edges of material being formed or forming equipment and bending parallel to direction of grain f low. For the approximate bend radius to use in bending various thicknesses and types of aluminum see Table 3-13. Actual practice may reveal that a larger or a smaller radius may be used in some instances. If tighter bend radii is required, then fabricators should proceed with additional caution and if needed, should seek assistance of engineering or laboratory metallurgists. 3-80. Diff iculties encountered with springback are most commonly associated with bending of the

3-71. This portion is intended to provide some of the information required to fabricate the various aluminum products into parts and assemblies. Aluminum is one of the most workable of all the common metals. It can be fabricated into a variety of shapes by conventional methods. 3-72. The formability varies considerably with alloy and temper. Specif ic application usually depends on the shape, strength and temper of the alloy. The preceeding will necessitate that the mechanic be well trained to cope with the variables associated with this material especially when the end use of the item is an aircraf t or a missile. 3-73. FORMING SHEET METAL.

3-74. GENERAL. The forming of aluminum (1100) is relatively easy, using approximately the same procedures as those used for common steel except that care must be taken to prevent scratching. Do not mark on any metal surface to be used as a structural component with a graphite pencil or any type of sharp pointed instrument. Use pencil, Aircraf t Marking, Specif ication MIL-P-83953, NSN 7510-00-537-6928 (Black),7510-00-537-6930 (Yellow), and 7510-00-537-6935 (Red). All shop equipment, tools and work area should be kept smooth, clean and free of rust and other foreign matter. 3-75. Alloyed aluminum (2024, 7075, 7178, etc.) are more diff icult to form, and extensive control is required to prevent scratching and radii cracking. Scratching will make forming more diff icult plus it provides an easy path for corrosion attack, especially on clad materials. The clad coating referenced is usually a sacrif icial corrosion resisting aluminum alloy coating sandwiched metalurgically to an alloyed core material. The thickness of the coating will depend on the thickness of the sheet or plate. The nominal cladding thickness is 4% of composite thickness for material under 0.063 inch; 2.5% for material in the range of 0.063 - 0.187 inch and 1.5% for material 0.188 inch and thicker. 3-76. The following general rules should be employed in the handling and forming operation: a. Provide clean area; free of chips, grit and dirt and other foreign material.

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T.O. 1-1A-9

stronger alloys, especially those having high yield strength. Springback problem associated with this material can be overcome to a certain degree by overforming. The amount of overforming utilized will depend on the temper and the alloy; the sof ter the material the less springback compensation
Table 3-13.

required. Other means of reducing springback is to bend the material in the sof t condition (Condition O) or immediately af ter quenching and reducing the thickness or the radius if allowed. Avoid reducing radii to the point that grain separation or bend cracking results.

Cold Bend Radii (Inside) for General Applications

Alloy and Temper 0.016 1100-0 3003-0 5052-0 6061-0 2014-0 2219-0 7075-0 7178-0 1100-H12 3003-H12 5052-H32 1100-H16 3003-H16 5052-H36 1100-H18 3003-H18 5052-H38 6061-T4 6061-T6 2219-T4 2219-T62,T81 2024-T4 2024-T3 2014-T3 7075-T6 7178-T6 7050-T7 7475 0.02 0.03 0.03 0.03 0.03 0 0.03 0.03 0.02 0.03 0.03 0.03 0.03 0.03 0.016 0.03 0.03 0.03 0.03 0.03 0-1T 2-3.5T 0.06 0.06 0.06 0.06 0.06 ---

Sheet Thickness = T (Inches) 0.032 0.03 0.03 0.03 0.03 0.06 0 2T 2T 0.03 0.03 0.06 0.06 0.06 0.06 0.032 2T 2T 2T 2T 2T 0-1T 2.5-4T 4T 4T 3T 5T 5T --0.040 0.03 0.06 0.06 0.06 0.09 -2T 2T 0.03 0.03 0.06 2T 2T 2T 0.064 2T 2T 3T 2T 2T 1-2T 3.5T 4T 4T 4T 6T 6T 0.063 0.06 0.06 0.06 0.06 0.09 0.5-1.5T 2T 2T 1T 1T 11/2T 2T 2T 2T 0.125 21/2T 21/2T 4T 2T 2T 1-2T 4-6T 5T 5T 5T 6T 6T --0.125 0.125 0.160 0.160 0.16 0.19 0.5-1.5T 2T 2T 1T 1T 2T 2T 21/2T 21/2T 0.1875 3T 3T 5T 3T 3T 1.5-2.5T 4-6T 6T 6T 6T 6-8T 6-8T 8T -0.1875 0.187 0.187 0.187 0.1875 0.312 0.5-1.5T 21/2T 21/2T 11/2T 11/2T 21/2T 21/2T 4T 4T 0.250 31/2T 41/2T 6T 4T 4T 1.5-2.5T 5-7T 6T 6T 6T 9-10T 9-10T 9T -9.5T -0.250 0.250 0.250 0.250 0.250 0.44 1-2T 3T 3T 11/2T 11/2T 2T 3T 5T 5T

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T.O. 1-1A-9

3-81. DRAW FORMING. Draw forming is def ined as a method where a male die (punch) and a female die is used to form a sheet blank into a hollow shell. Draw forming is accomplished by forcing the male die and the metal blank into the female die. Generally mechanical press either single or double action and hydraulic presses are used to perform the drawing operation. Results will depend on die design, radii of die forming surfaces, f inish of die, surface clearance between punch and female die, blank hold down pressure, shape of blank, material allowance on blank, elongation factor of material, temper, shape of part being formed, drawing speed, and lubricant. Optium results usually requires experimentation and adjustment of one or more of these factors. Drawing of very deep shells require more experimentation and the utilization of a succession of limit draws. Because of the work hardening resulting from each draw, reduction in successive draws must be less. In severe conditions an intermediate anneal is sometimes used. Condition O material of the heat treatable alloys can be heat treated af ter drawing to obtain higher strength and to relieve the effect of work hardening. However, the non-heat treatable alloys can only be annealed to relieve the effect of work hardening. This material should not be annealed if high strength is the major requirement. 3-82. The recommended material to manufacture drawing dies is hardened tool steel for large scale production; kirksite and plastic for medium or short run production; and phenolic and hardwood for piece production. 3-83. STRETCH FORMING. This process involves stretching a sheet or strip to just beyond the elastic limit where permanent set will take place with a minimum amount of springback. Stretch forming is usually accomplished by gripping two opposite edges f ixed vises and stretching by moving a ram carrying the form block against the sheet. The ram pressure being suff icient to cause the material to stretch and wrap to the contour of the form block. 3-84. Stretch forming is normally restricted to relatively large parts with large radii of curvature and shallow depth, such as contoured skin. The advantage is uniform contoured parts at faster speed than can be obtained by hand forming with a yoder hammer or other means. Also, the condition of the material is more uniform than that obtained by hand forming. The disadvantage is high cost of initial equipment, which is limited to AMA level repair facilities. 3-85. Material used for stretch forming should be limited to alloys with fairly high elongation and

good spread between yield and tensile strength. Most of the common alloys are formed in the annealed condition. It is possible to stretch form the heat treatable alloys in tempers T4 or T6, where the shape is not too deep or where narrow width material is used. For the deeper curved shapes, the material is formed in the annealed Otemper, heat treated and reformed, to eliminate distortion resulting from heat treatment. As previously stated the material should be reformed as fast as possible af ter heat treatment. In some instances the material is formed immediately af ter heat treating and quenching. Selection of a system or condition of material to be utilized will require experimentation and the subsequent utilization of the system that gives the best results. 3-86. HYDRAULIC PRESS FORMING. The rubber pad hydropress can be utilized to form many varieties of parts from aluminum and its alloys with relative ease. Phenolic, masonite, kirksite and some types of hard setting molding plastic have been used successfully as form blocks to press sheet metal parts such as ribs, spars, fans, etc. The press forming operations are usually accomplished by setting the form block (normally male) on the lower press platen and placing a prepared sheet metal blank on the block. The blank is located on the block with locating pins, to prevent shif ting of blank when the pressure is applied (the sheet metal blank should be cut to size and edges deburred prior to pressing). The rubber pad f illed press head is then lowered or closed over the form block and the rubber envelope, the form block forcing the blank to conform to the form blocks contour. This type forming is usually limited to relatively f lat parts having f langes, beads and lightening holes. However, some types of large radii contoured parts can be formed with a combination of hand forming and pressing operations. It is recommended that additional rubber be supplemented in the form of sheets when performing the above to prevent damage to the rubber press pad. The rubber sheet used should have a shore hardness of 50-80 durometers. The design of foam block for hydropress forming require compensation for springback even through the material normally used is Condition O or annealed. Normal practice is to under cut the form block 2-7o depending on the alloy and radii of the form block. 3-87. DROP HAMMER FORMING. The drop hammer can be used to form deep pan shaped and beaded type parts. Kirksite with a plastic surface insert is satisfactory for male and female dies. The surface of kirksite dies used without plastic insert should be smooth to prevent galling and scratching of the aluminum surface. When forming deep pans and complicated shaped parts it is

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T.O. 1-1A-9

often necessary to use drawings rings, pads or 2-3 stage dies. An intermediate anneal is sometimes used to relieve the hardened condition (cold work) resulting from the forming operation. 3-88. JOGGLING. A joggle is an offset formed to provide for an overlap of a sheet or angle which is projecting in the same plain. The inside joggle radii should be approximately the same as used for straight bending. Joggle run out or length as a normal rule should be three times the depth of the joggle for the medium strength alloys (2024, 2014, etc.) and approximately four times the depth for the higher strength alloys (7075, 7178, 7079 etc). Where deep and tight joggles are required, annealed material should be used with heat treatment to follow. 3-89. HOT-FORMING. Hot forming is not generally recommended, however, it is sometimes used where it is not possible to form an article by other methods. Accomplishment shall not be attempted unless adequate facilities are available to control temperature requirements. Actual formability will depend on the temperature that various alloys are heated. The higher the temperature the easier formed. Excessively high temperature shall not be used, as considerable loss in strength and corrosion resistance will occur. Frequent checks should be made using an accurate contact pyrometer. Table 3-14 cites the recommended times and temperature (accumulative) for the various alloys. The losses in strength as a result of re-heating at the temperature cited by this table will not exceed 5%. Equal formability will be obtained with shorter periods of heating in most cases and the minimum times should be used. It should be understood that this table cited the maximum accumulative times at cited temperature. 3-90. SPINNING. Spinning is an art and makes exacting demands upon the skill and experience of the mechanic performing the operation. For this reason mass production of parts is impractical. However, it can be used to advantages where only a few parts are required and to assist in the

removal of buckles and wrinkles in drawn shell shaped objects. 3-91. Forming by spinning is a fairly simple process, an aluminum disc (circle) is placed in a lathe in conjunction with a form block usually made of hardwood; as the disc and form block are revolved, the disc is molded to the form block by applying pressure with a spinning stick or tool. Aluminum soap, tallow or ordinary soap can be used as a lubricant. 3-92. The best adapted materials for spinning are the sof ter alloys i.e., 1100, 3003, 5052, 6061, etc. Other alloys can be used where the shape to be spun is not excessively deep or where the spinning is done in stages and intermediate annealing is utilized to remove the effect of strain hardening (work hardening) resulting from the spinning operation. Hot forming is used in some instances when spinning the heavier gauge materials and harder alloys. 3-93. BLANKING AND SHEARING. Accurate shearing will be affected by the thickness of material, type of shear or knife blades, condition of material, adjustment and sharpness of blades, size of cut and the relationship of the width of the cut to sheet thickness. 3-94. Normally most aluminum alloys can be sheared 1/2 inch and less in thickness except for the harder alloys i.e., 7075-T6 and 7178-T6. These alloys have a tendency to crack in the vicinity of the cut especially if the sheer blades are dull or nicked. The above will naturally require that tooling used be designed to handle the thickness of material to be cut. Correct clearance between shear blades is important for good shearing. Too little clearance will quickly dull or otherwise damage the blades or knives; too much will cause the material to be burred, or even to fold between blades. Normal clearance is from one-tenth to oneeighth the sheet thickness. Blade life will be prolonged by occasionally lubricating. When the capacity of shear is doubtful the shear manufacturer should be consulted.

3-31

T.O. 1-1A-9

Table 3-14.

Maximum Accumulative Reheat Times for Hot Forming Heat Treatable Alloys at Different Temperatures

ALLOY 2014-T6 2024-T81 2024-T86 6061-T6 7075-T6

450oF To Temp 5 Min 5 Min 5 Min No

425oF To Temp 15 Min 15 Min 15 Min No Temp No No

400oF 5-15 Min 30 Min 30 Min 30 Min 5-10 Min No No

375oF 30-60 Min 1 Hr 1 Hr 1-2 Hrs 30-60 Min No No

350oF 2-4 Hrs 2-4 Hrs 2-4 Hrs 8-10 Hrs 1-2 Hrs No No

325oF 8-10 Hrs ----5-100 Hrs 2-4 Hrs No No

300oF 20-50 H 20-40 H 10-20 H 100-200 H 10-12 H No No

*2014-T4, 2014-T3 No *2024-T4, 2024-T3 No

* These materials should not be hot formed unless subsequently artif icially aged. 3-95. BLANKING. Blanking is usually accomplished utilizing a blanking die in almost any type of punch press equipment. The essential factors requiring control are die clearance, shearing edge lead, and stripping action. The shearing principle is primarily the same as that encountered with the squaring shear. However, the method of grinding punch dies will vary according to the results required and in such manner that will reduce load on equipment. Commonly two or more high points are ground on die to keep side thrust on the punch at a minimum. Lubrication is essential in blanking operations. Suitable lubricants are engine oil, kerosene and lard oil which are normally used in mixed form.

Paragraphs 3-96 through 3-155 deleted. Tables 3-15 through 3-16 deleted. Pages 3-33 through 3-38 deleted.

3-32 Change 1

T.O. 1-1A-9

3-156. 3-157. 3-158. 3-159. 3-160. 3-161.

Deleted. Deleted. Deleted. Deleted. Deleted. Deleted.

3-162. RIVETING. Riveting is the most common method of assembling components fabricated from aluminum. Typical advantages of this method of mechanical fastening are simplicity of application, consistent joint uniformity, easily inspected (X Ray and other type equipment not required.), low cost, and in many cases lighter weight. 3-163. The rivets used in USAF Weapon System structures require that the alloys and shapes be closely controlled by specif ication/standards, to assure structural integrity and uniformity. These rivets are presently classif ied as solid shank, hishear, blind (structural-non-structural) explosive/ chemical expanded. They are available in a variety of shapes, alloys, sizes, lengths and types. The most common alloys utilized are aluminum because the structure alloys are normally aluminum. In addition some of the aluminum rivet characteristics can be changed by heat treating which facilitates application (see paragraph 3-37.) 3-164. All of the aluminum alloys could be used to manufacture rivets; however, due to some alloys having superior properties they have been selected as standard. See Table 3-17 for alloys head, identification, MS/AN standard cross references, etc., for general rivets used on AF weapons systems.

3-165. Rivets in aluminum alloys 1100(A), 5056(B), 2117(AD) are used in the condition received Alloys 2017(D) and 2024(DD) of ten referred to as Ice Box Rivets require heat treatment prior to use (see paragraph 3-43). Rivets in alloy 2017 and 2024 should be driven immediately after quenching with a maximum delay of 20 minutes or refrigerated to delay aging. The customary procedure (unless only a few rivets are involved) is to place the rivets under refrigeration immediately after heat treatment The time the rivets may be used will depend on refrigeration equipment available. Cooling to 32oF will retard natural aging to the extent that the rivets may be driven up to 24 hours. Cooling rivets +0-10oF and below will retard natural aging to the extent that the rivets may be retained for use indef initely. 3-166. Rivets utilized with extended driving time should be closely inspected af ter upsetting for cracks. If inspection reveals that rivets are cracked, discontinue use, remove defective rivets and obtain reheat treated rivets prior to continuing the assembly operation. 3-167. If for some reason it is necessary to determine if a rivet has been heat treated this may be done by Rockwell Hardness testing. Test by supporting rivets in a vee block and hardness reading taken with a 1/16 inch ball 60 kilogram load . A hardness of over 75 will indicate a heat treated rivet.

(3-39 blank)/3-40

Change 1

T.O. 1-1A-9

CAUTION Heat treatment and most other operations requiring use of heat will be accomplished prior to installing rivets, since heating af ter rivets are installed will cause warping and possible corrosion if salt bath is used. The salt from the bath will contaminate cracks and crevices of the assembly and complete removal can not be assured. 3-168. Shear strength (ultimate) of a driven rivet can be determined by the formula Ps=SsAN. Ps=ultimate shear strength (pounds), Ss=specif ied shear strength of the driven rivet (psi), A=cross sectional (area of the driven rivet, normally equal to hole cross section (square inch) and N=number of shear planes. For shear strength of protruding and f lush head rivets see Table 3-19. 3-169. The load required to cause tensile failure of a plate in a rivet joint can be determined by the formula Ts=P+ (D-A) Tp. Ts=ultimate tensile strength (pounds), PT = specif ied ultimate tensile strength of the plate (psi), D=pitch of the rivets (inch) - pitch is the distance between the center of two adjacent rivets on the same gauge line, A=diameter of hole (inch) and Tp=thickness of plate. 3-170. Rivet Selection. Unless otherwise specified rivets should be selected that have comparable strength and alloy as material being assembled. This is an important factor in preventing

corrosion from dissimilar metal contact and to assure structurely sound assemblies. The following tables are provided as a general guide for selection of rivet alloy vs assembly alloy. 3-171. The formula Ps = Sb AC can be used to determine failure in bearing strength. Ps = ultimate bearing strength of the joints (lbs), Sb = specified ultimate bearing strength of the plate (psi) and AC = projected crushing area (bearing area) of rivet, or diameter (sq in) see table 3-20 for typical bearing properties of aluminum alloy plates and shapes. 3-172. Rivet hole preparation is one of the key factors in controlling successful upsetting of rivet head, material separation and buckling which weakens the structural strength of the rivet joint, and corrosion attack of rivets and material af ter equipment is placed in service/use. The rivet hole should be drilled, punched/reamed to size that allows the minimum clearance (apprximately 0.003 for thin sheet and up to about 0.020 for 0.750 1.000 inch thick material) required to insert rivet without forcing. Theoretical rivets holes should be completed i.e., drilled, reamed to size, deburred, chips removed that may lodge or be trapped in between surface of metal and treated (anodized etc.) before starting to rivet assembly. The above cannot always be accomplished especially where the assembly is large and requires the application of a large amount of rivets due to hole tolerance and variations in holding clamping/pressures. To overcome these problems requires that holes be pilot drilled end reamed to size at time rivet is to be installed. This method has a twofold purpose: (1) allows easy insertion of rivets, (2) prevents

3-41

T.O. 1-1A-9

elongation of rivet holes and resulting weakening of rivet joint. 3-173. Rivet holes drilled/reamed af ter assembly is started should be treated by coating with zinc
Table 3-17.

chromate primer or other approved material. Two methods for coating rivets and improving protection of hole surfaces from corrosion are:

General Rivet (Alum) Identification Chart

OLD AN/ STD AN456 USAF460

SUPERSEDING MS STD

FORM

MATERIAL See AN470 See MS20601 See MS20601 Same Same 1100 5056 2117 2017 2024

HEAD AND NUMERICAL IDENT CODE

CONDITION

HEAT TREAT

MS20470 See MS20601

Brazier Head Solid Modif ied 1000 Flush Head Blind Type II Class 2 Protruding Head Type II Class I Blind Same Same Universal Head Solid

USAF461

See MS20600

USAF463 NAF1195 AN470

See MS20600 See MS20600 MS20470

A-Plain B-Raised Cross AD-Dimple D-Raised Dot DD-Raised Dash B AD M B AD M B

F F T-4 T-4 T-4 F T-4 F T-4 F

No No No Yes Yes No No No No No No No

MS20600

Protruding Head-Blind Type II, Class I 100 Flash Head Blind Type II, Class 2 Protruding Head Blind Chemically Expanded Type I, Class I, Styles A & B
o

5056 2117 Monel 5056 2117 Monel 5056

MS20601

MS20602

2017

T-4

No

3-42

T.O. 1-1A-9

Table 3-17.

General Rivet (Alum) Identification Chart - Continued

OLD AN/ STD

SUPERSEDING MS STD

FORM

MATERIAL 5056 2117

HEAD AND NUMERICAL IDENT CODE B AD

CONDITION

HEAT TREAT

MS20604

Universal Head Blind Class I Non Struct

F T-4

No No No

Monel M or MP (MP = Monel Plated) MS20605 100o Flash Head Blind Class 2, Non Struct 5056 2117 B AD F T-4

No No No

Monel M or MP (MP = Monel Plated) 5056 2117 B AD F T-4

MS20606

Modified Trusshead Blind Class 3 Non-Struct

No No No

Monel M or MP (MP = Monel Plated) 1010 Recessed Triangle Annealed C-None CW Annealed Raised Dots Class A Annealed

MS20613

Universal Head Solid

No

302 MS20615 Universal Head Solid Copper Monel

No No No

NOTE: Copper, steel, and monel listed for information purposes only. For special rivets see manufacturing drawing, data, specif ication, etc. For other information on rivets see T.O. 1-1A-8/1-1A-1.

3-43

T.O. 1-1A-9

Table 3-17.

General Rivet (Alum) Identification Chart - Continued

OLD AN/ STD AN426

SUPERSEDING MS STD

FORM

MATERIAL 1100 5056 2117 2017 2024

HEAD AND NUMERICAL IDENT CODE A-Plain B-Raised Cross AD-Dimple D-Raised Dot DD-Raised Dashes Recessed Triangle C-None FRecessed Dash M-None Head Ident Recessed Triangle C-None F-Head Ident None M-None

CONDITION

HEAT TREAT

MS20426

Countersunk 100o

F F T-4 T-4 T-4

No No No Yes Yes

NOTE: See paragraph 3-44 for heat treat data. AN427 MS20427 Countersunk 100o 1006/ 1010 Copper 302/304 Monel M AN430 AN435 MS20470 MS20435 Round Head Solid 1006 A A A No No No

Round Head replaced by universal See AN470 + M520470 A No

NOTE: Listed for Reference only.

Copper 302/304

A A

No No

Monel AN441 AN442 AN450 Use MS20435 Use MS20470 MS20450 See AN435 See AN70+ MS20470 Countersunk & oval tubular 1006/ 1010/ 1015 Copper 2117 Brass MONEL AN455 MS20470 Brazier Head Solid Superseded by Universal. See AN470

Blank/ None C-None AD-None B-None M-None

No

Note: Listed for Reference only.

A T-4 Grade B A

No No No No

3-44

T.O. 1-1A-9

Table 3-18.

General Aluminum Rivet Selection Chart (Rivet Alloy vs Assembly Alloy)

Rivet Alloy 1100 2117-T4 (AD)

Assembly Alloy 1100, 3003, 3004, 5052 3003 - H16 and H-18, 5052 - H16 and H18, 2014, 2017, 2024, 6061, 7075, and 7178 2014, 2017, 2024, 5052, 6061, 7075 and 7178 5052 and magnesium alloys, AZ31B, etc. a. Allow more space for chips to be formed and expelled from tool than allowed for steel. b. Design tools (grind tool) so that chips and cuttings are expelled away from the work piece. c. Keep cutting edges of tools sharp, smooth, free of burrs, wire edges and scratches. d. Use high machining speeds, moderate feeds and depths of cut. e. Apply lubricant/coolant in large quantities to tool when cutting. 3-178. The higher speeds utilized for machining aluminum requires: a. Machines be free of vibration and lost motion. b. Rigid support of tool near cutting edge to minimize clatter and vibration. c. Secure clamping of work to machine to avoid distortion or slippage. d. Use of proper lubricant, cutting compound or coolants to prevent overheating, warpage/distortion and to provide adequate lubrication to cutting tool. 3-179. CUTTING TOOLS FOR MACHINING ALUMINUM. There are four general types of tool steel material that can be used to machine aluminum. They should be selected in accordance with availability and scope of job to be accomplished. The following is a suggested guide for selection of tools: a. High carbon tool steel is adequate for machining a small number of parts or where cutting speed required is relatively low. This material will exceed the performance of some of the other types of tools when used for fragile tools such as drills, taps, etc., because it does not break as easily as the other types. Stock material is

2017-T4 (D), 2024T4 (DD) 5056-H32 (B) a. Spraying holes with primer af ter drilling and immediately preceding installation of rivet. b. Dipping rivet in zinc chromate primer and installing while still wet. 3-174. For additional information on rivets (strengths, factors, etc.) see MIL-HDBK-5, T.O.s 11A-8 and 1-1A-1. 3-175. MACHINING. The resistance encountered in cutting alminum alloys is low in comparison to other metals. In fact most of the aluminum alloys will machine approximately 10 times faster than steel. This factor combined with other properties, i.e., strength, heat treatability, weight, corrosion resistance, etc. makes aluminum a preferred material in many instances for fabrication of parts by machining. Brass (free machining) is the only other material with comparable machining properties. 3-176. Personnel accomplishing the work should be properly trained in machining aluminum as with other types of metals. Due to various circumstances personnel familiar with machining steel products are required to machine aluminum without proper training/information on speeds, feeds, tools etc., required to effectively accomplish a specific task. The purpose of this section is to provide a general guide for selection of tools, machining, speeds, etc. 3-177. The tools used for machining aluminum will normally require more rake side-top and operation at higher/feeds than used for steel. The amount of rake required will depend on composition, physical form (cast or wrought) and temper. The more ductile or sof ter the alloy the more rake required. The following general practices are recommended for shaf ing, grinding and maintaining tools for cutting aluminum:

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T.O. 1-1A-9

obtainable in accordance with Federal Specif ication QQ-T-580 where required for local fabrication of high carbon tools etc. b. High speed tool steel is the most common type used for machining except on the higher silicon alloys. (1) Availability, reasonable cost.

lard oil such as Specif ication C-O-376 or mineral oil, Specif ication VV-O-241 is recommended. In practice it will be found that some machining operations can be performed dry. 3-182. Tables 3-22 and 3-23 cite suggested turning speeds, tool angles and feeds. Tool projection in relation to work should be set at or slightly above work piece center line. Sturdy construction of tools and holders is essential to minimize vibration/chatter at the high speeds aluminum alloys are machined. NOTE Parting tools should have less top rake than turning tools. Recommend top rake angles of 12o - 20o and front clearances of 4o - 8o grind face concave (slightly) and so that corner adjacent to work will lead opposite corner by 4o - 12o or as required for best results. 3-183. MILLING - ALUMINUM. Milling of aluminum alloys should be accomplished at high cutter speeds. The limitations will usually depend on the machine and type cutters used. The reason for the higher cutter speeds is that at low speeds the cutters will have a tendency to load and gum. This will normally clear as the speed is increased. 3-184. The tooling for milling should be selected according to the operation and duration/size of job to be performed. The cutters should have fewer teeth and should be ground with more top and side rake than those used for milling steels. Most operations can be accomplished with spiral cutters. Nick tooth cutters are used when reduction in size of chips is required. Solid-tooth cutters with large helix angles are used where free-cutting tools are required. When cutters with large helix angles are used it is of ten necessary that two interlocking cutters of opposite helixes be employed to alleviate axial thrust. 3-185. Tool alloys should be selected for milling aluminum as follows: a. For short runs high carbon steel is normally satisfactory. b. For production runs of extended duration high speed steel is recommended. c. Where climb milling/high speeds are utilized, carbide tipped tools are recommended for extended runs.

(2) Heat resistance (will retain cutting edge up to about 950oF dull red). (3) Permits use of large rake angle required. Federal Specif ication QQ-T-590 applies to stock material. All the various classes (T1, T2, T3, etc.) may be used for machining aluminum. Class T1 (18-4-1) general purpose type is the most widely used. c. Where long production runs are involved cemented carbide (solid or tipped) tools give better service. The carbide tools have been known to last thirty times longer than high speed tool steel. The carbide tools are also recommended for cutting high silicon content alloys. Because of the brittleness of the cemented carbide tool the cutting angle should be greater than those recommended for high carbon/high speed steels. d. Diamond tipped tools should only be used for light f inishing cute or special f inishing operations. Normal cutting of 75o - 90o are used with top rake angles of 6o - 10o. Tool projection (or set) should be slightly above center line (CL) of the work. 3-180. TURNING. To properly perform the turning operation f irmly attach the work to the machine (lathe) chuck, collet or faceplate. The work should be held in the best manner to minimize distortion from chuck or centrifugal force action during the turning operation. Long rods/ stock should be supported by ball or roller bearing tailstock centers which are more satisfactory than solid or f ixed centers in resisting thrusts from centrifugal force and thermal expansion. Sof t liners may be used between work and machine jaw faces to prevent jaw teeth from damaging/marring work piece. When it is necessary that work be held by clamping from inside diameter outward the tightness of jaws should be checked frequently to be sure that work is not being released as a result of thermal expansion. 3-181. The recommended cutting f luids are the soluble oil emulsion which combine the functions of cooling and lubricating for general purpose use. For heavy cutting especially when speeds are low,

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T.O. 1-1A-9

Table 3-19.

Shear Strength of Protruding and Flush Head Aluminum Alloy Rivets, Inch Pounds

Size of Rivet(In Dia) Alloy + driven temper 5056 FSU = 28 KSI 2117-T321, FSU = 30 KSI 2017-T31, FSU = 34 KSI 2017-T3, FSU = 38 KSI 2024-T31, FSU = 41 KSI

1/16 99 106 120 135 145

3/32 203 217 297 275 296

1/8 363 388 442 494 531

5/32 556 596 675 755 815

3/16 802 862 977 1,090 1,180

1/4 1,450 1,550 1,760 1,970 2,120

5/16 2,290 2,460 2,970 3,110 3,360

3/8 3,280 3,510 3,970 4,450 4,800

FSU = Average Shear Strength of alloy in specif ied temper. KSI = 1000 lbs square inch example: 34 KSI = 34,000 lbs per square inch. Single shear rivet strength correction factor (resulting from use in thin plates and shapes). Sheet thickness (in) 0.016 0.018 0.020 0.025 0.032 0.036 0.040 0.045 0.050 0.063 0.071 0.080 0.090 0.100 0.125 0.160 0.190 0.250 Double shear rivet strength correction factor (resulting from use in thin plates and shapes) SIZE OF RIVETS Sheet Thick Inch 0.016 0.018 0.020 1/16 0.688 0.753 0.792 3/32 1/8 5/32 3/16 1/4 5/16 3/8 0.0964 0.0984 0.0996 1.000 0.972 1.000 0.964 0.980 0.996 1.000 0.964 0.980 0.996 1.000 0.972 1.000 0.964 0.980 0.996 1.000 0.964 0.974 0.984 0.996 1.000 0.972 1.000

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T.O. 1-1A-9

Table 3-19.

Shear Strength of Protruding and Flush Head Aluminum Alloy Rivets, Inch Pounds - Continued

0.025 0.032 0.036 0.040 0.045 0.050 0.063 0.071 0.080 0.090 0.100 0.125 0.160 0.190 0.250

0.870 0.935 0.974 0.987 1.000

0.714 0.818 0.857 0.896 0.922 0.961 1.000 0.688 0.740 0.792 0.831 0.870 0.935 0.974 1.000 0.688 0.740 0.792 0.883 0.919 0.948 0.974 1.000 0.714 0.818 0.857 0.896 0.922 0.961 1.000 0.688 0.740 0.792 0.831 0.870 0.935 0.987 1.000 0.688 0.753 0.792 0.883 0.835 0.974 1.000 0.714 0.818 0.883 0.935 1.000

Note: Values (lbs) of shear strength should be multiplied by the correction factor whenever the D/T = rivet diameter/plates sheet or shape thickness ratio is large enough to require correction. Example: Rivet diameter 1/8 (alloy 2117 - T3) installed in 0.040 sheet, shear factor is 388 lbs correction factor 0.996 = 388 0.996 2328 3492 3492 386.448 corrected shear pounds
Table 3-20. Bearing Properties, Typical, of Aluminum Alloy Plates and Shapes

Edge Distance = 1.5 X Rivet Diameter Alloy 1100 - 0 1100 - H12 1100 - H14 1100 - H16 1100 - H18 3003 - 0 3003 - H12 3003 - H16 3003 - H18 Yield Strength 10,000 18,000 22,000 23,000 27,000 12,000 21,000 28,000 32,000 Ultimate Strength 21,000 23,000 24,000 16,000 19,000 22,000 27,000 34,000 38,000

Edge Distance = 2.0X X Rivet Diameter Yield Strength 12,000 21,000 23,000 26,000 32,000 15,000 24,000 33,000 38,000 Ultimate Strength 27,000 29,000 31,000 34,000 38,000 34,000 36,000 42,000 46,000

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T.O. 1-1A-9

Table 3-20.

Bearing Properties, Typical, of Aluminum Alloy Plates and Shapes - Continued

Edge Distance = 1.5 X Rivet Diameter Alloy 2014 - T4 2014 - T6 2024 - T3 Alclad 2024-T-3 2024 - T36 Alclad 2024-T36 5052 - 0 5052 - H32 5052 - H34 5052 - H36 5052 - H38 6061 - T4 6061 - T6 7075 - T6 Alclad 7075-T6 Yield Strength 56,000 84,000 64,000 60,000 80,000 74,000 25,000 37,000 41,000 47,000 50,000 29,000 56,000 101,000 94,000 Ultimate Strength 93,000 105,000 102,000 96,000 110,000 100,000 46,000 54,000 59,000 62,000 66,000 56,000 72,000 123,000 114,000

Edge Distance = 2.0X X Rivet Diameter Yield Strength 64,000 96,000 74,000 69,000 91,000 85,000 30,000 42,000 47,000 54,000 58,000 34,000 64,000 115,000 107,000 Ultimate Strength 118,000 133,000 129,000 122,000 139,000 127,000 61,000 71,000 78,000 82,000 86,000 73,000 94,000 156,000 144,000

3-186. Milling cutters should be inclined to work and beveled on leading corner (least bevel for f inish cuts) to minimize clatter. 3-187. The cutting f luids for milling aluminum should combine cooling and lubrication properties. Coolant lubrication should be applied under pressure (atomized spray if available) in large quantities to tool and work. The recommended cutting f luids are water base cutting f luids such as soluble oils and emulsions, mixed 1 part to 15 for high speeds and 1 part to 30 for low speed cutting. 3-188. Tables 3-24 and 3-25 cite suggested speeds, contour and tool angles, for milling aluminum. The best combination of cutting speeds, feed and cut for a given job will depend on design of tool/cutter, kind of tool material, condition of machine, machine power, size, clamping method and type material being worked. 3-189. SHAPING AND PLANING. The speed at which aluminum alloys can be cut by planing and shaping is somewhat slower in comparison to other machining methods, due to equipment design and limitations.

The slower cutting speeds can be overcome to some extent by securely anchoring the work to the machine and using heavy rough cutting feeds. The tools used for rough cut should be (round nose) of heavy construction and properly ground to operate efficiently. Rough cut tools should be ground with moderate amount of rake to provide maximum cutting edge support. Finish tool should have more top rake and an extra large amount of side rake. Finishing tool shall be used with f ine feeds only due to the additional side and top rake (finish cut should not exceed 0.018 inch). 3-190. Most cutting operations by shaping and planning can be accomplished without cutting f luids, however f ine f inishing can be improved by lubrication. Recommended cutting compounds are kerosene, mixture of 50-50 lard-oil and soluble oil. 3-191. Tables 3-26 and 3-27 cite suggested turning speeds, tool angles and feeds. Secure clamping of work is re-emphasized especially when heavy cutting feeds are to be used.

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T.O. 1-1A-9

Table 3-21.

Standard Rivet Hole Sizes with Corresponding Shear and Bearing Areas for Cold Driven Aluminum Alloy Rivets

3-192. DRILLING ALUMINUM ALLOY. Standard type twist drills may be used satisfactorily for many drilling operations in aluminum alloys. However, better results can be obtained with improved designed drills where sof t material and drilling of thick material or deep holes are involved. These drills are usually designed having more spiral twists per inch (see f igure 3-2). The additional spiral twist gives more worm action or force to drill causing the drill to cut/feed faster and is helpful in removing chips, especially in deep hole drilling operations. 3-193. Generally a drill for a given job should be selected according to the thickness, type alloy and

machine/drill motor to be utilized. The following is a general guide for the selection of drills and recommended speeds: a. Drill press. Point Angle: 118o - 140o for general work and 90o 120o for high silicon. Spiral Angle: 24o - 28o for thin stock and medium depth holes up to 6 times drill diameters, 24o - 48o for deep holes over 6 times drill diameter.

3-50 Change 3

T.O. 1-1A-9

Table 3-22.

Turning Speeds and Feeds

ALLOY TYPE AND TEMPER Soft Series, 1100 All temp 5052-H12, H14

CUT INCHES

CUTTING SPEED FPM 700 - 1600

FEED, IN./REV

OPER

TOOL MATERIAL Plain high carbon/high speed Plain high carbon/high speed Carbide Carbide

0.250 Maximum

0.050 Maximum

Rough

0.040 Maximum

1500 - 3500

0.004 - 0.015

Finish

2011-2024-0 5056-0-6061-0 7075-0, 113 138, 214, 212 750, 220, 122 HARD SERIES

0.250 Maximum 0.020 Maximum 0.010 Maximum

4000 - 7000 6000 - 8000 At Minimum vibration

0.012 Maximum 0.010 Maximum 0.002 - 0.005

Rough Finish

Finish only Diamond

0.200 Maximum

400 - 650

0.007 - 0.020

Rough

Plain high carbon/high speed Plain high carbon/high speed Carbide Carbide Diamond tipped Diamond tipped Plain high carbon/high speed Plain high carbon/high speed Carbide Carbide

108, 319, 43

0.020 Maximum

600 Maximum

0.002 - 0.004

Finish

5052-H34, H36, H38 T4, 2024-T3 7075-T6, 7178T6 6061-T4, T6, etc. HIGH SILICON SERIES

0.200 Maximum 0.020 Maximum Not recommended 0.006 Maximum 0.120 Maximum

500 - 1300 700 - 2500

0.010 Maximum 0.010 Maximum

Rough Finish Rough

At minimum vibration 600 Maximum

0.002 - 0.004 0.007 - 0.020

Finish Rough

0.020

600 Maximum

0.002 - 0.004

Finish

4032, 333, A132, 132, 356

0.120 Maximum 0.020 Maximum

500 - 1000 500 - 1500

0.008 Maximum 0.004 Maximum

Rough Finish

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Table 3-22.

Turning Speeds and Feeds - Continued

ALLOY TYPE AND TEMPER etc

CUT INCHES

CUTTING SPEED FPM NOT RECOMMENDED

FEED, IN./REV

OPER Rough

TOOL MATERIAL Diamond tipped Diamond tipped

0.006

At minimum vibration
Table 3-23.

0.001 - 0.003

Finish

Tool Angles - Turning

TOOL ANGLES Cutting Angles Top Rake Side Rake Front Clear Side Clear

PLAIN HIGH CARBON/HIGH SPEED 30o - 50o 30o - 53o 10o - 20o 7o - 10o 7o - 10o
Table 3-24.

CARBIDE 52o - 80o 0o- 32o 5o - 10o 6o - 10o 6o - 10o

DIAMOND 74o - 88o 10o - 0o 0o - 6o Nose Radii 0.06 - 0.10 ---

Milling - Speeds and Feeds

ALLOY Temper Soft

CUT Inches 0.250 Maximum

CUTTER SPEED Ft/minutes 700 - 2000 Ft/minutes 10 Maximum

FEED Inches per tooth 0.005 - 0.025

OPER

TOOL MATERIAL

Rough

High carbon/ High Speed Carbide Tipped

Soft Hard Hard Soft Soft

0.020 Maximum 0.200 Maximum 0.020 Maximum 0.300 Maximum 0.020 Maximum

5000 Maximum 500 - 1500 4000 Maximum 3000 - 15000 3000 - 15000

10 Maximum 10 Maximum 10 Maximum 20 Maximum 20 Maximum

0.005 - 0.025 0.005 - 0-025 0.005 - 0.025 0.004 - 0.020 0.004 - 0.020

Finish Rough Finish Rough Finish

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Table 3-24.

Milling - Speeds and Feeds - Continued

ALLOY Hard Hard

CUT 0.250 Maximum 0.020 Maximum

CUTTER SPEED 3000 - 15000 4000 - 15000 20 Maximum 20 Maximum

FEED 0.004 - 0.020 0.004 - 0.020

OPER Rough Finish

TOOL MATERIAL Carbide Tipped

Lip Clearance (lip relief): 17o for sof t alloys 15o for medium and hard alloys, 12o for silicone alloys Speed: 600 f t/min, with high speed drills and up to 2000 f t/min with carbide tipped drills. Feed: 0.004 - 0.012 inch per revolution for drills 3/8 inch diameter, 0.006 - 0.020 in/rev for 3/8 - 1 1/4 inch diameter and 0.016 to 0.035 in/rev for drills over 1 1/4 inch diameter. When using carbide tipped drill, feed should be slightly less. Feed also may be determined by the formular feeds = square root of drill diameter (inches) divided by 60 feet = Drill diameter (IN) + 0.002. b. Lathe/screw-machine. Point Angle: 118o - 140o Spiral Angle: 0o - 28o Lip Clearance (lip relief): 15o - 20o Speed f t/min up to 1500 Feed inches/revolution 0.004-0.016. c. Portable Drills Electric/Air Driven. Due to variables involved no set factors can be given. However, factors given for drill press should be used as a guide. Feed should be adjusted in accordance with speed of motor to prevent tip heating and also to satisfy operation/operator.
Table 3-25.

WARNING When operating any machinery all safety precautions must be observed, i.e., safety goggles shall be worn when grinding/ drilling. Machinery shall be inspected to insure that safety guards are in place/ for safe operation etc. prior to operating. Work shall be securely clamped to prevent slippage. Consult safety officer when in doubt about the safety of an operation. 3-194. The drilling of thin material normally does not require coolant/lubrication however adequate lubrication is essential to drill life and hole quality when drilling holes of 1/4 inch depth or more. Soluble oil emulsions and lard oil mixtures are satisfactory for general drilling. The lubrication should be applied by forced feed spray/f low where possible and the drill should be withdrawn at intervals to be sure lubricant f lows to the drill tip (f ill holes completely) when drill is withdrawn.

Tool Angles - Milling

TOOL ANGLES Cutting Angle Top Rake Clearance

HIGH CARBON/HIGH SPEED 48o - 67o 20o - 35o 3o - 7o Primary 7o - 12o Secondary 68o - 97o 10o - 15o

CARBIDE

3o - 7o Primary 7o - 12o Secondary 10o - 20o Approximately 1 tooth per inch of diameter.

Helix Tooth Spacing

10o - 50o Course - Sufficient for chip Clearance.

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Table 3-26.

Shaping and Planing-Speeds and Feeds

METHOD Shaping Shaping Planing Planing

CUT INCHES 1/4 Maximum 0.005 - 0.014 3/8 Maximum 0.005 - 0.018

CUTTING SPEED Maximum speed of RAM Maximum speed of RAM Maximum speed of Table Maximum speed of Table
Table 3-27.

FEED (INCHES) 0.008 - 0.031 0.094 - 0.156 0.020 - 0.100 0.050 - 0.375

OPER Rough Finish Rough Finish

TOOL MATERIAL High Carbon/ High Speed High Carbon/ High Speed High Carbon/ High Speed High Carbon/ High Speed

Shaping Tool Angles

OPERATION ROUGH FINISH Top rake Bottom Clear Side Rake Side Clear Cutting Angle 19o - 10o 43o - 52o 7o - 9o 8o - 10o 30o - 40o 50o - 60o 7o - 9o 0o - 0o 64o - 71o 30o - 37o

TOOL MATERIAL HIGH CARBON/HIGH SPEED HIGH CARBON/HIGH SPEED HIGH CARBON/HIGH SPEED HIGH CARBON/HIGH SPEED HIGH CARBON/HIGH SPEED HIGH CARBON/HIGH SPEED

3-54

T.O. 1-1A-9

Figure 3-2.

Drill Designs and Recommended Cutting Angles

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T.O. 1-1A-9

Table 3-28.

Thread Constant for Various Standard Thread Forms

PERCENT OF FULL THREAD DESIRED THREAD FORM American Std Course Series C = Whitworth C = British Assn Std C = Amer Std 60o Stub C = Amer Std Sq C = Amer Std 10 modif ied Sq Sq C = 3-195. TAPPING. The taps used for threading aluminum alloys should be of the spiral f luted type for best results. Straight f luted tape can be used but have a tendency to clog and tear the threads during the tapping operation. Spiral f luted taps for cutting right-handed threads should have a right-hand spiral of about 40o angle with a generous back off taper and highly polished f lutes. 3-196. Spiral - Pointed or Gun Taps (straight f luted except they have a short spiral on the starting end) cut aluminum more freely than the other types. With this type tap the major portion of cutting occurs at the spiral end and curls ahead of the tap. The use of the Gun Tap is therefore limited to tapping holes which have room for the cuttings ahead of the tool. This spiral pointed tap should not be used for cutting tapered thread or for bottoming taps. 3-197. The following procedures and tools are recommended for tapping aluminum alloys: a. Cutting Speed: 40 to 130 feet/minute use lower speed for hard alloys and higher speed for soft alloys. b. Tap Type Selection: For blind holes and bottoming use spiral f luted; for semi-blind use spiral pointed (gun taps); and for hole through work use spiral pointed (gun taps). c. Thread Type: Rounded or f lattened (turn coated) thread contour for general use. d. Tool Angles: Spiral f lute-grind a lead spiral extending one full thread beyond chamfer on straight f luted tap. To make gun tap and spiral f lute tap should be 28o to 40o; cutting angel 40o to 45o; top rake 45o to 50o; back rake 4 - 8o; cutter area (included angles); 2 f lute 36o to 72o and 3 f lutes 24oto 48o.
o

75% 0.9743 0.9605 0.9000 0.6525 0.7500 0.7500

80% 1.0392 1.0245 0.9600 0.6960 0.8000 0.8000

85% 1.1042 1.0886 1.0200 0.7395 0.8500 0.8500

90% 1.1691 1.1526 1.0800 0.7830 0.9000 0.9000

e. Tapping Allowance: Drill diameter for general tapping should be from 0.005 to 0.006 inches per inch larger than standard for the same thread in steel or in accordance with the following.
C Drill Diameter = (1.005 X tap diameter)-thread per inch

C = Thread constant for various thread forms and percentages of thread depth required as given in Table 3-28. f. Lubrication: For high speed tapping use lard oil/mineral oil and for hand tapping a more viscous lubricant is recommended such as heavy grease/oil, white lead, etc. 3-198. FILING. 3-199. Hand f iles of the single cut type having milled teeth usually give the best results for f iling aluminum. The main consideration in f ile design/ selection for aluminum is to provide ample chip space clearance. The cuttings generated are large and have a tendency to powder, pack and clog between f ile teeth. To overcome clogging problem chip space is increased, grooves are cut deeper and teeth are cut with generous side and top rake. 3-200. For f inish f iling a long angle mill f ile (single) (cut) with tooth spacing of 14-24 teeth per inch with side rake angle of 45o to 55o is recommended. In absence of the preferred f ile the same effect can be obtained using standard mill cut f iles by adjusting angle of f iling incidence to the metal worked. The f ile is of ten adjusted until force or motion applied is parallel to the work piece for best results. A good general purpose f ile is the curved tooth type (of ten called vixen) having about ten deeply cut teeth per inch. It can be used for heavy and f inish cuts. Lightly double cut f iles having tooth spacing of 14 - 20 per inch can be used for light duty rough cutting and f inishing when working the harder alloys. User should be

3-56

T.O. 1-1A-9

careful not to drag f ile across work on back stroke as with any f illing operation. Files shall be kept clean and free of rust. Clogged f iles can be cleaned by wire brushing. The use of chalk or talc on f ile will help prevent clogging. 3-201. Machine f iling using rotary f iles (miniature milling cutters having spiralled sharp teeth with smooth deeply cut f lutes) are operated at high speed. The rotary f iles are operated up to 10,000 RPM for small diameter and to 2,000 maximum peripheral feet/min for the larger diameter. The teeth should be coarse (about 14 teeth per inch) with deep polished f lute and spiral notched design. CAUTION Wear goggles or face shield when f iling with rotary f iles to protect eyes. 3-202. REAMING. Generally most of the different type reamers may be used for aluminum, but for best results the spiral f luted reamers are recommended - solid, expansion or adjustable. The spiral should be opposite to the rotation to prevent reamer from feeding and hogging into the hole. Holes to be f inished by reaming should be drilled sufficiently under-size to assure positive cutting rather than scraping and swedging (indication of oversize drilled holes and improper feed is the projection of a lip around hole diameter af ter the reaming operation is accomplished). Finish reamers should be maintained with exceptionally keen cutting edges and highly polished f lutes for smooth work. 3-203. The following procedures and tools are recommended for reaming aluminum alloys: a. Tool material: High carbon steel for general use; high speed steel/or carbide tipped for durability and continued production jobs. b. Tool type: Straight/spiral with 10o spiral f lute and solid teeth. c. Clearance and rake angles: Top rake 5o to 8 ; clearance angle primary 4o to 7o, secondary angle 15o to 20o; cutting angle 84o to 90o.
o

3-204. SAWING. It should be emphasized that the same principles which govern the shape of cutting tools for aluminum should be applied, as far as practicable to saws for aluminum. 3-205. Band Saws. Band saw blades of spring temper steel having a tooth spacing from 4 to 11 teeth per inch and with amply radiused gullets are recommended for aluminum alloys. Curved or copying cuts are made with band saws. In any type of work, high blade speed are desirable with a speed range from 1,500 to 5,000 feet per minute. For heavy sections the saw teeth should be fairly coarse with a slight set and a slight amount of front rake, the restricted chip space requires the use of coarser tooth spacing of about four teeth per inch to avoid clogging and binding. Also the f lexible back type of saw with teeth hardened to the bottom of the gullet is used for heavy work. Blades having as many as 14 teeth per inch are satisfactory for thin materials. A good and simple general rule to follow when sawing aluminum is that the spacing of the teeth on band saws for aluminum should be as coarse as is consistent with the thickness of the material being sawed. The sof ter alloys require appreciably more blade set than do the harder, heat treated alloys. Usually an alternate side rake of about 15o and a top rake or hook of 10o to 20o proves quite satisfactory. This amount of hook, however, requires a power feed and securely clamped work. For hand feeds the top rake must be reduced considerably to avoid overfeeding. 3-206. The band saw blades must be well supported by side rollers and back support both immediately below the saw table and about 2 or 3 inches above the work. The top blade supports are placed slightly in advance of those below the tables and the blade should be allowed to vibrate freely to eliminate excessive saw breakage. As a general rule, a noisy band saw is cutting more efficiently than the saw that cuts quietly. Quiet smooth cutting band saws usually produce smooth burnished surfaces accompanied by excessive heat and consequently decreased blade life. 3-207. Hack Saws. Hack saw blades of the wavyset type are well suited for cutting aluminum by hand. The wavy set type of blade having 5 to 15 teeth per inch has sufficient chip space to avoid clogging and binding on aluminum alloys. For extremely f ine work a jewelers blade may be used. 3-208. Special routing machines are available which cut varied prof iles from aluminum sheet or plate rapidly and efficiently. 3-209. Lubricants and coolants. Power hacksaws and hand saws require a cutting lubricant for most operations involving thick sections. Soluble oil

d. Machine speed and hole reaming allowance: Cutting speeds up to 400 f t/min for straight holes, tapered hole should be somewhat slower about 300 - 350. The desired feed in inches/revolution is 0.003 to 0.010. Hole to be reamed should be undersize 0.005 - 0.015 inch diameter (reaming allowance). e. Cutting f luids: Soluble oil/mixture of kerosene and lard oil, light weight machine oil.

3-57

T.O. 1-1A-9

cutting compounds and neutral mineral-base lubricating oils applied to the sides of the blade aid in minimizing friction and gullet clogging. Light applications of heavy grease or paraffin wax will provide ample lubrication for some work. A wide selection of lubricants exists, ranging from tallow or grease stick to kerosene-thinned mineral base lubricating oil. Stick type lubricants should be applied very frequently. Experience has revealed in most cases it is more convenient and adaptable to use the f luid type lubricant applied freely through a recycling system directly to the blade and work stock. 3-210. GRINDING. The grinding characteristics of the various aluminum alloys vary in many instances. The harder free-cutting aluminum alloys may be ground satisfactorily with free cutting commercial silicon carbide grinding wheels, such as crystalon, carborundum and natalon. Rough grinding operations are usually performed by use of resin bonded wheels of medium hardeners and grit sizes of 24 to 30. Also the aluminum abrasives from No. 14 to No. 36 have been found to be satisfactory for rough grindings. 3-211. Common alloys, particularly in their softer tempers have a tendency to clog the wheels and do not f inish to as bright and smooth a surface as the harder materials. 3-212. Caution should be taken in selecting the proper grade of each commercial make of wheel. Once the grinding wheel has been selected there are three variables that affect the quality of a f inish; these are the wheel speed, work speed and grinding compound. Experienced operators have proven that their own good judgement is a determining factor as to the correct wheel and work speeds, however, wheel speeds of about 6,000 feet per minute have given good results. 3-213. For f inish work, a sof t silicon carbide wheel of 30 to 40 grit in a vitrif ied bond have proven to be very satisfactory. A grinding compound of soluble cutting oil and water works well. However, the f ine grindings of aluminum must be strained from the compound before reusing in order to prevent deep scratches on the f inished surface. 3-214. Special care should be exercised when grinding castings and wrought alloy products that have been heat treated, since their greater resistance to cutting or grinding generates a considerable amount of heat which may cause warping and damage to the material. 3-215. Lubricants and Coolants. Generous applications of stick grease are recommended to prevent clogging of the grinding wheels during rough

grinding, while copious quantities of a low viscosity coolant type grinding compound are essential and recommended for f inish grinding. Soluble oil emulsions of the proportions of 30 or 40 to 1 are most suitable. 3-216. POLISHING. Polishing or f inishing aluminum and most of its alloys, by the application of proper machining procedures, gives it a smooth lustrous f inish. Aluminum and its alloys are polished in the same manner as other metals, but a lower wheel-to-metal pressure is used for aluminum. 3-217. Polishing is the act of removing marks, scratches or abrasion on the metal resulting from previous handling and operations; it must be understood that a more gentle cutting action or finer abrasives are used for polishing aluminum than used for steel. The various operations covered under the polishing category include roughing, greasing or oiling, buffing and coloring. These operations are brief ly described in the following paragraph. 3-218. ROUGHING. This is a term used to describe the preliminary f inishing operation or process, used to prepare aluminum surfaces having deep scratches gouges or unusually rough surfaces, for subsequent polishing procedures. Roughing is not required on smooth undented or unscratched surfaces. The preliminary f inishing or roughing process usually employs a f lexible aluminum oxide paper disc, a semi f lexible bonded muslin or canvas wheel, faced with suitable abrasives. Usually 50 - 100 grit abrasives are for this process and are set in an adhesive in accordance with standard practice. The peripheral speed of these discs runs around 6,000 feet per minute; faster wheel speeds would cause heating or ridging of the sof t metal surface. Heating is also reduced by small applications of tallow or a tallow oil mixture. 3-219. GREASING OR OILING. This is a refined or gentle roughing procedure for f inishing aluminum surfaces. Application is visually employed by a sof t wheel faced with 100 to 200 grit aluminum oxide emery, plus a light coat of tallow or beeswax lubricant to prevent excessive heating. Here again, peripheral speeds of about 6,000 FPM are used. 3-220. Greasing or oiling is a necessary operation in f inishing coatings and other fabricated work which has been marred by previous operations. Excess aluminum pick-up on the wheels as results from overheating will cause deep scratches in the metal.

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T.O. 1-1A-9

3-221. BUFFING. This is a term used to describe a f inishing procedure employed to obtain a smooth high luster on an aluminum surface. This high luster f inish is obtained by use of a f ine abrasive, such as tripole powder mixed with a grease binder, which is applied to the face of the wheel. These wheels usually consist of muslin discs sewed together, turned at a peripheral speed of 7,000 FPM. 3-222. Many factors, such as, the thread count of the buff, the pressure applied to the buff against the work, the buffing compound used, the speed of the buff or wheel and the skill and experience of the operator must be considered in obtaining a satisfactory and quality type f inish. 3-223. HARDNESS TESTING.

method of inspection is not acceptable for inspection of parts subject to internal defects, i.e. inclusion in castings and forging or any part subject to internal stress, etc. 3-230. Defects are indicated by darkening of cracked or void areas af ter the anodic treatment. Insufficient rinsing in cold water af ter anodizing produces stains which may be confused with defects. In case of doubt strip f ilm from part and reanodize. If the indications do not reappear the defects shall be considered absent and part should not be rejected for that reason. NOTE For additional general information on inspection and testing see Section VIII of this technical order. 3-231. ALUMINUM ALLOY EFFECTS ON SCRATCHES ON CLAD ALUMINUM ALLOY. The purpose of the following information on the effects of scratches on aluminum alloys is to assist in eliminating controversy in depots and f ield inspection, regarding serviceability of aluminum alloy, sheet, skin and aircraf t structural parts which have been scratched, abraded or discolored from the stand point of corrosion resistance and fatigue strength. 3-232. In some instances, serviceable aluminum alloy parts and sheets, have been disposed of due to lack of knowledge by inspection personnel as to the effect of various depth scratches on the strength and corrosion resistance of the clad alloy. Also, attempts have been made to remove scratches from aircraf t skin by sanding, buffing, or polishing resulting in removal of much of the cladding material and causing decrease in strength and corrosion resistance. 3-233. ALLOWABLE DEFECTS. a. The following surface defects are those which do not affect the strength or corrosion resistance. (1) Scratches which penetrate the surface layer of clad aluminum alloy sheets or parts but do not extend beneath the cladding are not serious or detrimental. (2) The presence of small corroded areas will not materially affect the strength of clad unless the corroded pitted area extends through the cladding down to or into the bare metal Clean corroded areas thoroughly by authorized methods (See Paragraph 3-242). (3) Stains are not grounds for rejection since they affect neither the strength nor the corrosion resistance.

3-224. Hardness is the resistance of a metal to deformation by scratching penetration or indentation, and is usually a good indication of strength. Metal hardness can be measured accurately by the Brinell, Rockwell or Vickers Process. 3-225. BRINELL HARDNESS. The Brinell technique is usually used to obtain the hardness of aluminum and aluminum alloys. This hardness value is obtained by applying a load through a ball indenter and measuring the permanent impression in the material. To obtain the hardness value of a material, divide the applied load in kilograms by the spherical area of the impression in square millimeters. Hardness value of aluminum alloy is tested by applying a load of 500 kilograms to a ball ten millimeters in diameter for 30 seconds. 3-226. NON-DESTRUCTIVE TESTING/INSPECTION.

3-227. Aluminum and aluminum alloys are susceptible to stress risers resulting from notching, nicking or scratching. A very close visual inspection is required of all raw material prior to any forming or machining operations. Before any fabrication commences it is necessary that all scratches, nicks and notches be removed by sanding, polishing and f iling. 3-228. ANODIZING PROCESS FOR INSPECTION OF ALUMINUM ALLOY PARTS. Parts for which anodic coating is applicable in accordance with MIL-A-8625 Type I, can be anodized for the inspection of defects as cited in Specif ication MILI-8474. 3-229. The parts are examined visually for indications of cracks, forging laps or other defects. Parts inspected by this method shall be limited to sheet stock and surface defect of forgings. This

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T.O. 1-1A-9

CAUTION No attempt will be made to remove scratches or other surface defects by sanding or buffing since the protective layer of cladding will be removed by such operations. 3-234. HARMFUL SCRATCHES. Scratches which extend through the cladding and penetrate the core material act as notches and create stress concentrations which will cause fatigue failure if the part is highly stressed or subjected to repeated small stress reversals. However, sheets so scratched may utilized for non-stressed applications. 3-235. INSPECTION. Assemblies fabricated from clad aluminum-alloy sheets will not be rejected by inspection personnel, unless the defect is of sufficient depth to adversely affect the mechanical properties or cover sufficient area to impair the corrosion resistance of the assembly. Scratches or abrasions which penetrate the cladding will not affect corrosion resistance. Scratches resulting from the normal handling and processing of clad aluminum-alloy sheet rarely extend through the cladding and penetrate the core. 3-236. TEST FOR DEPTH OF SCRATCHES. Since it is very difficult to measure the depth of a scratch on a sheet without cross sectioning the sheet, it has been found convenient (on clad material) to use a spot test to determine whether or not a scratch extends through the cladding. 3-237. On alloys except 7075 and 7178 the spot test is made by placing a drop of caustic solution (10% by weight of sodium hydroxide, NaOH, in water) on a portion of the scratch, and allowing it to react for 5 minutes. The caustic solution will then be rinsed off the sheet with water, and the spot allowed to dry. If a black residue remains in the base of the scratch at the spot tested, it indicates that the scratch extends to the core. If no black color is visible and only a white residue remains in the base of the scratch, it indicates that the scratch does not penetrate through the cladding. For alloys 7075 and 7178 a drop of 10% cadmium chloride solution will produce a dark discolorationm within two minutes if the scratch penetrates the clad. The cadmium chloride applied as above will not cause 2024 to discolor within two minutes. 3-238. When making the spot test to determine whether a scratch extends to the core, it is advisable for comparison purposes to spot test an adjacent area in which there are no scratches. It is

then easier to determine whether the residue which remains is black or white. 3-239. Before making the spot test, the sheet area will be cleaned and degreased with solvent Federal Specif ication P-D-680, Type II, or other suitable solvent, so that the caustic solution will react properly. 3-240. Caution will be exercised to make sure that all of the caustic solution is removed from the sheet by thorough rinsing, since the caustic solution is very corrosive to aluminum and aluminum alloys. Care wi11 be taken not to use excessive amounts of the caustic solution for the same reason and it is preferable that only one drop be used for each test. The caustic solution will be prepared fresh for each series of tests to be made. 3-241. DISPOSITION OF SCRATCHED SHEETS/PARTS. a. All scratched clad aluminum-alloy sheets wi11 be utilized to the fullest extent. Serviceable portions of damaged sheets will be used in the manufacture of smaller parts and assemblies. Only that portion of sheet that is scratched and otherwise damaged beyond serviceability will be administratively condemned. b. Parts (air weapon) shall be closely inspected as cited and they do not meet specif ied requirement shall be condemned and replaced as directed. 3-242. CLEANING OF ALUMINUM ALLOY SHEET (STOCK). 3-243. Solvent Cleaning. Stubborn or exceptionally oily sheets may be cleaned by using solvent, Federal Specif ication P-D-680, Type II, before cleaning with alkali solution. The cleaning will be accomplished by brushing, soaking, scrubbing and wiping. Material or equipment that would scratch or abrade the surface shall not be used. Also material shall not be stored af ter solvent cleaning and prior to alkaline cleaning, unless solvent is completely removed from the surfaces of the metal. 3-244. Alkali Cleaning Solution. Composition of solution is 4 to 6 oz of cleaner specif ication MIL-C5543 to one gallon of water. The material is cleaned by immersing in the solution (as prepared by instructions cited in paragraph 3-245) for 4-6 minutes, thoroughly rinsing in water (fresh tap) and then completely drying. Never pile/store material while damp, wet or moist. Refer to T.O. 00-85A23-1 for packaging and storage.

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T.O. 1-1A-9

9 gallons of water. CAUTION Do not use strong alkali solution because it will etch the aluminum. 3-245. Preparation. Use water heated to a temperature of 170oF (77oC). Add not more than one pound of cleaner at a time. Prepare the solution in the following manner: a. b. Fill the task 1/2 to 2/3 full of water. Carefully dissolve the alkaline cleaner. b. Parts shall be immersed for 3 to 5 minutes in cold acid (50o - 105oF). 3-248. After removing from the acid, the parts shall be washed in fresh hot or cold running water for a sufficient length of time to thoroughly remove the acid. Diluted solution of sodium dichromate (Na2Cr2 O7) 12 to 14 ounces per gallon of water, shall be added to the rinse water as a corrosion inhibitor. The rinsing time depends upon the freshness of the solution, size of the part and the amount of solution circulated. One half hour or less should be sufficient. Parts shall then be completely dried by blasting with compressed air or other approved method. NOTE The sheet will stain when rinsed with sodium dichromate. The stronger the solution the darker the stain. A light detectable stain is desired on corroded areas. If the stain is dark reduce the amount of sodium dichromate added to rinse water. 3-249. Corrosion Removal and Treatment of Aluminum Sheets When Immersion Is Not Practical. 3-250. The surface shall be cleaned with water base cleaner, Specif ication MIL-C-25769, Type II. a. Heavily soiled areas. Dissolve the contents of two 5-pound packages in 10 gallons of water. Stir with a wooden paddle until fully dissolved. b. Lightly soiled areas. Dissolve four 5-pound packages in 50 gallons of water (a 55 gallon drum is suitable for this purpose). Agitate thoroughly with wooden paddle to insure proper mixture. c. Application. Apply the solution by spraying, or with a mop, sponge, or brush. Allow to remain on the surface for several minutes while agitating with a brush. Rinse thoroughly with a spray or stream of water. Do not allow solution to dry before rinsing as less effective cleaning will result. 3-251. Corrosion Removal. To remove corrosion products use a metal conditioner and brightener, Specification MIL-C-38334.

c. Add water to operating level and stir thoroughly with a wooden paddle or other means. 3-246. Maintain solution in the following manner: a. Add tap water to balance-up solution loss.

b. Make addition as required to maintain the active alkali concentration between 4 and 6 oz alkaline cleaner for each gallon of water added and stir thoroughly. c. Prepare a new solution when contamination impares the cleaning ability of the solution. d. Clean the tank thoroughly before preparing a new solution. 3-247. Corrosion Removal from Aluminum Alloy Sheets. Corrosion is removed by immersing the sheet in the following acid cleaning solution: CAUTION When using acid solution wear approved clothing, acid resisting gloves, aprons/ coveralls, face shields or respirator. If solution is splashed into eyes, f lush thoroughly with water immediately, and then report to dispensary. For special instructions, contact local safety officer a. Nitric-Hydrof luoric Acid Cleaning. The solution shall consist of 1 gallon technical nitric acid (58-62% HNO3) (39.5o Be). 1/2 pint technical hydrof luoric acid (48oHF) (1.15 Sp).

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WARNING When using acid solution wear approved clothing, acid resistant gloves, aprons/coveralls, face shields or respirator. If solution is splashed into eyes, f lush thoroughly with water immediately, and then report to dispensary. For special instructions contact local safety officer. CAUTION Metal conditioner and brightener is for use only on aluminum alloys, and it shall not be used just for the sake of improving the appearance of material. Material in storage shall not be treated with this material more than one time. a. Prepare the brightening solution by mixing Specification MIL-C-38334 compound with an equal amount of water, in a rubber pail. b. Apply enough diluted brightener to completely cover the area being treated with a nonmetallic bristle brush. c. Agitate the brightener by scrubbing with a non-metallic bristle brush. Depending on the ambient temperature and amount of corrosion deposits present, allow approximately 5 to 10 minutes from application of brightener before rinsing. When using brightener at high ambient temperature (above 80oF) leave brightener on for shorter periods of time. Do not leave brightener on the surface longer than necessary to dissolve the corrosion. d. Rinse the brightener from the surface (using approximately 50 gallons of water per minute. Insure that all traces of brightener have been removed (shown by no foaming or bubbles while rinsing). 3-252. Chromate Conversion Coating Specif ication MIL-C-5541, for aluminum alloys. Aluminum alloys which are treated with Specif ication MIL-C-

38334 shall be treated with Specif ication MIL-C5541. Most solutions conforming to Specif ication MIL-C-5541 leave a stain. A clear Specif ication MIL-C-5541 coating is available (reference QPL 5541) and should be used when a bright metal f inish is desired.

WARNING

Conversion coating is a toxic chemical and requires use of rubber gloves by personnel during its application. If acid, accidentally contacts the skin or eyes, f lush immediately with plenty of clear water. Consult a physician if eyes are affected or if skin is burned. Do not permit Specif ication MIL-C5541 material to contact paint thinner, acetone or other combustible materials. Fire may result.

a. Mix the solution in a stainless steel, rubber or plastic container; not in lead, copper alloy or glass. b. Mix in accordance with manufacturers instructions. c. Apply the conversion coating (light) by using a f iber bristle brush or a clean, sof t cloth. Keep the surface wet with the solution until a coating is formed which may take from 1 to 5 minutes depending on the surface condition of the metal. NOTE Do not permit excess conversion coating to dry on the metal surface because the residue is difficult to f lush off with water. d. Rinse with clear water, or sponge the area with a clean, moist cloth, frequently rinsing the cloth in clear water. Thorough rinsing is required. e. Allow the surface to air dry. To speed drying the surface may be blown dry with warm clean air (140oF maximum).

3-62

T.O. 1-1A-9

WARNING Any absorbent material used in applying or wiping up MIL-C-5541 material shall be rinsed in water before discarding. They are extreme fire hazards if allowed to dry otherwise. CAUTION Avoid brushing or rubbing the newly applied chemical conversion coating, since it is sof t and can be easily rubbed off the surface before completely drying.

been cleaned and treated for corrosion in accordance with T.O. 1-1A-9 Section III, date . . . . . . If original markings are removed as a result of the cleaning and treatment process, the material shall be remarked (staggered) at each end and in the middle with the Specif ication, size/thickness, temper and type or grade. The marking may be applied with Black paint Specification TT-L-50, MIL-E-7729 or Magic Marker manufactured by Speeddry Products Inc., Richmond Hill, N.Y. or Equal. A felt tip pen may also be used. 3-253. For Packaging, Packing,. and Storage of Aluminum Alloy Sheets and Plates Refer to T.O. 00-85A-23-1. 3-254. ANODIC COATINGS FOR ALUMINUM. Anodizing is the anodic process of treating aluminum alloys; a thin f ilm of artif icially produced oxide is formed on the surface of the metal by electrochemical reaction. Military Specif ication MILA-8625 lists the requirements of aluminum anodizing, and TO 42C2-1-7 gives the anodizing process. 3-255. Military Specif ication MIL-C-5541 lists the requirements for corrosion protection and paint base of aluminum by the use of chemical film. These chemical f ilms are substitutes that may be used in lieu of anodic f ilms, and may be applied by spray, brush, or immersion as specif ied by QPL-5541. The anodizing method is preferrable to chemical f ilms on aluminum parts where facilities are available. For process procedures applying to chemical f ilms, refer to Technical Orders 1-1-8 and 1-1-2.

NOTE A light (just visible to the naked eye) evenly dispersed conversion coating is all that is required. It is recommended that a test panel be prepared and subjected to complete cleaning/ treating procedure before applying material to a sheet. The test panel shall be used to determine the dwell time of MIL-C-5541 material. When clear material is being used, no control of discoloration is necessary. After the procedures cited in paragraphs 3-252 through 3-263 have been complied with, an AF Form 50A will be attached to each sheet with a statement that, This material has

3-63/(3-64 blank)

T.O. 1-1A-9

SECTION IV MAGNESIUM ALLOYS

4-1. CLASSIFICATION. of stress, measured in pounds per square inch, at which permanent deformation results from material failure. The data in Tables 4-4, 4-5 and 4-6 lists the nominal yield strengths of various alloys. The yield point in magnesium is not reached abruptly, but rather a gradual yielding when the metal is stressed above the proportional limit. Tensile and yield strengths decrease at elevated temperatures. 4-7. TEMPER is the condition produced in the alloy by mechanically or thermally treating it to alter its mechanical properties. Mechanical includes cold rolling, cold working, etc.; thermal includes annealing, solution and precipitation heat treat and stabilization treating. See paragraph 412 for temper designations. 4-8. SHEAR STRENGTH is the maximum amount (in pounds per square inch) in cross sectional stress that a material will sustain before permanent deformation or rupture occurs. 4-9. ELONGATION is the linear stretch of a material during tensile loading measured before and af ter rupture. In magnesium it is the increase in distance which occurs when stretch is applied between two gage marks placed 2 inches apart on the test specimen. Af ter rupture the two pieces are f itted together and remeasured. The elongation is the percentile difference of the amount of stretch in ratio to the original 2 inches. 4-10. PHYSICAL PROPERTIES. Magnesium, in its pure state, has a specif ic gravity of 1.74, weighing .063 pounds per cubic inch. Similar data for magnesium alloys are included in Table 4-6 as well as other physical property information. 4-11. CHEMICAL PROPERTIES. Chemically bare magnesium is resistant to attack by alkalis, chromic and hydrof luoric acids and many organic chemicals including hydrocarbons, aldehydes, alcohols, phenols, amines, esters and most oils. It is susceptible to attack by salts and by galvanic corrosion from contact with dissimilar metals and other materials. Adequate protection of the metal against unfavorable conditions can be maintained generally, by using proper surface f inish (See paragraph 4-93) and assembly protection. The chemical property constituents of the various alloys are listed in Table 4-3. 4-12. TEMPER DESIGNATION SYSTEM. The hyphenated suffix symbol which follows an alloy designation denotes the condition of temper, (heat

4-2. Magnesium alloys are produced and used in many shapes and forms, i.e., castings, extruded bars, rods, tubing, sheets and plate and forgings. They are suitable for varied stress and non-stress aerospace applications. Their inherent strength, lightweight, shock and vibration resistance are factors which make their use advantageous. The weight for an equal volume of magnesium is approximately two-thirds of that for aluminum and one-f ifth of that for steel. 4-3. The current system used to identify magnesium alloys, is a two letter, two or three digit number designation in that order. The letters designate the major alloying elements, (arranged in decreasing percentage order, or in alphabetical order if the elements are of equal amounts), followed by the respective digital percentages of these elements. The percentage is rounded off to the nearest whole number or if a tolerance range of the alloy is specif ied, the mean of the range (rounded off to nearest whole number) is used. A suffix letter following the percentage digits, denotes the latest qualif ied revision of the alloy. For example: Alloy Designation AZ92A would consist of 9% (mean value) aluminum and 2% (mean value) zinc as the major alloying elements. The suffix A indicates this is the f irst qualif ied alloy of this type. One exception to the use of the suffix letter is that an X denotes that impurity content is controlled to a low limit. Some of the letters used to designate various alloying elements are: A Aluminum, H Thorium, M Manganese, 4-4. DEFINITIONS. E Rare Earth, K Zirconium, Z Zinc.

4-5. HARDNESS. Hardness is the resistance of a metal to plastic deformation from penetration, indentation, or scratching. The degree of hardness is usually a good indication of the metals strength. The hardness of a metal can be accurately measured using the Brinell on Rockwell process of testing. Tables 4-4, 4-5 and 4-6 list the nominal hardness of various magnesium alloys. Brinell hardness testing is explained in Section VIII of this manual. 4-6. TENSILE STRENGTH. The useful tensile strength of a metal is the maximum stress it can sustain in tension or compression without permanent deformation. The yield strength is that point

4-1

T.O. 1-1A-9

treat or strain hardening), to which the alloy has been processed. These symbols and their meanings are listed below: (Heat treating itself is discussed in subsequent paragraphs of this section of the manual). -AC As-Cast -F As-fabricated -O Annealed -W Solution heat treated - unstable temper -T Treated to produce stable tempers other than for -O -T2 Annealed (cast products only) -T3 Solution heat treated and then cold worked -T4 Solution heat treated -T5 Artif icially aged only -T6 Solution heat treated and then artif icially aged -T7 Solution heat treated and stabilized -T8 Solution heat treated, cold worked and then artif icially aged -T9 Solution heat treated, artif icially aged and then cold worked -T10 Artif icially aged and then cold worked -H1 Strain hardened only -H2 Strain hardened and partially annealed -H3 Strain hardened and stabilized Added suffix digits 2, 4, 6, 8, to the H1, H2, H3 symbols indicate the degree of strain hardening, i.e., 2=1/4 hard, 4=1/2 hard, 6=3/4 hard, and 8=full hard. 4-13. SAFETY REQUIREMENTS FOR HANDLING AND FABRICATION OF MAGNESIUM ALLOYS. 4-14. There are two special major areas of safety precautions to observe in proceeding of magnesium alloys other than general shop safety practices. One is the fact some alloys contain thorium, a radioactive element (e.g., HK31A, HM21A, HM31A) and the other is the low melting point/ rapid oxidation (f ire hazard) characteristics of the metal. Where the application of heat is to be made to a thorium alloy, both of these areas must be considered.

standard of 0.1 milligram per cubic meter (mg/m3) of thorium in air is a safe limit for continuous atmospheric exposure and is readily met in processing magnesium alloys containing up to 10% thorium, For example: Stirring alloy melt of 5% thorium content resulted in 0.002 mg/m3 atmospheric contamination and grinding air alloy of 3% thorium content gave thorium contamination in the breathing zone ranging from 0.008 to 0.035 mg/m3. Only long exposure to f ine dust or fumes need cause concern as to radioactive toxicity of magnesium-thorium. Normal dust control precautions, followed to avoid f ire hazards, can be expected to control any health hazards that might result from f ine dust in grinding the low thorium content alloys. In welding these alloys without local exhaust, concentrations of thorium above the tentative limit of 0.1 mg/m3 of air were found in the breathing zone. Use of local exhaust reduced thorium concentrations to well within acceptable 1imits . If ventilation is such that the visible fumes f low away from the welder, it is adequate, providing such fumes are not permitted to accumulate in the immediate vicinity. An alternate practice involves use of ventilated welders hood, if there is not sufficient room ventilation to control contamination of the general atmosphere. Thorium containing scrap and wet grinding sludge may be disposed of by burning providing an AEC ammendment is secured for the basic AEC license. If burned, the ashes which will then contain the thorium, must be disposed of in accordance with AEC Standards for Protection Against Radiation 10 CFR Part 20. As an alternative the ashes or scrap may be turned over to an AEC licensed scrap dealer, through applicable disposal procedures, See T.O.00-110N-4 4-16. For indoor storage of thorium alloy sheets and plates, the size of stacks should be limited to 1000 cubic feet with an aisle width not less than one-half the stacks height. Such storage is within the normal recommendations for f ire safety. 4-17. Radiation surveys have shown that exposure of workers handling the referenced thorium alloys is well within the safe limits set by the AEC. Assuming hand contact, the body one foot away from the alloy for an entire 40 hour work week, the exposure would be 168 millirems (mr) to the hands and 72 mr to the whole body. These are maximum values which probably would not be approached in actual practice. The corresponding AEC permissible safe limits are 1500 mr/week for the hands and 300 mr/week for the whole body. 4-18. Despite the relative safety present in the handling, to rage and processing of thorium containing alloys, it is mandatory that all such actions be made according to the requirements and

WARNING Magnesium thorium alloys shall be handled, stored and disposed of in accordance with T.O. 00-110N-4. 4-15. MAGNESIUM-THORIUM ALLOYS (HK31, HM21, HM31, HZ32, ZH42, ZH62) are mildly radioactive but are within the safe limits set by the Atomic Energy Commission (AEC) and represent no hazard to personnel under normal conditions. A

4-2

T.O. 1-1A-9

restrictions of the 00-100 series technical orders, as applicable, and AEC regulations. As previously stated, the normal precautions taken in the shop processing of magnesium will suffice for safe handling of thorium alloys. These precautions are noted in the following paragraphs on safety precautions. 4-19. SAFETY PRECAUTIONS FOR ALL ALLOYS (INCLUDING FIRE HAZARDS). 4-20. Since magnesium will ignite and burn fiercely when heated to a point near its melting
Table 4-1.

temperature, certain precautions should be taken during working of it. 4-21. Machining Safety Rules. During machining operations, observance of the following rules will control any potential f ire hazard: a. Keep all cutting tools sharp and ground with adequate relief and clearance angles b. Use heavy feeds to produce thick chips.

Cross-Reference, Alloy Designation to Specifications

ALLOY AM100A AZ31B

FED SPEC QQ-M-56 QQ-M-55 QQ-M-31 QQ-M-40 WW-T-825 QQ-M-44 QQ-M-44 QQ-M-44 ____ ____ ____ QQ-M-31 QQ-M-40 WW-T-825

MIL SPEC __ __ __ __ __ __ __ __ MIL-R6944 __ __ __ __ __ __ MIL-R6944 MIL-C19163 MIL-C19163 MIL-C19163 MIL-R6944 ___ ___ ___ ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

HNBK 502 52 510 52 510 510 510 __ __ __ __ 520 530 520 __ 50 50 __ __ 523 532 505 505 __ 501 501 504 __ 500

SAE AMS 4483

ASTM (ASME) B80 B199 B107 B91 B217 B90 B90 B90 B260 B107 B217 B90 B107 B91 B217 B260 B80 B80 B199 B260 B107 B91 B80 B199 B199 B94 B94 B80 B199 B80

USE Sand Casting Permanent Mold Casting Extruded Bars, Rods, Shapes Forgings Extruded Tubes Sheet and Plate Sheet and Plate Sheet and Plate Welding Rod Extruded Bars, Rods, Shapes Extruded Tubes Sheet and Plate Extruded Bars, Rods, Shapes Forgings Extruded Tubes Welding Rod Sand Castings Sand Castings Permanent Mold Castings Welding Rod Extruded Bars, Rods, Shapes Forgings Sand Castings Permanent Mold Castings Permanent Mold Castings Die Castings Die Castings Sand Castings Permanent Mold Castings Sand Castings

4375 4376 4377 __ __ __ __ 4350 4358 4350 __ 4420, 4422 4424 __ __ __ 4360 __ __ __ 4490 __ 4437 __ 4434

AZ31C

AZ61A

AZ63A

QQ-M-56 QQ-M-56 QQ-M-55 ____

AZ80A AZ81A AZ91A AZ91B AZ91C AZ92A

QQ-M-31 QQ-M-40 QQ-M-56 QQ-M-55 QQ-M-55 QQ-M-38 QQ-M-38 QQ-M-56 QQ-M-55 QQ-M-56

MIL-C19163

4-3

T.O. 1-1A-9

Table 4-1.

Cross-Reference, Alloy Designation to Specifications - Continued

ALLOY AZ92A (Cont)

FED SPEC QQ-M-55 ____

MIL SPEC MIL-C19163 MIL-R6944 ___ ___ ___ ___ ___ MIL-R6944 ___ MIL-M26075 MIL-M26075 MIL-R6944 ___ MIL-M8917 MIL-H8916 MIL-H8916 ___ MIL-M45207 ___ ___ ___ ___ MIL-R6944 ___ ___ ___ ___ ___ ___ ___ MIL-M46039

HNBK 503 __ __ __ __ 506 506 __ 507 507

SAE AMS 4484 __ __ 4440, 4441 __ 4442 __ __ 4445 4384 4385

ASTM (ASME) B199 B260 B80 B80 B199 B80 B199 B260 B80 B90

USE Permanent Mold Castings Welding Rod Sand Castings Sand Castings Permanent Mold Castings Sand Castings Permanent Mold Castings Welding Rod Sand Castings Sheet and Plate

EK30A EK41A

QQ-M-56 QQ-M-56 QQ-M-55

EZ33A

QQ-M-56 QQ-M-55 ____ QQ-M-56 ____

HK31A*

* HK21A*

____ QQ-M-40 ____ ____ ____

__ __ __ __ __ __ __ 522 533 522 51 __ __ __ 53 534 __ __ 508 __

__ __ 4390 4388 4389 4447 __ _ _ _ _ _ _ _ _ _ _

B260 __ B90 B107 __ B80 B80 B107 __ B217 B90 B260 __ __ B91 B90 __ __ B80 __

Welding Rod Forgings Sheet and Plate Extruded Bars, Rods, Shapes Extruded Bars, Rods, Shapes Sand Castings Sand Castings Extruded Bars, Rods, Shapes Forgings Extruded Tubes Sheet and Plate Welding Rod Sand Castings Permanent Mold Castings Forgings Sheet and Plate Sand Castings Sand Castings Sand Castings Extrusions

HM31A*

HZ32A* KIA MIA

QQ-M-56 QQ-M-56 QQ-M-31 QQ-M-40 WW-T-825 QQ-M-44 ____ QQ-M-56 QQ-M-55 QQ-M-40 ____ QQ-M-56 ____ QQ-M-56 ____

QE22A TA54A ZE10A ZE41A ZH42* ZH62* ZK21A

__ __ __ __ __ __ 4438 4387

4-4

T.O. 1-1A-9

Table 4-1.

Cross-Reference, Alloy Designation to Specifications - Continued

ALLOY ZK51A ZK60A ZK60B ZK61A

FED SPEC QQ-M-56 QQ-M-31 QQ-M-40 WW-T-825 ____ QQ-M-56

MIL SPEC ___ ___ ___ ___ MIL-M26696 ___

HNBK 509 524 __ 524 __ 513

SAE AMS 4443 4352 4362 4352 __ 4444

ASTM (ASME) B80 B107 B91 B217 __ B80

USE Sand Castings Extruded Bars, Rods, Shapes Forgings Extruded Tubes Extruded Bars, Rods, Shapes Sand Castings

*These alloys contain radioactive thorium element. See paragraph 4-15 for precautionary instructions. MISC SPECIFICATION MIL-M-3171 Magnesium alloy, processes for corrosion protection of SAE-AMS-M-6857 Magnesium alloy castings, heat treatment of

Change 4

4-5

T.O. 1-1A-9

Table 4-2.

Alloy Designation Cross-Reference

NEW DESIGNATOR AZ63A MIA MIB MIA MIA MIA A292A AZ92A AM100A AZ91A AZ31B AZ31B AZ31B AZ31B AZ61A AZ61A AZ61A AZ80A AZ80A ZK60A EX41A EZ33A TA54A

FORMER DOW REVERE H M M M M M C C G R FS-1 FS-1 FS-1 FS-1 J-1 J-1 J-1 0-1 0-1 __ __ __ __

FORMER AMERICAN MAGNESIUM AM265 AM3S AM403 AM3S AM3S AM3S AM260 AM260 AM240 AM263 AM52S AM52S AM52S AM52S AMC57S AMC57S AMC57S AMC58S AMC58S AMA76S AMA130 AMA131 AM65S

FORMER * MILITARY ____ AN-M-26 AN-M-30 AN-T-73 AN-M-22 AN-M-30 ____ ____ ____ AN-M-16 AN-M-27 AN-T-72 ____ AN-M-29 AN-M-24 AN-T-71 AN-M-20 AN-M-25 AN-M-21 ____ ____ ____ ____

NEW FEDERAL QQ-M-56 QQ-M-31 QQ-M-56 WW-T-825 QQ-M-40 QQ-M-44 QQ-M-56 QQ-M-55 QQ-M-55 QQ-M-38 QQ-M-31 WW-T-825 ____ QQ-M-44 QQ-M-31 WW-T-825 QQ-M-40 QQ-M-31 QQ-M-40 QQ-M-31 ____ ____ QQ-M-40

USE Castings, Sand Extruded Bars, Rods, Shapes Castings, Sand Extruded Tube Forgings Sheet Castings, Sand Castings, Perm Mold Castings, Perm Mold Castings, Die Extruded Bar, Rod, Shape Extruded Tube Forgings Sheet Extruded Bar, Rod, Shape Extruded Tubes Forgings Extruded Bar, Rod, Shape Forgings Extruded Bar, Rod, Shape Castings, Perm Mold Castings, Perm Mold Forgings

NOTES: *These AN Specif ications have been superseded by the listed Federal Specif ications.

4-6

Table 4-3.

Chemical Properties of Magnesium Alloys

ALLOY

AL

MN

ZINC

ZIRCONIUM

RARE EARTH ----------------------2-3.0 3.0-5.0 2.5-4.0 ------0.1mx ----1.8-2.5 --0.120.22

THORIUM

SI

CU

NICKEL

MG

FORMS

AM100A AZ31B(1)(2) AZ31C AZ63A(2) AZ80A AZ81A AZ91A AZ91A AZ91B AZ91C AZ92A EK30A EK41A EZ33A HK31A* HM21A* HM31A* HZ32A* KIA MIA(1) QE22A(3) TA54A(4) ZE10A

9.3-10.7 2.5-3.5 2.4-3.6 5.3-6.7 7.8-9.2 7.0-8.1 8.1-9.3 8.1-9.7 8.3-9.7 8.1-9.3 8.3-9.7 --------------------3.0-4.0 ---

0.10 0.20 0.15 0.15 0.12 0.13 0.13 0.13 0.13 0.13 0.10 ------0.15mx 0.45-1.1 1.2mn ----1.2 --0.20 ---

0.30max 0.6-1.4 0.5-1.5 2.5-3.5 0.2-0.8 0.40-1.0 0.4-1.0 0.4-1.0 0.4-1.0 0.4-1.0 1.6-2.4 0.3 max 0.3 2.0-3.1 0.3mx ----1.7-2.5 ------0.3mx 1.0-1.5

----------------------0.20 min 0.4-1.0 0.5-1.0 0.4-1.0 ----0.5-1.0 0.4-1.0 --0.4-1.0 -----

----------------------------2.5-4.0 1.5-2.5 2.5-3.5 2.5-4.0 -----------

0.30 0.10 0.10 0.10 0.30 0.30 0.30 0.50 0.50 0.30 0.30 -------

0.10 0.05 0.10 0.05 0.25 0.10 0.10 0.10 0.30 0.10 0.25 0.10 0.10 0.10 0.10

0.01 0.005 0.03 0.005 0.01 0.01 0.01 0.03 0.03 0.01 0.01 0.01 0.01 0.01 0.01 ----0.01 --0.01 0.01 0.01 ---

Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal Bal

Castings, sand, perm mold Extruded Bars, rods, shapes tubes = sheets Same Castings, sand and perm mold Extruded bars, rods, shapes, forgings Castings, sands and perm mold Castings, perm mold Castings, Die Castings, Die Castings, sand and perm mold Same Castings, sand only Castings, sand and perm mold Castings, Sand/Sheet Plate Castings, Sand/Sheet/Plate Forgings, Sheet/Plate Extruded Bars/Rods/Shapes Castings, Sand Castings, Sand Extruded Bars, rods, shapes tube-sheets-forgings Castings, sand Forgings Sheet and Plate

--------0.10 --0.30 ---

----0.10 --0.05 0.10 0.05 ---

T.O. 1-1A-9

4-7

4-8
ALLOY AL MN ZINC ZE41A ZH42* ZH62A* ZK20A ZK51A ZK60A ZK60B ----------------------------4.25 3.0-4.5 5.2-6.2 2.0-2.6 3.6-5.5 4.8-6.2 4.8-6.8

T.O. 1-1A-9

Table 4-3.

Chemical Properties of Magnesium Alloys - Continued

ZIRCONIUM

RARE EARTH 1.25 -------------

THORIUM

SI

CU

NICKEL

MG

FORMS

0.5 0.5 0.5-1.0 0.45mn 0.5-1.0 0.45 0.45

--1.5-2.5 1.4-2.2 ---------

---------------

----0.10 --0.10 --0.10

----0.01 --0.01 --0.01

Bal Bal Bal Bal Bal Ba1 Bal

Castings, Sand Castings, Sand Castings, Sand Extrusions Castings, Sand Extruded Bars/Rods/Shapes Tube-Forgings Same

*NOTE: These alloys contain radioactive thorium. See paragraph 4-15 (1) Calcium, AZ31B, 0.04---MIA, 0.4.0.14 (2) Iron, AZ31B, 0.005---AZ61A, 0.005---AZ63A, 0.005. (3) Silver, QE22A, 2.5-3.0 (4) Tin, TA54A, 4.6-6.0

Table 4-4.

Mechanical Properties Magnesium Extrusions and Forgings at Room Temperature - Typical

ALLOY & C0ND

FORM

DIEMN (DIA THICKNESS: WALL THKNESS - INS)

CROSS SECTIONAL AREA (INCHES)

MIN TENSILE STR (1000PSI)

MIN TEN YLD STR (1000PSI)

MIN ELONGAtion (2 %) 7 7 7 7 8 8 9 7 7 9 8 6 4 4 4 2 4

MIN SHEAR STR (1000PSI)

HARDNESS (BRINELL)

AZ31B-F and AZ31C-F

Bars, Rods, shapes

Hollow shapes AZ61A-F Bars, rods, shapes Hollow shapes AZ80A-F Bars, Rods, shapes

0.249 and under 0.250-1.499 0.500-2.499 2.500-4.999 All dimensions 0.249 and under 0.250-1.499 0.250-4.999 All dimensions 0.249 and under 0.250-1.499 1.500-2.499 2.500-4.999 0.249 and under 0.250-2.499 2.500-4.999 Not applicable 0.249 and under 0.250-1.499 1.500-2.499 2.500-4.999 All dimensions All dimensions All dimensions All dimensions All dimensions

All All All All All All All All All All All All All All All All

areas areas areas areas areas areas areas areas areas areas areas areas areas areas areas areas

35 35 34 32 32 38 39 40 36 43 43 43 42 47 48 45 37 30 32 32 29 28 43 43 40 45 46

21 22 22 20 16 21 24 22 16 28 28 28 27 30 33 30 26 not not not not not 31 31 28 36 38 req req req req req

17 17 17 -17 -18 -18 19 19 19 --21 --

-49 --49 -60 -60 60 60 60 60 82 82 82

T-5

Same

HM31A-T5* MIA-F

Bars, rods, shapes Bars, rods, shapes

Under 4.000 All All All All All areas areas areas areas areas

Hollow shapes ZK60A-F Bars, rods, shapes Hollow shapes Bars, rods, shapes Hollow shapes

2 3 2 2 2 5 4 5 4 4

-15 15 -15 22 22 -22 22

44 44 44 44 44 75 75 -82 82

4.999 and under 5.000-29.999 All areas 4.999 and under All areas

T5

T.O. 1-1A-9

4-9

4-10
ALLOY & C0ND FORM AZ31B-F and AZ31C-F AZ61A-F MIA-F ZK60A-F ZK60A-T5 AZ31B-F AZ61A-F AZ80A-F AZ80A-T5 T6 MIA IA54A-F ZK60A-T5

T.O. 1-1A-9

Table 4-4.

Mechanical Properties Magnesium Extrusions and Forgings at Room Temperature - Typical - Continued

DIEMN (DIA THICKNESS: WALL THKNESS - INS)

CROSS SECTIONAL AREA (INCHES)

MIN TENSILE STR (1000PSI)

MIN TEN YLD STR (1000PSI)

MIN ELONGAtion (2 %)

MIN SHEAR STR (1000PSI)

HARDNESS (BRINELL)

EXTRUDED TUBES 0.050-0.500 Not applicable 32 16 8 -46

0.050-0.500 0.050-0.500 0.050-0.250 0.050-0.250

Not applicable Not applicable Not applicable Not applicable DIE FORGINGS

28 40 46 46

-28 38 38

2 5 5 4

-----

42 75 75 82

34 38 42 42 50 (typ) 30 36 42

19 22 26 28 34 (typ) 18 22 26

6 6 5 2 5 (typ) 3 7 7

17 19 20 20 -14 ---

55 55 69 72 72 47 ---

NOTE: This alloy contains radioactive elements. See paragraph 4-15 for precautions.

Table 4-5.

Mechanical Properties Magnesium Alloy Sheet and Plate at Room Temperature - Typical

ALLOY & COND AZ31B-F AZ31B-H10 -H11 -H23 -H24

DIMENSION THICKNESS (INCHES) All gauges 0.251-2.000 0.016-0.250 0.016-0.064 0.065-0.064 0.016-0.063 0.065-0.250 0.251-0.500 0.501-1.000 0.501-0.750 0.751-1.000 1.001-1.500 0.016-0.060 0.061-0.250 0.251-0.500 0.501-2.000 All gauges 0.016-0.250 0.251-0.500 0.501-1.000 1.001-3.000 0.016-0.125 0.126-0.250 0.251-1.000 1.001-3.000 0.016-0.250 0.251-0.500 0.501-1.000 1.001-2.000 All Gauges All gauges 0.016-0.060 0.061-0.250 0.251-0.500 0.016-0.125 0.126-0.188 0.189-0.250

MINIMUM** TENSILE STRENGTH (1000PSI) 35 (typical) 30 32 39 39 39 39 37 37 37 37 35 32 32 32 30 32 30 30 30 29 34 31 34 33 31 32 30 29 33 (typ) 35 (typ) 30 30 29 36 34 31

MINIMUM** TENSILE YIELD STR (1000PSI) 19 (typical) 12 12 25 25 29 29 24 22 25 23 22 18 15 15 15 15 16 16 15 14 26 22 25 25 18 21 19 18 18 (typ) 26 (typ) 18 15 12 25 22 20

MIN ELONGATION (2--%)

MINIMUM SHEAR STRENGTH (1000PSI) -----18 18 -----17 17 -------21 21 20 20 ----

HARDNESS (BRINELL)

USE Tooling Plate Standard Plate Standard Plate and Sheet Standard Sheet and Plate Spec Sheet and Plate Same Same Same Spec Sheet and Plate Spec Sheet and Plate Same Same Same Tread plate Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet and and and and Plate Plate Plate Plate

12 (typical) 10 12 4 4 4 4 10 10 8 8 8 12 12 12 10 8 12 12 12 12 4 4 4 4 4 6 6 6 17 (typ) 7 (typ) 15 15 12 4 4 4

-H26 -0

AZ31C-F HK31A-0*

--73 73 -----56 56 --52 ----57 57 ---

-H24*

(typ) (typ) (typ) (typ)

HM21A-T8

MIA-O H ZE10-0 H24

17 (typ) 7 (typ)

48 54

Sheet and Plate Sheet and Plate Sheet and Plate

T.O. 1-1A-9

* Contains radioactive thorium element. See paragraph 4-19 for precautionary data. ** Values given are all minimum unless otherwise noted beside value.

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Table 4-6.

Mechanical Properties of Magnesium Alloy Castings at Room Temperatures

ALLOY & COND

TENSILE STRENGTH (1000 PSI) TYPE MIN

TENSILE STRENGTH YIELD (1000 PSI) TYPE MIN 12 13 16 22 14 14 16 19 14 14 14 12 19 14 14 17 21 16 16 18 15 15 14 6 25 19 21.6 -22 24 26 10 10 15 17 10 10 10 16 10 10 10 12 16 10 10 11 18 14 14 16 14 13 13 6 25 19 --22 20 26

TYPICAL ELONGATION IN 2--% TYPE MIN 2 10 4 1 6 12 4 5 12 2.5 11 2 5 2 10 1 2 3 1 3 3 8 7 14 2 2.5 4.5 12 4 8 5 -6 2 -4 7 2 3 7 -7 -3 1 6 -1 2 -1 2 4 4 14 2 2.5 --5 5 5

SHEAR STRENGTH (1000 PSI) 18 20 21 21 16 17 17 19 17 16 17 -19 16 17 16 20 18 18.7 19.4 19.8 21 20 --23 --24 22 26 HARDNESS (Brinell) 54 52 69 69 50 55 55 73 55 52 55 -73 65 63 80 84 45 45 50 50 55 57 --62 --70 65 68

AM100A-F -T4 -T6 -T61 AZ63A-F -T4 -T5 -T6 AZ81A-T4 AZ91C-F -T4 -T5 -T6 AZ92A-F -T4 -T5 -T6 EK30A-T6 EK41A-T5 -T6 EZ33A-T5 HK31A-T6* HZ32A-T5* KIA-F QE22A-T6 ZE41A-T5 ZH42-T51* ZH42-T4* ZH62A-T5 ZK51A-T5 ZK61A-T6

22 40 40 40 29 40 30 40 40 24 40 23 40 24 40 26 40 23 23 25 23 30 29 24 35 28 32.5 33.6 35.0 40 39

20 34 34 34 24 34 24 34 34 18 34 23 34 20 34 20 34 20 20 22 20 27 27 24 35 28 -35 35 34 39

DIE CASTINGS AZ91A-F AZ91B-F 33 33 --22 22 --3 3 --20 20 67 67

NOTE: *This alloy contains radioactive thorium element. See paragraph 4-19 precautionary instructions.

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Table 4-7.

Physical Properties Magnesium Alloy @68oF

ALLOY & COND

SPECIFIC GRAVITY 1.81 1.81 1.81 1.77 1.80 1.82 1.82 1.82 1.80 1.81 1.81 1.81 1.81 1.81 1.83 1.83 1.83 1.79 1.81 1.81 1.83 1.79 1.77 1.80 1.83 1.76 1.87 1.76 1.86 1.86 1.80 1.81 1.83 1.83 1.83 1.80

DENSITY LBS/CU in 0.065 0.065 0.065 0.064 0.065 0.066 0.066 0.066 0.065 0.065 0.065 0.065 0.065 0.065 0.066 0.066 0.066 0.065 0.065 0.065 0.066 0.065 0.064 0.065 0.066 0.064 0.067 0.063 0.067 0.067 0.645 0.066 0.066 0.066 0.066 0.065

MELTING RANGEoF 867-1101 867-1101 867-1101 1116-1169 977-1145 850-1130 850-1130 850-1130 914-1130 914-1132 875-1105 875-1105 875-1105 875-1105 830-1100 830-1100 830-1100 1100-1184 1193 1193 1010-1189 1092-1204 1100-1195 1121-1202 1026-1198 1200 -1100-1200 1180 1180 -1020-1185 968-1175 968-1175 968-1175 1145

ELECTRICAL CONDUCTIVITY (IACS) 11.5 9.9 12.3 18.5 11.6 15.0 12.3 13.8 10.6 12.0 10.1 11.5 9.9 11.2 12.3 10.5 12.3 27.0 24.0 26.0 25.0 22.0 26.0 26.5 34.5 --23.9 26.5 -28.0 29.0 30.0 31.0 --

AM100A-F -T4 -T6 AZ31B and AZ31C AZ61A AZ63A-F -T4 -T6 AZ80A AZ81A AZ91A-AZ91B AZ91C-F -T4 -T6 AZ92A-AC -T4 -T6 EK30A EK41A-T5 -T6 EZ33A HK31A-T6 HM21A HM-31A-F HM32A MI-A TA54A ZE10A ZH42 ZH62A ZK21A ZK51A ZK60A-F -T5 ZK60B ZK61A

NOTE: Percentage conductivity of annealed copper at 68oF (international annealed copper standard). c. Machine the metal dry whenever possible, avoiding f ine feeds and keeping speeds below 500 700 surface feet per minute during turning and boring. If a coolant is def initely required use a mineral oil. d. Keep work areas clean. e. Store magnesium chips in clean, plainly labeled, covered, non-combustible containers where they will remain dry. Do not allow chips to accumulate on machines or operators clothing. Machinists should not wear textured or fuzzy clothing and chips and sawdust should not be allowed to accumulate in cuffs or pockets. f. Do not permit tools to rub on the work after a cut has been made. g. Keep an adequate supply of a recommended magnesium f ire extinguisher within reach of the operators. If chips should become ignited, extinguish them as follows:

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T.O. 1-1A-9

WARNING Water or any of the common liquid or foam type extinguishers will intensify a magnesium chip f ire and may cause an explosion and shall not be used. (1) Cover with a layer of G-1 or Met-L-X powder. Clean, dry unrusted cast iron chips, graphite powder, clean dry sand, talc and pitch may also be used. (2) Actively burning f ires on combustible surfaces should be covered with a 1/2 inch layer or more of extinguishing powder; then the entire mass shoveled into an iron container or onto a piece of iron plate. Alternately, a one or two inch layer of powder can be spread on the f loor or surface nearby and the burning metal transferred to it, then add more powder as required. (3) High cutting speeds, extremely f ine feeds, dull, chipped or improperly designed tools, tool dwell on work af ter feed is stopped, tool rub, or tool hitting a steel or iron insert increase the chances of chip ignition. Keeping the cutting speed below 700 feet per minute will greatly reduce the fire possibilities even with a dull or poorly designed tool and f ine feeds. 4-22. GRINDING AND POLISHING SAFETY PRACTICES. During grinding and polishing operations a proper dust collection system must be used. Figure 4-1 illustrates acceptable type collectors. The dust produced during grinding and polishing of magnesium must be removed immediately from the working area with a properly designed wet type dust collection system. Proper systems precipitate the magnesium dust by a heavy spray of water and must be so designed that dust or sludge cannot accumulate and dry out to a f lammable state. Small collectors as shown in Figure 4-1, detail A serving one or two grinders are the best. The grinder-to-collector ducts should be short and straight. The self opening vents illustrated prevent hydrogen collection during shut down. The grinders power supply, air exhaust blower and liquid level controller should be electrically water connected so cessation or failure of the dust collector operation will shut the grinder off. In addition a suitable devise should be installed in the system that will insure the collector system is in full operation and has changed the air in the ducts, etc., several times before the grinder begins running. Dry type f ilter collectors or central collector systems which carry the dust through long dry ducts should not be used for magnesium. The collector portrayed in Figure 4-1, detail B is used

with booth type portable grinding and polishing where the dust passes through the grate with the air being circulated into a liquid spray which removes the dust. Design the booth to catch all the dust possible. On individual grinders for small scale work, as shown in Figure 4-1, detail C, the hood design and the oil pan combine to afford a satisfactory dust collection. Any dust escaping the hood should be kept swept up and properly disposed of. 4-23. The following specif ic safety rules pertain to the grinding and polishing of magnesium: a. Magnesium grinding should be done on equipment set aside and labeled for that purpose. Do not grind sparking material on these grinders unless the magnesium dust has been completely removed from the equipment system. In addition, the grinding wheel or belt must be replaced prior to grinding of any other metal. b. If chrome pickled magnesium is to be ground, sparks may result. Therefore, dust and air-dust mixtures must not be allowed to accumulate within spark range. c. Maintain adequate supplies of plainly labeled approved f ire extinguishing powder and suitable dispensing tools readily available to operators. Fire control is the same as detailed in paragraph 4-21 for machine chips. d. Keep dust from accumulating on surrounding f loors, benches, windows, etc. If such accumulation is evident the collector system is not operating properly and must be checked and repaired. Periodically and no less than once a month, completely clean the entire collector systems. Inspect and clean the grinder to collector ducts daily or move frequently if the volume of collection is high. e. Dispose of grinding sludge as soon as it is removed from the equipment. Do not store or allow to even partially dry since it is extremely f lammable. This may be done by spreading it on a layer of f ire brick or hard burned paving brick to a maximum depth of 3 to 4, then placing a combustible material on top of it and burning the entire lot. The sludge will burn with intense heat, therefore, a safe location must be used. A method of rendering magnesium sludge chemically inactive and non-combustible by reacting it with a 5% solution of ferrous chloride (Fe C122H2O) is detailed in the National Fire Protection Associations Bulletin No. 48, Standards for Magnesium. f. The clothing of operators should be smooth and f ire retardant without pockets and cuffs. Caps should be worn. All clothing should be easy to remove and kept free of dust accumulations.

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T.O. 1-1A-9

4-24.

Deleted.

4-25. HEAT TREATING SAFETY PRACTICES. Heat treating of magnesium alloys requires the exercising of certain def inite rules, if safe and good quality workmanship is to result. The following rules should be closely followed: a. Use furnace equipment having two sets of temperature controls, operating independently of each other. b. Standardize checking procedures and adjustments of all equipment and of operating cycles. c. Load the furnace with castings of one identical alloy only. Insure the castings are clean. d. Use SO2 (Sulfur Dioxide) atmosphere to control oxidation. e. Use the recommended time and temperature operating ranges at all times. f. Provide approved f ire extinguishing equipment.

covered with the powder, the furnace load should be allowed to cool with the door open. For the handling of large quantities of G-1 powder, pumps have been constructed which can throw 75-100 lbs/ minute onto the f ire through a 30 foot hose and nozzle. (2) Boron Trif luoride (BF3) Gas Method.

WARNING Boron trif luoride vapor or gas is toxic in the proportion of more than 1 part per million by volume of air when exposures are prolonged or frequently repeated. Five parts per million by volume of air or more are usually present in visible clouds of material resulting from the release of the gas to atmosphere. Therefore, personnel must not enter such clouds or any area where there is reason to believe the safe level is exceeded unless wearing a gas mask with an acid gas canister containing a dust f iller. Analysis of atmosphere in the workers breathing zone will be accomplished to assure personnel safety. This is an effective gaseous means of extinguishing magnesium f ires in heat treating furnaces. The gas is introduced into the furnace from a storage cylinder through an entry port preferably located near f loor level. Connect the gas feed line to this port, open the feed line valve to provide about 2 lbs/minute (depending on furnace size and number of gas cylinders) and maintain gas f low until furnace temperature drops to 700oF indicating the f ire is out. The furnace door should be kept closed during this action and until a def inite temperature drop below 700oF is evident. Running the furnace circulating fans for about 1 minute af ter the gas is f irst introduced will assist in gas dispersal, then shut the fan off. The gas cylinder used should be f itted with a Monel needle valve and a tee for attaching a 0-160 psi pressure gauge. A suitable gas transfer system uses a 5/16 f lexible bronze hose to carry the gas to the furnace where it enters through a 1/4 steel pipe entry port. Using 10 feet of hose and feed of pipe, a gauge pressure of 15-30 psi will deliver 1-2 lbs of BF3 per minute. The cylinders may be permanently connected or brought to the furnace, when needed, on a suitable dolly. This gas does not require heating in order to f low. The cylinders should be weight checked for contents every 6 months.

WARNING Water and other extinguishers for Class A, B, and C f ires shall not be used. 4-26. If a f ire should occur for any reason, as evidenced by excessive furnace temperature and omission of a light colored smoke, proceed as follows: a. Shut off all power, fuel and SO2 feed lines to the furnace. b. Notify f ire marshal control crew at once. c. Begin f ire extinguishing procedures using one of the following methods: (1) G-1 Powder Method. Where it can be safely done, a small f ire should be removed from the furnace, dumped into an iron container and then extinguished by covering with G-1 powder which is a graphite base powder of the Pyrene CO2 Company. Metal Fyr Powder of the Fyr Fyter Company is the same material. In large furnaces or with f ires of high intensity, the powder can be applied to the burning parts with a shovel (assuming the furnace door can be opened safely). Paper bags f illed with the powder can be used if the f ire is so located that such bags can be thrown in effectively. Remove parts not burning with long handled hooks. Af ter all burning parts have been

Change 1

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(3) Boron Trichloride (BCL3) Gaseous Method. This material has been successfully used to extinguish magnesium heat treat furnace f ires. However, there are several factors involved with its use which makes it less preferred than boron trif luoride, these include: ten times more concentration than the 0.04% of boron trif luoride, the gas must be heated to f low freely; it is more expensive than trif luoride; the liquid is corrosive and the fumes irritating with a health hazard similar to hydrochloric acid fumes. Workmen should not occupy areas where noticeable vapors are present unless wearing a gas mask with an acid gas canister containing a dust f ilter. If this agent must be used, the liquid containing cylinders should be heated with infrared lights to provide the heat necessary to insure adequate gas f low. The cylinder outlet should be f itted with a special valve and gauge to control gas f low. Flexible 5/8 ID neoprene hose may be used to connect the cylinder to a steel pipe for insertion into the furnace port. Otherwise its use in extinguishing a furnace f ire is similar to the procedures for boron trif luoride. 4-27. IDENTIFICATION OF ALLOY. 4-28. Positive identif ication of an alloy, from a constituency standpoint, can only be determined by laboratory analysis. However, whether a light metal is magnesium or not can be generally determined by a simple test consisting of placing the test metal in contact with an 0.5% solution of silver nitrate, and observing the reaction for 1 minute. The solution is made by dissolving 0.5g. of silver nitrate in 100 ml. of water. Formation of a black deposit of metallic silver on the metal indicates magnesium or high-magnesium alloy. Then immerse the metal in a chrome pickle chemical solution, Type I Specif ication MIL-M-3171 (Commercially known as DOW No. 1). The solution should be freshly prepared and the test operator familiar with the colors of chemical treatment. If the metal assumes a very bright brassy coating, it indicates it is aluminum free alloy. If a greyish

iridescent coating forms the alloy contains aluminum. The solution is made in the proportions of 24 ounces sodium dichromate and 24 f luid ounces concentrated nitric acid to enough water to make one gallon. Prior to the test the metal should be thoroughly cleaned down to the base metal, if necessary, by grinding or f iling a clean area on the surface. 4-29. HEAT TREATING MAGNESIUM ALLOYS - GENERAL.

NOTE SAE-AMS-M-6857, Heat Treatment of Magnesium Alloy Castings, will be the control for heat treatment of magnesium alloy castings used on aerospace equipment. For complete description of magnesium alloy castings heat treat requirements, refer to latest issue of SAE-AMS-M-6857. Additional Heat Treatment information is discussed in Section IX.

4-30. PRECAUTIONS DURING HEATING. Of f irst importance in the heat processing of these alloys is a clear understanding of the characteristics of the metal relative to heat. Pure magnesium will melt at approximately 1202oF. The alloys melting points range from 830oF to 1204oF, approximately, according to their element constituency. Therefore, during any heating of alloy items, specif ied temperature maximums must be closely adhered to, particularly during solution heat treating. The metal is easily burned and overheating will also cause formation of molten pools within it, either condition resulting in ruining of the metal. Certain alloys such as AZ63A Type 1, or AZ92A Type 1, are subject to eutectic melting of some of its elements if heated too rapidly. They must be brought up to heat treating temperature slowly enough to prevent this. In the case of these two

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examples, no less than two hours should be consumed in bringing them from 640oF to treating temperature. 4-31. An additional and no less important characteristic of the metal relative to heat treatment, is that it is subject to excessive surface oxidation at 750oF and higher temperatures. In an oxidizing atmosphere, this characteristic can result in ignition and f ierce burning. To prevent such occurrences, a protective atmosphere containing sufficient sulphur dioxide, carbon dioxide or other satisfactory oxidation inhibitor shall be used when heating to 750oF and over. When oxidation inhibitors are used, their concentration percentage in the furnace atmosphere should be periodically checked for correct amounts. The particular requirements for various alloys are detailed in paragraph 4-46 in this section. These requirements and those of other pertinent specif ications and instructions should be consulted and strictly adhered to in processing the metal. The safety measures def ined in paragraph 4-1 must be rigidly practiced. 4-32. HEAT TREATING EQUIPMENT.

4-33. Furnaces used for solution heat treatment shall be of the air chamber type with forced air circulation. Heating provisions can be gas, electricity or oil. Their design must be such as to make impossible, direct heating element radiation or f lame impingement on the articles being treated. The furnaces shall be installed with the necessary control, temperature measuring and recording instrument equipment to assure complete and accurate control. The temperature control shall be capable of maintaining a given temperature to within 10o F at any point in the working zone, after the charge has been brought up to this temperature. Each furnace used shall be equipped with a separate manual reset safety cut-out which will turn off the heat source in the event of any malfunction or failure of the regular automatic controls. The safety cut-outs shall be set as close as practicable above the maximum solution heat treating temperature for the alloy being treated. This will be above the variation expected but shall not be more than 10oF above the maximum heat treat temperature of the alloy being processed. There shall also be protective devices to shut off the heat source in case of circulation air stoppage. These devices shall be interconnected with a manual reset control. 4-34. Upon initial furnace installation and af ter any maintenance on the furnace or its equipment which might affect its operational characteristics, a temperature survey shall be made to test its

capability of maintaining the minimum and maximum temperatures required for the various treatments it will be used for. A minimum of 9 test locations within the furnace load area should be checked. One in each corner, one in the center and one for each 25 cubic feet of furnace volume up to the maximum of 400 cubic feet. A monthly survey should be made af ter the initial survey, unless separate load thermocouples are employed, to record actual metal temperatures. The monthly survey should consist of one test for a solution heat treat temperature and one test for a precipitation heat treat temperature, one for each 40 cubic feet of heat treating volume with a minimum, of 9 test locations required regardless of the volume. In addition, a periodic survey should be made, using the test criteria of the initial survey. For all surveys, the furnaces should be allowed to heat to a point stabilization before taking any readings. The temperature of all test locations should be determined at 5 to 10 minute intervals after insertion of the temperature sensing elements in the furnace. The maximum temperature variation of all elements shall not exceed 20oF and shall not exceed the solution or precipitation heat treating range at any time af ter equilibrium is reached. 4-35. Furnace control temperature measuring instruments shall not be used as test instruments during any survey. The thermocouple and sensing elements should be replaced periodically because of the in-service incurred effects of oxidation and deterioration. 4-36. Pyrometers used with the automatic control system to indicate, maintain and record the furnace temperatures, should preferably be of the potentiometer type. 4-37. Suitable jigs, f ixtures, trays, hangers, racks, ventilators and other equipment shall be used in processing the articles. 4-38. HEAT TREATMENT SOLUTION. Solution for heat treating of magnesium alloyed articles is accomplished by heating at an elevated temperature in an air furnace for a specif ic length of time (holding period); during which certain alloying elements enter into uniform solid solution, since the alloys tend to become plastic at high heat treat temperatures, it is mandatory that suitable support be provided for articles being processed to prevent warping. Table 4-8 below lists the recommended soaking and holding time for solution heat treating alloys. The holding periods given are for castings up to 2 inches thick. Items thicker than 2 inches will require longer periods. 4-39. AZ92A (Type 2), AZ91C and QE22A sand castings and AM100A permanent mold castings

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T.O. 1-1A-9

may be charged into the furnace which is at the heat treating temperature. Since magnesium castings are subject to excessive surface oxidation at temperatures of 750oF and over, a protective atmosphere containing sufficient sulphur dioxide, carbon dioxide or other satisfactory oxidation inhibitor shall be used when solution heat treating at 750oF and over. The whole casting must be heat treated, not just part of it. 4-40. Precipitation heat treatment or artif icial aging of alloys is accomplished at temperature lower than those of the solution treatment. Suggested aging treatments for various alloys are as cited in Table 4-9.
Table 4-8.

4-41. Stabilization heat treating an alloy increases its creep strength and retards growth at service encountered elevated temperatures. The same general procedure of heating to temperature, holding for a time and cooling to room temperature is used as in the other two types, only the temperature and time elements are different. When applied to a solution treat treated alloy, it increases the alloys yield strength. Actually stabilization treatment is a high temperature aging treatment accomplished quickly rather than allowing an alloy to age naturally over a period of time.

Solution Heat Treating Temperatures and Holding Times

ALLOY AM100A AZ63A (Type 1) AZ63A (Type 2)* AZ81A AZ91C AZ92A (Type 1) AZ92A (Type 2) HK31A QE22A** ZK61A

TEMPERATURE RANGE 790-800 720-730 (F to T4) 720-740 (F to T4) 770-785 770-785 760-770 775-785 1045-1055 970-990 925-935 or 895-905

TIME PERIOD(HRS) 16-24 10-14 10-14 16-24 16-24 16-24 14-22 2 4-8 2 10

MAX TEMP oF 810 734 745 785 785 775 785 1060 1000 935 935

* Contains calcium. ** Quench in 150oF water bath within 30 seconds af ter opening of furnace. 4-42. Annealing of magnesium alloys is accomplished to relieve internal stresses, generally resulting from forming operations; sof ten the material for forming; improve the ductility; and/or refine the grain structure. The alloy is heated to the proper temperature, soaked or held at that temperature for a specif ied time and cooled to room temperature. The desired effects are gained by controlling the temperature, hold time and cooling medium exposure. Avoid excessive time at temperature to prevent unwanted grain growth. Conversely, no attempt should be made to shorten the time at temperature and over all annealing time by increasing the temperature, since elements of the alloy subject to melting points lower then the alloy itself can go into solution. 4-43. HEAT TREATING PROCEDURES. Placing of articles to be treated in the furnace, (generally referred to as charging the furnace), should not be done in a haphazard fashion. Individual pieces should be racked or supported to prevent distorting without interfering with the free f low of the heated atmosphere around the article. Distortion or warping can occur due to the semi-plastic qualities of the alloys at the furnace elevated temperatures during solution heat treat. Distortion is not a particular problem during precipitation or stabilization treatment or annealing. However, it is good practice to handle magnesium alloy articles with care at all times under elevated heat conditions. In the case of complicated formed parts, it may be necessary to utilize a specially contoured

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T.O. 1-1A-9

jig or f ixture to adequately protect the design contour of the item at high temperatures. 4-44. Cooling af ter treating is accomplished in either still or blast air, depending upon the alloy. The one exception is alloy QE22A which is water quenched. The water should be at 150oF temperature. 4-45. ALLOY GENERAL CHARACTERISTIC INFORMATION. 4-46. In the following paragraphs are brief summaries of the general characteristics of the various alloys.
Table 4-9.

a. AM100-A - Used in pressure tight sand end permanent mold castings with good combination of tensile strength, yield strength and elongation. Solution heat treat in 0.5% SO2 atmosphere 20 hours at 790oF; cool in strong air blast. Partially artificial aging -12 hours at 325oF; cool in still air. Completely artif icial age 5 hours at 450oF; cool in still air or oven. Aging increases basic yield strength and hardness and decreases toughness and elongation.

Artificial Aging (Precipitation Treatment)

ALLOY & TEMPER AM100A-T6 AM100A-T5* AZ63A-T6 AZ63A-T5* AZ91C-T6 AZ92A-T6 (Type 1) AZ92A-T6 (Type 2) AZ92A-T5* (Type 2) EZ33A-T5* HK31A-T6 HZ32A-T5* QE22A-T6 ZH62A-T5* ZK51A-T5* ZK61A-T5* ZK61A-T6

AGING TREATMENT 5 hours at 450oF or 24 hours at 400oF 5 hours at 450oF 5 hours at 425oF or 5 hours at 450oF 4 hours at 500oF or 5 hours at 450oF 16 hours at 335oF or 4 hours at 420oF 4 hours at 500oF or 5 hours at 425oF 5 hours at 450oF or 16 hours at 400oF or 20 hours at 350oF 5 hours at 450oF 2 hours at 650oF or 5 hours at 420oF or 5 hours at 420oF 16 hours at 400oF 16 hours at 600oF 8 hours at 400oF 2 hours at 625oF or 16 hours at 350oF 8 hours at 424oF or 12 hours at 350oF 48 hours at 300oF 48 hours at 265oF

*T5 is aged from as-cast condition. Others are aged from T4 condition. b. AZ31B and C - Used in low cost extruded bars, rods, shapes, structural sections and tubing with moderate mechanical properties and high elongation sheet and plate; good formability and strength, high resistance to corrosion, good weldability. Liquid temperature 1170oF; solid 1120oF. Hot working temperature is 450 - 800oF. Annealing temperature 650oF. Stress relief of extrusions and annealed sheet = 500oF for 15 minutes; hard rolled sheet = 300oF for 60 minutes. Foreign equivalents are: British DTD 120A Sheet, 1351350 forgings; German and Italian, Electron AZ31; French - SOC Gen Air Magnesium, F3 and T8. c. AZ61A - Use in general purpose extrusions with good properties, intermediate cost; press forgings with good mechanical properties. Rarely used in sheet form. Hot working temperature 350o750oF; shortness temperature above 780oF. Anneal

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650oF. Heat treat annealed sheet extrusions and forgings 15 minutes at 500oF rolled sheet 400oF for 15 minutes. Foreign equivalents are British BS 1351 (forgings) BS 1354 (extrusions); German AZM. d. AZ63A - Used in sand castings for good strength properties with best ductility and toughness. Solution heat treat at 740oF in a 0.5%SO2atmosphere for 10 hours then cool in air. Aging is done at 450oF for 5 hours and cooled in air or furnace. Stabilize at 300oF at 4 hours and cool in air. Foreign equivalents are Elektron AZG, British DTD59A(as cast)and DTD-289 (heat treated). Good salt water anti-corrosion properties.
Table 4-10.

e. AZ80A - Used for extruded and press forged products. Heat treatable. Hot working temperature 600-750oF. Shortness temperature above 775oF, annealing temperature 725oF. Stress relief: as extruded, 500oF for 15 minutes, extruded and artificially aged 400oF for 60 minutes; forgings 500o F for 15 minutes. Foreign equivalents are British 1351 (forgings); German AZ855 Helium or Argon-arc weldable using AZ92A welding rod or may be resistance welded. Stress relieve af ter welding.

Deleted.

Table 4-11.

Deleted.

f. AZ81A - Used in sand or permanent mold castings for good strength, excellent ductility, pressure tightness and toughness. Readily castable with low micro-shrinkage tendency. Solution heat treat 775oF for 18 hours, cool in air or by fan. Stabilizing treatment 500oF, 4 hours and air cool. To prevent germination (grain growth) an alternate heat treat of 775oF for 6 hours, 2 hours at 665oF and 10 hours at 775oF may be used. g. AZ91A, AZ91B - AZ91A - used for die castings generally. h. AZ91C - AZ91B - is also die cast alloy but has higher impurity content. AZ91C is used for pressure tight sand and permanent mold castings having high tensile and weld strength. Shortness temperatures are above 750oF. Heat treat: T-4 condition, 16 hours at 780oF, cool in air blast and then age at 400oF for 4 hours; T-7 condition, 5 hours at 450oF. Foreign equivalents are Elektron AZ91 and British DTD136A. Good impact resistance in T-4 temper. T-6 has good yield strength and, ductility. i. AZ92A - Used in pressure tight sand and permanent mold castings. Has high tensile and yield strengths. Solution heat treat 20 hours at 760oF in an atmosphere of 0.5% SO2. Cool in strong air blast. Artif icial aging is done at 420oF for 14 hours. Cool in air or oven. Stabilize for 4 hours at 500oF, then cool in air. Equal to AX63A in salt water corrosion resistance. j. EK30A - Used in sand casting for elevated temperature applications. Has good strength properties in temperature range 300o- 500oF. Solution heat treat at 1060oF maximum 16 hours then cool in air by fan. Age at 400oF then air cool.

k. EK41A - Used as pressure tight sand casting alloy. Good strength at 300o - 500oF. Solution heat treat at 1060oF maximum 16 hours then cool in air or with fan. Age at 400oF 16 hours, air cool. l. EZ33A - Used for pressure tight, good strength sand and permanent mold castings where temperatures may reach 500oF in use. Age at 420oF for 5 hours. Forgeign equivalent British ZRE1. m. HK31A - Used in sand castings for elevated temperature use up to 650oF and sheet and plate applications. Has excellent weld and forming characteristics in sheet/plate form and retains good strength up to 650oF. Hot working temperature is 800o to 1050oF. Anneal at 750oF. Solution heat treat sand castings by loading into a 1050oF furnace and holding for 2 hours, then fan or air cool. Age for 16 hours at 400oF. H23 sheet may be stress relieved af ter welding at 650oF for 1 hour or 675oF for 20 minutes. Sheet may be resistance welded. n. HM21A - Used sheet, plate and forgings, usable at 650oF and above. Hot work at 850oF 1100oF Anneal at 850oF. Heat treat forgings (T5)450oF for 16 hours. Resistance welding is also satisfactory. o. HM31A - Used in extruded bars, rods, shapes and tubing for elevated temperature service. Exposure to temperatures through 600oF for periods of 1000 hours caused practically no change in short time room and elevated temperature properties. Superior modulus of elasticity particularly at elevated temperatures. Hot work at 700oF - 1000oF.

4-20 Change 1

T.O. 1-1A-9

p. HZ32A - Used for sand castings. It is of properties for medium and long range exposure at temperatures above 500oF and is pressure tight. q. KIQA - Casting alloy with comparatively low strength has excellent damping characteristics. r. MIA - Used for wrought products and provides for moderate mechanical properties with excellent weldability, corrosion resistance and hot formability. Hot work at 560o - 1000oF. Anneal at 700oF. Stress relieve annealed sheet at 500oF, in 15 minutes; hard rolled sheet at 400oF in 60 minutes; and extrusions at 500oF in 15 minutes. Foreign equivalents are British BS1352 (forgings) and German AM503. s. QE22A - Castings have high yield strength at elevated temperatures. Solution heat treat at 970o-990oF 4 to 8 hours. Quench in 150oF water bath. t. TA54A - Best hammer forging alloy.

strength at room temperatures and moderate longtime creep resistance at temperatures up to 480oF are required. The alloy is a precipitation hardening one from the as-cast condition and requires no solution heat treatment. Maximum hardness is developed at 480oF in 24 hours. More ductility and better shock resistance may be obtained by overaging at temperatures such as 750oF. For T51 condition treat at 480oF for 24 hours; T4 condition 750oF for 24 hours. x. ZH62A - Used as a high strength good ductility structural alloy at normal temperatures and has the highest yield strength of any alloy except ZK61A-T6. Heat treat at 480oF for 12 hours. Foreign equivalent is British T26. y. ZK21A - An alloy of moderate strength for extrusion fabrication. Good weldability using shielded arc and AZ61A or AZ92A, rod. Resistance welding also satisfactory. ZK51A - Used for high yield strength, good ductility, sand castings. Heat treat for 12 hours at 350oF. Foreign equivalent is British Z52. z. ZK60A - Used as a wrought alloy for extruded shapes and press forgings. Has high strength and good ductility characteristics. Hot work at 600o-750oF. Shortness temperature is 950oF. Age at 300oF for 24 hours, air cool. Foreign equivalent is German ZW6. aa. ZK61A - Casting Alloy. Solution heat treat at 925o - 935oF for 2 hours or 895o - 905o F for 10 hours.

u. ZE10A - Used for low cost, moderate strength sheet and plate. No stress relief required after welding. Hot work at 500o - 900oF. Anneal 400oF. AZ61A or EX33A rod is preferred for welding. v. ZE41A - A good strength, pressure tight, weldable alloy, where temperatures are below 200oF. Age 2 hours at 625oF, air cool; 16 hours at 350oF air cool. Foreign equivalent - British RZ5. w. ZH42A - Used in sand castings for aircraf t engines and airframe structures where high

Paragraphs 4-47 through 4-51 deleted.

Change 1

4-21

T.O. 1-1A-9

Figure 4-1.

Typical Dust Collectors for Magnesium

4-22 Change 1

Paragraphs 4-52 through 4-95 deleted. Tables 4-12 through 4-31 deleted. Figures 4-2 through 4-4 deleted. Pages 4-23 through 4-43/(4-44 blank) deleted.

T.O. 1-1A-9

SECTION V TITANIUM AND TITANIUM ALLOYS

5-1. CLASSIFICATION. difficulties encountered in the fabrication of parts, since the absorption of small amounts of oxygen or nitrogen makes vast changes in the characteristics of this metal during welding, heat treatment, or any application of heat in excess of 800oF. 5-9. Operations involving titanium requiring the application of heat in excess of 800oF must be performed in a closely controlled atmosphere by methods explained in future paragraphs. The nominal mechanical properties are listed in Table 5-2. 5-10. METHODS OF IDENTIFICATION. Methods of distinguishing titanium alloys from other metals are simple and def inite. One quick method is to contact the titanium with a grinding wheel. This results in a pure white trace ending in a brilliant white burst. Also, identif ication can be accomplished by moistening the titanium and marking the surface with a piece of glass. This leaves a dark line similar in appearance to a pencil mark. Titanium is non-magnetic. To positively identify the various alloys, a chemical or spectographic analysis is necessary. 5-11. HARDNESS TESTING. Hardness is the resistance of a metal to plastic deformation by penetration, indentation, or scratching, and is usually a good indication of strength. This property can be measured accurately by the Brinell, Rockwell or Vickers Technique. The hardness to be expected from the various alloys and unalloyed titanium is listed in Table 5-2. 5-12. TENSILE TESTING. The useful strength of a metal is the maximum load which can be applied without permanent deformation. This factor is commonly called yield strength. The tensile strength of a metal is that load, in pounds per square inch, at which complete failure occurs. In the case of titanium the yield strength is the most important factor and is therefore used by industry to designate the various types of unalloyed titanium. 5-13. NON-DESTRUCTIVE TESTING. Titanium and titanium alloys are highly susceptible to stress risers resulting from scratching, nicking, and notching. For this reason, close visual inspection is required of all raw stock prior to any forming or machining operations. All scratches, nicks and notches must be removed, before fabrication, by sanding and polishing.

5-2. Titanium is produced in pure form as well as in various alloys. Pure titanium is commonly known as unalloyed. It can be cast, formed, joined, and machined with relative ease as compared to the various alloy grades. Unalloyed titanium cannot be heat treated. Therefore, its uses are limited to end items not requiring the higher strengths obtained from the heat treatable alloys. 5-3. Titanium is a very active metal, and readily dissolves carbon, oxygen, and nitrogen. The most pronounced effects are obtained from oxygen and nitrogen. For this reason, any heating process must be performed in a closely controlled atmosphere to prevent the absorption of oxygen and nitrogen to a point of brittleness. 5-4. GENERAL.

5-5. MILITARY AND COMMERCIAL DESIGNATIONS. There are presently two military specifications in existence (See Table 5-1) covering alloyed and unalloyed titanium in classes established to designate various chemical compositions. For the selection of the proper class and form of stock required for a particular purpose, reference will be made to Table 5-1. 5-6. PHYSICAL PROPERTIES. Limited physical properties are available on the titanium compositions covered by existing military specif ications. Compared to other materials, the melting point of titanium is higher than that of any of the other construction materials currently in use. The density of titanium is intermediate to aluminum and steel. Electrical resistivities of titanium are similar to those of corrosion-resistant steel. The modulus of elasticity is somewhat more than half that of the alloy steels and the coefficient of expansion is less than half that of austenitic stainless steels. 5-7. MECHANICAL PROPERTIES. As previously pointed out, titanium is a very active metal and readily dissolves carbon, oxygen and nitrogen. All three elements tend to harden the metal; oxygen and nitrogen having the most pronounced effect. 5-8. The control of these elements causes considerable difficulty in obtaining correct mechanical properties during the fabrication of titanium. This variation in mechanical properties is the cause of

5-1

T.O. 1-1A-9

Table 5-1.

Specification Cross Reference Titanium Alloys

Comp/Alloy Designation

Form/Commodity

Specification Data AMS Military

Other

COMMERCIALLY PURE (UNALLOYED) 40KS1 (A-40 55A) YIELD SHEET, STRIP PLATE Tubing Welded Tubing Seamless 55KS1 (A55; 65A) Yield Sheet, Strip Plate Forgings 70KS1 (A70; 75A) Yield 70KS1 (A70; 100A) Sheet Strip Plate Bars, Forgings and Forging Stock 4901 4921 4902 4941 4942 4900 MIL-T-9046 Type I, COMP. C MIL-F-83142 Comp. 1 MIL-T-9046 Type I, COMP. B MIL-T-9046 Type I, COMP. A A70; HA-1970; MST70 RS70; Ti-75A, NA2-7126G A70; HA-1970; MST70 RS70; Ti-75A A55; HA-1950; MST 55 RS55; T1-65A; NA2-7123B MIL-T-9046 Type I, COMP. A A-40; HA1940; MST-40; RS-40; Ti-55A A40; 55A

ALPHA TITANIUM ALLOY 5AL-2.5Sn (A110AT) Sheet Strip, Plate Bars and Forgings 5AL-2.5Sn EL1 Sheet Strip Plate 4910 MIL-T-9046 Type II, COMP. A MIL-T-9047 Comp. 2 MIL-T-9046 Type II, COMP. B MIL-T-9047 Comp. 3 MIL-T-9046 Type II, COMP. C MIL-T-9046 Type II, COMP. D MIL-T-9046 Type II, COMP. E A-110AT; HA5137; 0.01 014; MST 5AL-2.5Sn; RS110C; T1-5AL2.5Sn;NA2-71269 A-110AT; HA5137; MST 5AL2.5Sn; RS110C; Ti-5AL-2.5Sn; NA2-7149A

4926 4966 4909

Bars and Forgings 5AL-SZr-5Sn Sheet, Strip Plate Sheet, Strip Plate Sheet, Strip Plate

4924

7AL-12Zr

7AL-2Cb-1Ta

5-2 Change 1

T.O. 1-1A-9

Comp/Alloy Designation

Form/Commodity

Specification Data AMS Military

Other

8AL-1MO-IV

Sheet, Strip, Plate Bars and Forgings Bars, Rings Forgings (Solution heat treated and stabilized)

4915 (Single ann1)

MIL-T-9046 Type II, COMP. F MIL-T-9047 Comp. 5

4972 4973

BETA TITANIUM ALLOYS 13V-11Cr-3AL Forgings Bars and Forgings 13.5V-11Cr-3AL (B120VCA) Plate, Sheet and Strips Solution Heat Treated Bars and Forgings Bars and Wire (Solution Heat Treated) 8Mn (C110M) Sheet, Strip Plate Forgings 4AL-3Mo-IV Sheet, Strip, Plate Sheet, Strip, Plate (Solution and Pretreated) 6AL-4V (C120AV) Sheet, Strip, Plate 4912 4977 4917 MIL-F-83142 Comp. 14 MIL-T-9047 Comp. 12 B-120VCA; MST 13V-11Cr-3AL; R120B; Ti-13V-11C4-3AL

11.5 Mo-6Zr-

MIL-T-9047 Comp. 13

4908

MIL-T-9046 Type III, COMP. A MIL-T-83142 Comp. 12 MIL-T-9046 Type III COMP. B

C110M, MST 8Mn; RS110A; Ti-8Mn; 0.01002

MST 4AL-3MO-IV; RS115; Ti-3AL 3MO-IV; LB-0170-104

4913

4911

MIL-T-9046 Type III, COMP. C

C-120AV; HA6510; MST 6AL-4V; RS120A; TI-6AL-4V; LB0170-110

Change 1

5-3

T.O. 1-1A-9

Table 5-1.

Specification Cross Reference Titanium Alloys - Continued

Comp/Alloy Designation

Form/Commodity

Specification Data AMS Military

Other

Bars and Forgings Bars and Forgings (Solution & Precipitation Heat Treated) Extrusions Wire, Welding Forgings 6AL-4VEL1 Sheet, Strip, Plate Bars and Forgings Forgings Wire, Welding (Extra low intertital environment controlled) 6AL-6V-2Sn Forgings Sheet, Strip, Plate Bars and Forgings

4928

MIL-T-9047 Comp. 6

C120AV; HA6510; MST-6AL-4V; RS120A; TI-6AL-4V; LB0170-110; 0.01037

4965

4935 4954 MIL-F-83142 COMP. 6 MIL-T-9046 Type III, COMP. D 4930 MIL-T-9047 Comp. 7 MIL-F-83142 Comp. F 4956

C120AV; HA6510; MST-6AL-4V; RS120A; Ti-6AL-4V; LB0170-147 C120AV

MIL-F-83142 Comp. 8 4918 MIL-T-9046 Type III, COMP. E MIL-T-9046 COMP. B

4973 (Ann1) 4979 (H.T.)

Forgings 7AL-4Mo (C135MO) Sheet, Strip, Plate Bars and Forgings 4970 (H.T.)

MIL-T-83142 Comp. 9 MIL-T-9046 Type III, COMP. F MIL-T-9047 Comp. 9 C135MO; HA-7146; MST 7AL4MO; RS 135; Ti-7AL-4MO; LB0170-122

5-4

T.O. 1-1A-9

Table 5-1.

Specification Cross Reference Titanium Alloys - Continued

Comp/Alloy Designation

Form/Commodity

Specification Data AMS Military

Other

7AL-4Mo (C135MO) (Cont) 6AL-2SN4Zr-2Mo

Forgings

MIL-F-83142 Comp. 13 MIL-T-9046 Type III, COMP. G 4979 (H.T.) 4976 (Ann1) MIL-T-9047 Comp. II

Sheet, Strip, Plate Bars and Forgings

6AL-2Sn4Zr-6Mo

Bars and Forgings

MIL-T-9047 Comp. 14 MISCELLANEOUS SPECIFICATIONS

Heat Treatment of Titanium and Titanium Alloys

1

SAE-AMS-H81200

There may be controlled requirements applicable to some specif ications listed in the same alloy type or series. Validate any difference and assure that selected specif ication material(s) will comply with end item specif ication requirements before specifying or using. The following manufactures names apply to designations listed under other: a. For designation beginning with A, B, C (example - A-40) CRUCIBLE STEEL CO. b. For designation beginning with HA (example HA-1940) HARVEY ALUMINUM CO. c. For designation beginning with MST (example MST-70) REACTIVE METAL CORP. d. For designation beginning with RS (example RS-40) REPUBLIC STEEL CO. e. For designation beginning with T1 (example T1-8Mn) TITANIUM METAL CORP. f. For designation beginning with LB or NA (example LB170-110 or NA2-7123B) NORTH AMERICAN AVIATION INC. g. For designation beginning with 0.0 (example 0.01015) CONVAIR OR GENERAL DYNAMICS CORP.

Change 4

5-5

T.O. 1-1A-9

5-14. FIRE DAMAGE. Fire damage to titanium and titanium alloys becomes critical above 1000oF due to the absorption of oxygen and nitrogen from the air which causes surface hardening to a point of brittleness. However, an overtemperatured condition is indicated by the formation of an oxide coating and can be easily detected by a light green to white color. If this indication is apparent following f ire damage to titanium aircraf t parts, the affected parts will be removed and replaced with serviceable parts. 5-15. HEAT TREATMENT - GENERAL. NOTE SAE-AMS-H-81200, Heat Treatment of Titanium and Titanium Alloys, will be the control document for heat treatment of titanium and titanium

alloys used on aerospace equipment. For complete description of titanium heat treat requirements, refer to latest issue of SAE-AMS-H-81200. Additional Heat Treatment information is discussed in Section IX.

5-16. A majority of the titanium alloys can be effectively heat treated to strengthen, anneal and stress relieve. The heating media for accomplishing the heat treatment can be air, combusted gases, protective atmosphere, inert atmosphere, or vacuum furnace. However, protective, inert atmospheres or vacuum shall be used as necessary to protect all parts (titanium or titanium alloy), etc., which comprise the furnace load to prevent reaction with the elements hydrogen, carbon, nitrogen and oxygen.

5-6

Change 4

Table 5-2.

Nominal Mechanical Properties at Room Temperature SOLUTION TREATED CONDITION Elong % in 2 in Rock well Hardness Yield Str (0.2% Off set) 1000 psi Min Tensil Str (Ultimate min) 1000 psi Elong % in 2 in Rock well Hardness SOLUTION TREATED AND AGED Yield Str Tensil Elong % in 2 in

ANNEALED CONDITION Yield Str (0.2% Off set) 1000 psi Min Tensil Str (Ultimate min) 1000 psi

MATERIAL TYPE MIL-T-9046 1/ TYPE I, Comp A (Unalloyed 40 ksi) Comp B (Unalloyed 70 ksi) Comp C (Unalloyed 65 ksi) TYPE II, Comp A (5AL-2.5SN) Comp B (5AL-2.5SnE11) Comp C (5AL-5Zr-5Sn) Comp D (7AL-23Zr) Comp E (7AL-2Cb-1Ta) Comp F (8AL-1Mo-IV) TYPE III, Comp A (8Mn) Comp B (4AL-3Mo-IV) Comp C (6AL-4C) Comp D (6AL-4V-EL1) Comp E (6AL-6V-2Sn) Comp F (7AL-4Mo) TYPE IV, Comp A (13V-11Cr-3A1) MIL-T-9047, Class 1 (Unalloyed) Class 2 (5AL, 2.5Sn) Class 3 (3AL, 5Cr) Class 4 (2Fe, 2Cr, 2Mo) Class 5 (6AL, 4V) Class 6 (6AL, 4V) Class 7 (5AL, 1.5Fe, 15Cr, 1.5Mo)

40-65 70-95 55-80 110 95 110 120 110 135 110 115 120 120 140 135 120 70 110 130 120 120 130 135

50 80 65 120 100 120 130 115 145 120 125 130 130 150 145 125 80 115-120 140 130 130 140 145

20 15 18 10 8-10 10 10 10 8-10 10 10 8 10 10 10 10 15 10 10 15 8 10 10

B88 C23 B95 C35 C35 C35 C38 Not recommended 130 150 160 160 160 120 C23 C36 C36 C36 C40 C39 145 150 160 160 5 5 150 160 160 175 5.0 5.0 170 125 8 5 10 10 10 155 145 160 160 160 170 160 170 170 170 5.0 5.0 8.0 8.0 10.0 Not recommended

C36 C36 C38

NOTE 1/ Comp A, B and C are classif ied as commerically pure.

T.O. 1-1A-9

5-7

T.O. 1-1A-9 above 1000oF under oxidizing conditions results in severe surface scaling as well as diffusion of oxygen. 5-22. HYDROGEN EMBRITTLEMENT. Hydrogen embrittlement is a major problem with titanium and titanium alloys. Hydrogen is readily absorbed from pickling, cleaning and scale removal solution at room temperature and from the atmosphere at elevated temperatures. Hydrogen embrittlement in the basically pure and alpha alloys is evident by a reduction in ductility and a slight increase in strength. This is associated with a decrease in impact strength at temperatures below 200oF and a shif t in the temperature range where the change from ductile to brittle occurs. With alpha-beta alloys, embrittlement is found at slow speeds of testing and under constant or sustained loads as demonstrated by tests on notched specimens. This type of embrittlement, which is similar to the embrittlement of steel, only becomes evident above a certain strength level. Solution heat treating and aging the alpha-beta alloys to high strength levels increases sensitivity to hydrogen embrittlement. 5-23. Quenching from solution heat treating for temperature wrought titanium alloys, except for alloy 3AL-13V-11Cr less than 2 inches thick, which maybe air cooled, shall be by total immersion in water. The water shall be of sufficient volume or circulation or both so that the water temperature upon completion of the quenching operation will not be more than 100oF. The quenching baths shall be located and arranged to permit rapid transfer of the load from the furnace to the bath. Maximum quench delay for immersion-type quenching shall be 4 seconds for wrought alloys up to 0.091 nominal thickness and 7 seconds for 0.091 and over. Quench delay time begins when furnace doors begin to open and ends when the last corner of the load is immersed. With extremely large loads or long lengths quench delay may be exceeded if performance test indicates that all parts comply with specif ication requirements. 5-24. AGING AND STRESS RELIEVING. For aging, the material shall be held within temperature range for sufficient time, depending on section size, for the necessary aging to take place and to insure that specif ied properties are developed. Wrought alloys should be fully quenched by air cooling from the aging temperature. The same applies for stress relieving except the time at temperature will depend on section size plus amount of cold work hardening present in the material. The material is also quenched by air cooling from the stress relieving temperature. NOTE All heat treating operations shall be performed uniformly on the whole part, etc., never on a portion thereof.

CAUTION Cracked ammonia or hydrogen shall not be used as a protective atmosphere for titanium and titanium alloys in any heat treating operations. 5-17. Air-chamber furnaces are more f lexible and economical for large volumes of work and for low temperature heat treatments; but at high temperatures where surface oxidation (above 1000oF) is significant, a muff le furnace utilizing external heating gives more protection, especially if gas heated. For general use, electric furnaces are preferred since heating can be accomplished internally or externally with a minimum of contamination. Furnaces which have given satisiactory results are vacuum furnaces capable of supplying pressures of one micron or less; and inert gas furnaces which control the atmosphere to 1% or less of oxygen and nitrogen combined. NOTE Avoid direct f lame impengement to prevent severe localized oxidation and contamination. Also avoid contact with scale or dirt. 5-18. Alternately direct resistance heating may be used where extremely short heat up cycle on nearly f inished parts is required to minimize surface oxidation. 5-19. The commercially pure, or unalloyed titanium, can only be hardened/strengthened by cold work. Stress relief and annealing are the only heat treatments applicable to these alloys. These processes of heat treatment are employed to remove residual stress resulting from grinding, work hardening, welding, etc. For recommended temperatures and times see Table 5-3. 5-20. The soaking period for heat treatment of titanium alloys shall be the minimum necesaary to develop the required mechanical properties. The minimum soaking period (when unknown) shall be determined by teat samples run prior to heat treating the f iniahed material or part. Excessive heat treat soaking periods ahall be avoided to prevent diffusion of oxygen hydrogen and nitrogen. Oxygen and nitrogen diffusion will take the form of a hard brittle surface layer which is difficult to distinguish from the base metal. The brittle layer must be removed by mechanical or chemical means prior to forming or application in stressed components. For the recommended soaking periods and temperatures see Table 5-3. 5-21. Scaling (oxidation) of titanium and titanium alloys starts at about 900oF. Light scaling which forms from exposure to temperatures up to 1000oF has little or no detrimental effect on mechanical properties. Heating to temperatures

5-8

Table 5-3.

Heat Treat, Stress Relief and Annealing Temperatures and Times

STRESS RELIEF TEMP oF MATERIAL

STRESS RELIEF TIME HOURS

ANNEALING TEMP oF

ANNEALING TIME HOURS

HEAT TREATING TEMP oF

H.T. SOAKING TIME MINUTES 14/

AGING TEMP oF

AGING SOAKING TIME HOURS

Unalloyed Commercially Pure Comp A, B and C Alpha Alloys 5A1-2.5Sn 5A1-5Zr-5Sn 7A1-12Zr 7A1-2Cb-1Ta 2/ 8A1-1Mo-1V 1/ Alpha-Beta Alloys 8Mn 3/

1000-1100 900 800

1/2-1 2-4 8

1000-1300

1 1/2-2

Hardened only by cold work

1080-1125 1100-1300 1275-1325 1000-1200 1285-1315

1-2 1/2-3/4 1/2-3/4 1/3-3/4 1/2

1335-1550 1335-1550 1630-1670 1630-1670 1430-1470

1/4-4 1/4-1 1/4-1 1/4-1 8

Hardened only by cold work

950-1000 800-1000 960-990 ---

1/2-2 1/2-15 3-5 --1/2-2 1/2 1/2-8 1/2-2 1/2-2 1/2-50 1/2-3 1/2-8 1/2-50

1250-1300 1175-1200 1360-1400 1250-1350 1250-1300 1225-1250 1425-1650 1180-1200 1275-1550 1300-1500 1425-1450 1275-1550

1 1/2 1/16-1/2 1/2-1 1/2 2-24 2-4 1/3-2 4-24 1/2-8 2-3 1-8 1/2-8 1420-1480 1620-1660 1350-1550 1650-1700 1670-1730 1575-1675 1675-1275 1650-1750 1360-1400

Not recommended 5-25 10-30 Not recommended 60-120 10-20 10-60 30-120 5-25 30-60 30-90 875-925 910-940 900-1000 950-1050 960-990 875-1175 975-1175 6-10 6-12 6-10 4-8 4-6 4-8 4-8 900-950 960-990 4-6 3-5

2Fe-2Cr-2Mo 4/ 2.5A1-16V 3A1-2.5V 4A1-4Mn 4A1-3Mo-1V 6/ 7/ 5/

1250-1350 900-1100 1000-1100 1100-1200 900-1200 1000-1100 900-1300 900-1200

5A1-1.25Fe-2.75Cr 7/ 8/ 5A1-1.5Fe-4Cr-1.2Mo 9/ 6A1-4V 7/ 10/ 5/ 6A1-6V-2Sn 9/ 15/ 7A1-4Mo 11/ 6A1-4V (low o) 10/ 5/ Beta Alloy

Not recommended

T.O. 1-1A-9

3A1-13V-11Cr 12/ 1A1-8V-5Fe 13/

900-1000 1000-1100

1/4-60 1/4-60

1430-1470 1200-1300

1/4-1 1/2-1 1/2

1375-1425 1375-1470

30-90 15-60

880-920 925-1000

2-60 1-3

5-9

5-10
MATERIAL

T.O. 1-1A-9

Table 5-3.

Heat Treat, Stress Relief and Annealing Temperatures and Times - Continued

STRESS RELIEF TEMP oF

STRESS RELIEF TIME HOURS

ANNEALING TEMP oF

ANNEALING TIME HOURS

HEAT TREATING TEMP oF

H.T. SOAKING TIME MINUTES 14/

AGING TEMP oF

AGING SOAKING TIME HOURS

1/ Sheet: Regular anneal furnace cool Duplex anneal. Mill anneal + 1435oF, 15 minutes air cool. Triplex anneal. Mill anneal + 1850oF, 5 minutes air cool, + 1375, 15 minutes air cool. Bar and Forgings: Duplex anneal 1650-1850, 1 hour air cool + 1000o-1100oF, 8-24 hours air cool. 2/ Bar Duplex anneal: Mill anneal + 1000o-1200oF, 1/2-6 hours air cool. 3/ Anneal furncee cool at 300oF per hour maximum to 1000oF to 1050oF. 4/ Stress relief may be accomplished at 800oF - 15 hours, 850oF - 5 hours, at 900oF - 1 hour and 950oF - 1/2 hour. 5/ For 100 % stress relief, 1000oF - 50 hours or 1200oF - 5 hours. For 50 % relief, 1000oF - 5 hours or 1100oF - 1/2 hour. 6/ Furnace cool at 300oF maximum from anneal temperature for maximum formability, also, formability may be improved by holding at annealing temperature 24 hours. 7/ Slow cool to 1000o-1050oF maximum from upper annealing temperature. 8/ Anneal sheet at temperature for 20 minutes. For bar hold at anneal temperature 2 hours. 9/ Air cool from annealing temperature. 10/ For sheet anneal, heat 1300o-1350oF, 1 hour, furnace cool at a rate of 50oF per hour maximum to 800oF. Air cool may be used for lower ductility requirements. For bar and forging anneal, heat at 1275o-1325oF for 2 hours, air cool. For hydrogen removal by vacuum annealing, heat at 1300oF-1500oF for 1/2-2 hours, then furnace cool to 1100oF maximum. 11/ Furnace cool from annealing temp (1425o-1450oF) to 1000o-1050oF maximum at 300oF per hour (maximum) for maximum formability. For maximum creep properties (after lowering from upper annealing) temperature hold at 1050o for 24 hours. 12/ Solution heat treatment recommended for annealing. Stress relieve at temperature cited during aging. If aging not employed, heat treat at 1000oF for 15 minutes. Aging time will depend on strength level required/desired. 13/ Furance cool from upper anneallng temperature at 300oF per hour maximum to 900oF. 14/ Longer soaking times may be necessary for specif ic forgings. Shorter times are satisfactory when soak time is accurately determined by thermocouples attached to the load. Soaking time shall be measured from the time all furnace control instruments indicate recovery to the required (minimum) process range. 15/ Age at 1050o-1150oF air cool for best combination of mechanical properties and termal stability.

T.O. 1-1A-9

5-25.

FABRICATION.

5-26. FORMING SHEET METAL-GENERAL. The forming of the unalloyed titantum can be accomplished at room temperature using approximately the same procedures as those extablished for 18-8 stainless steel. The basic difficulties encountered are sheet thickness, property variations, direction of grain f low and f latness. The above factors combined with high yield strength, high tensile strength and low uniform elongation of commercial titanium alloys makes forming difficult. The current equipment available was designed for material of uniform quality and considerable work is required for adaptation to form titanium. 5-27. BENDING. Straight-Edge Bending of titanium using power brake on hand forming equipment can be accomplished to a limited degree using the methods developed for stainless steel. The factors which require control are the compensation for springback and the bend radii. Springback is comparable to that of hard stainless steel when formed at room temperature. The bend radii will depend on the type of material or alloy and whether forming is accomplished hot or cold. The forming of material requiring tight bends or small radii necessitates the application of heat in the range of 500oF. The heat should be applied for only short periods of time to avoid excessive oxygen and nitrogen contamination which causes embrittlement. For approximate cold bend radii of sheet titanium see Table 5-4. Actual practice may reveal that smaller bend radii can be used. 5-28. DRAW FORMING. Deep draw forming should not be attempted unless adequate equipment and facilities are available. This will require that facilities be maintained for heating and controlling temperatures of the blanks to be formed and the dies used in the forming operation. 5-29. HYDRAULIC PRESS FORMING. Rubber pad hydropress forming can be accomplished either hot or cold depending on the type tooling employed and the press pressures used. This type of forming is used on parts that are predominately f lat and have f langes, beads, and lightening holes. A male form block is set on the lower press platen and the blank held in place on the block by locating pins. A press-contained rubber pad (45 to 55 Shore Durometer hardness and about 8 inches thick) is located over the form block and blank. The press is then closed. As the ram is lowered, the rubber pad envelops the form block forcing the sheet metal blank to conform to its contour. 5-30. Many parts can be formed at room temperature on the hydropress if f lange clips, wedges and

hinge-type dies are used. When cold forming is employed, it is usually desirable to partially form the parts, stress-relieve at 1000oF for 20 minutes, then f inish form. Hot forming for severely contoured parts or when only low-forming pressures are available is accomplished between 600oF and 800oF. For this procedure, the form block is heated to the required temperature, the blank positioned and covered with powdered or shredded asbestos; then a rubber pad 70 to 80 Durometer hardness is placed on top. This extra pad of rubber serves two purposes: First, it provides additional rigidity for forming; and second, it protects the press-contained rubber from the hot form block. 5-31. Tooling for hydropress form blocks, if elevated temperature forming is to be used, requires that pressure plates and dies be made somewhat thicker than in normal practice. If long runs are anticipated, it is recommended that form blocks be made from a good grade of hot-work tool steel due to the galling action of titanium at elevated temperatures. 5-32. STRETCH FORMING. Stretch forming has been used on titanium primarily to bend angles, hat sections, Z-sections and channels and to stretch form skins so that they will f it the contour of the airplane fuselage. This type of forming is accomplished by gripping the section to be formed in knurled jaws, loading until plastic deformation begins, then wrapping the part around a female die. This operation is performed at room temperature and should be done at a very slow rate. Spring back is equivalent to that of 1/4 hard 18-8 stainless steel. All blanks for stretch-forming should have the edges polished to remove any notch effects. Approximately 0.025 inch of sheared edges should be removed. 5-33. DROP-HAMMER FORMING. Drop-hammer forming of titanium has been very successful and has been accomplished both at room and at elevated temperatures. Kirksite is satisfactory for male and female dies where only a few parts are required. If long runs are to be made, ductile iron or laminated steel dies are usually necessary. In drop-hammer forming, the best results have been obtained by warning the female die to a temperature of 200o to 300oF to remove the chill and heating the blank to a temperature of 800o 1000oF for 10 to 15 minutes. The part is then struck and set in the die. Usually a stress relief operation at 1000oF for 20 minutes is necessary, then a restrike operation. In most instances, a f inished part requiring no hand work is obtained.

5-11

T.O. 1-1A-9

Table 5-4.

Recommended Minimum CCLD Bend Radii

TYPE/COMP Type I - Commercially Pure Comp A (unalloyed 40,000 psi) Comp B (unalloyed 70,000 psi) Comp C (unalloyed 55,000 psi) Type II - Alpha Titanium Alloy Comp A (5AL02.5Sn) Comp B (5AL-2.5Sn EL1) Comp C (5AL-5Zr-5Sn) Comp D (7AL-12Zr) Comp E (7AL-2Cb-1Ta) Comp F (8AL- 1Mo-1V) Type III - Alpha-Beta Comp A (8Mn) Comp B (4AL-3Mo-1V) Comp C (6AL-4V) Comp D (6AL-4V) Comp E (6AL-6V-2Sn) Comp F (7AL-4Mo) Type IV - Beta Comp A (13V-11Cr-3AL)

MINIMUM BEND RADIUS (90 DEGREE BEND) 1/ 0.070 & under thickness over 0.070 to 0.187

2T 2.5T 2T 4T 4T 4.5T 5T -4.5T 3T 3.5T 4.5T 4.5T --3T

2.5T 3T 2.5T 4.5T 4.5T 5T 5T -5T 3.5T 4T 5T 5T --3-5T

1/ T = Thickness of material. Example: A piece of 0.040 MIL-T-9046, Type II, Composition A, would require a bend radii of 4 x 0.040 = 0.160 bend radii (minimum). 5-34. JOGGLING. Joggling of titanium can be accomplished without any particular difficulty provided the following rules are adhered to: a. The joggle die corner radius should not be less than 3T-8T. b. Joggle run-out should be the determining factors whether joggles are formed hot or cold. Joggles should be formed hot where a ratio of joggle run-out to joggle depth is less than 8.1. c. Minimum joggle run-outs should be as follows: Hot joggling - four times the joggle depth. Cold joggling - eight times the joggle depth. 5-35. BLANKING AND SHEARING. These operations compare to those of 18-8 stainless steel in the 1/4 hard condition for commercially pure, and the alloys compare to 1/2 hard 18-8 stainless steel. The force required for titanium and its alloys is greater and the dies wear faster. Materials up to 0.125 inch in thickness have been sheared on 1/2 inch capacity f lat bed shears designed for steel. If this capacity is to be exceeded, the shear designer should be consulted. 5-36. Before any forming or other operations are performed 0.025 inch of the sheared, blanked, sawed, or nibbed edges should be removed to prevent stress risers that will cause a tear in the part during forming operations. 5-37. Deleted.

Paragraphs 5-38 through 5-42 deleted. Pages 5-13 through 5-14 deleted.

5-12 Change 2

T.O. 1-1A-9

5-43. 5-44. 5-45. 5-46.

Deleted. Deleted. Deleted. Deleted.

5-47. SOLDERING. Limited information is available on soldering. It is possible to successfully solder titanium where little strength is required, by precoating with a thin f ilm of silver, copper or tin from their chloride salts. This can be accomplished by heating the chloride salts-coated titanium in an atmosphere controlled furnace as previously mentioned in paragraph 5-18. The resultant f ilm should be made wet with either a 60% tin-40% lead or a 50%-50% tin and lead solder. Since the deposited f ilm may dissolve in the liquid solder and dewet the surface, it is important that the time and temperature be held to a minimum. 5-48. RIVETING. Riveting of titanium can be accomplished using conventional equipment with rivets manufactured from commercially pure material; however, the rivet holes require close tolerances to insure good gripping. The driving time is

increased about 65% over that required for high strength aluminum rivets. Better results can be obtained by using the squeeze method rather than the rivet gun and bucking bar. When it is necessary to have f lush-head rivets, dimpling can be accomplished at temperatures of 500oF to 700oF. Other types of rivets such as high strength aluminum, stainless steel and monel are also used to join titanium. 5-49. Due to difficulties involved, the above mentioned method will probably be replaced in most cases with rivets of the high shear series, i.e., pin rivets such as NAS1806 through NAS1816, tension rivet NAS-2006 through NAS-2010, and shear rivet NAS-2406 through NAS-2412. 5-50. As with other metals, it is necessary to take precautions to avoid galvanic corrosion when titanium is riveted to other metals. This can be accomplished by coating the titanium with zinc chromate primer Specif ication MIL-P-8585.

Table 5-5 deleted.

Change 1

5-15/(5-16 blank)

T.O. 1-1A-9

5-51.

MACHINING AND GRINDING.

5-52. MACHINING. Commercially pure, unalloyed titanium machines similarly to 18-8 stainless steel, but the alloy grades are somewhat harder. Variations in actual practice will depend on the type of work, equipment, and f inish, so the following information is only intended as a guide. 5-53. The basic requirements are: rigid machine setups, use of a good cutting f luid that emphasizes cooling rather than lubrication, sharp and proper tools, slow speeds and heavy feeds. Since titanium has a tendency to gall and seize on other metals, the use of sharp tools is very important. Sliding contact, and riding of the tool on the work must be avoided. 5-54. TURNING. Commercially pure and alloy titanium is not difficult to turn. Carbide tools such as metal carbides C91 and Carboloy 44A and other similar types give the best results for turning titanium. Cobalt-type high speed steels give the best results of the many types available. Cast alloy tools such as Stellite, Lantung, Rexalloy, etc., may be used when carbide is not available, or when the high speed steels, are not satisfactory. 5-55. The recommended cutting f luids are waterbase cutting f luids such as soluble oils or chemical type f luids. 5-56. Tables 5-6 and 5-7 show suggested turning speeds, tool angles and feeds. All work should be accomplished with live centers since galling or seizing will occur on dead centers. Tool sharpness is again emphasized because a nick or a seized chip on a tool increases temperature and will cause rapid tool failures. 5-57. MILLING. Considering the type of tool which is required in milling operations, it can be readily seen that this type of machining is more difficult than turning. The difficulty encountered is that chips remain tightly welded to the cutters edge at the end of cut or during the portion of the revolution that it does not cut. As the cutter starts the next machining portion the chips are knocked off. This damages the cutting edge and the tool fails rapidly. 5-58. One method that can be utilized to relieve this difficulty to a great extent is climb milling. The cutter machines the thinnest portion of the chip as it leaves the cut. Thus, the area of contact between chip and tool is at a minimum when the chip is removed at the start of the next cutting portion of the revolution. This will reduce the danger of chipping the tool. The machine used for climb milling should be in good condition because

if there is any lost motion in the feed mechanism of the table, the piece being cut will be pulled into the cutter. This may damage the cutter or the work piece. 5-59. For effective milling, the work feed should move in the same direction as the cutting teeth, and for face milling the teeth should emerge from the cut in the same direction that the work is fed. 5-60. To select the appropriate tool material it is advisable to try both cast alloy and carbide tools to determine the better of the two for large milling jobs. This should be done since the cutter usually fails because of chipping, and the results are not as satisfactory with carbide as they are with castalloy tools. The increase in cutting speeds (20 to 30%) possible by using carbide rather than cast (all alloy tools) does not always compensate for the additional tool grinding cost. 5-61. The same water-base cutting f luids used for turning are recommended for milling; however, carbide tools may give better results when dry. 5-62. See Table 5-8 for recommended speed and feeds. For tool grinding information see Table 5-9. 5-63. DRILLING. Drilling of titanium can be accomplished successfully with ordinary high speed steel drills. Low speeds and heavy positive feeds are required. The unsupported portion of the drill should be as short as possible to provide maximum rigidity and to prevent drill running. All holes should be drilled without pilot holes if possible. As with other materials, chip removal is one of the principal problems and the appearance of the chip is an indication of the sharpness and correct grinding of the drill. In drilling deep holes, intermittent drilling is recommended. That is, the drill is removed from the hole at intervals to remove the chips. 5-64. The cutting f luids recommended are sulfurized and chlorinated coolants for drills with diameters of less than 1/4 inch and mixtures of mineral oil or soluble oil with water for hole sizes larger than 1/4 inch diameter. 5-65. The cutting speed should be 50 to 60 FPM for the pure grade of titanium and 30 to 50 FPM for alloy grades. Feeds should be 0.005 to 0.009 inch for 1/4 to 1/2 inch diameter drills; 0.002 to 0.005 inch for smaller drills. Point angle, 90o for drills 1/4 inch diameter and larger and 140o for drills 1/8 inch diameter or less; but 90o, 118o and 140o should be tried on large jobs to determine the angle that will give the best result. Helix angle 28o to 35o and lip relief 10o. Additional information on drills may be obtained from NAS907.

5-17

T.O. 1-1A-9

Table 5-6.

Turning Speeds for Titanium Alloys

TYPE Unalloyed 70,000 PSI 5A1, 2.5 Sn 3A1, 5Cr 2Fe, Cr 2 Mo 6A1, 4V 4A1, 4Mn 5A1, 1.5 Fe 1.5 Cr, 1.5 Mo

MILITARY MIL-T-9047C Class 1

CUTTING SPEED FPM 250-300 150-170 170-200 120-160 30-60 50-80

FEED, in/rev 0.010-0.020 0.004-0.007 0.005-0.010 0.008-0.015 0.004-0.007 0.005-0.010

TOOL MATERIAL Carbide Hi-Speed Steel Cast Allloy Carbide Bi-Speed Steel Cast Alloy

Classes 2, 3, 4, 5, and 6

Class 7

110-150 20-40 40-70

0.005-0.012 0.003-0.006 0.004-0.008

Carbide Hi-Speed Steel Cast Alloy

NOTE: For cutting forging skin speed 1/4 of that above and feeds about 1/2.
Table 5-7. Tool Angles for Alloys

TOOL ANGLES Back Rake Side Rake Side Cutting Edge Angle End Cutting Edge Angle Relief Nose Radius 0o 6
o

CARBIDE

HIGH SPEED STEEL 5o Pos 5 - 15

o o

CAST ALLOY 5 Pos 5o - 15o 5o - 15o 5o 5o 0.005 inch to 0.010 inch

6o 6o 6o 0.040 inch

5o - 15o 5o 5o 0.010 inch

Table 5-8.

Speeds and Feeds for Milling

TYPE Unalloyed 70,000 PSI 5A1, 2.5Sn 3A1, 5CR 2Fe, 2Cr, 2Mo, 6A1, 4V 4A1, 4Mn 5A1, 1.5Fe, 1.5Cr 1.5Mo

MILITARY MIL-T-9047C Class 1 Class 2, 3, 4, 5, 6

MILLING SPEED FPM 160-180 120-140 80-120 80-100

FEED, IPT -IN INCHES 0.004-0.008 0.004-0.008 0.004-0.008 0.004-0.008

TOOL MATERIAL Carbide Cast Alloy Carbide Cast Alloy

Class 7

70-110 70-90

0.004-0.008 0.004-0.008

Carbide Cast Alloy

5-18

T.O. 1-1A-9

Table 5-9.

Angles for Tool Grinding

ANGLES Axial Rake Radial Rake Corner Angle End Cutting Edge Angle Relief

CAST ALLOY TOOL 0o 0o 30o 6o 12o

CARBIDE TOOL 0o 0o 60o 6o 6-10o

c. Cutting f luid; Active cutting oil such as oil, cutting, sulfurized mineral, Specif ication VV-O283, Grade 1. 5-69. REAMING. Preparation of the hole to be reamed and the type of reamer used is the keynote to successful reaming operations. As with tapping operations, the hole to be reamed should be drilled with a sharp drill. A straight-f luted reamer can be used, but spiral-f luted reamers with carbide tips usually produce the best results. Speeds of 40-200 FPM and feeds of 0.005 to 0.008 inch are satisfactory; however, these factors depend on the size of the hole. Feeds should increase in proportion to the size of the hole. The removal of larger amounts lessens the degree of concentricity. If the degree of concentricity is an important factor, smaller amounts should be removed. 5-70. GRINDING. The essential requirements for grinding are the selection and use of grinding f luids and abrasive wheels. Grinding of titanium is different from grinding steel in that the abrasive grain of the wheel wears or is dissolved by a surface reaction, rather than wheel wear which is caused by breakage. To overcome this problem, lower wheel speeds and the use of aluminum oxide or sof t bonded silicone carbide wheels employing wet grinding methods are recommended. Recommended wheel speeds are; 1500-2000 SFPM and table feeds of 400 to 500 inches per minute with down feed of 0.001 inch maximum per pass and using 0.05 inch cross feed for highest grinding ratios.

5-66. TAPPING. Due to the galling and seizing that are characteristic of titanium, tapping is one of the more difficult machining operations. Chip removal is one of the problems that will require considerable attention in an effort to tap titanium. Another problem will be the smear of titanium. Build up from smear will cause the tap to freeze or bind in the hole. These problems can be alleviated to some extent by the use of an active cutting f luid such as sulphurized and chlorinated oil. 5-67. Power equipment should be used when possible and a hole to be tapped should be drilled with a sharp drill to prevent excessive hardening of the hole wall. In the attempt to tap titanium, difficulties involved can be minimized by reducing the thread to 55 or 65% from the standard 78%. 5-68. The following are procedures and material recommended for tapping titanium: a. Cutting speed: 40 to 50 FPM for unalloyed and 20 to 30 FPM for the alloy grades. b. Type of Tap: Gun or spiral point, 2 f luted in sizes 1/4-20 or 1ess; 3 f luted in sizes greater than 1/4-20.

5-19/(5-20 blank)

T.O. 1-1A-9

SECTION VI COPPER AND COPPER BASE ALLOYS

6-1. COPPER AND COPPER BASE ALLOYS. and has an electrical conductivity of 20%. Berryllium-coppers are widely used for tools where nonsparking qualities are desired. MANGANESE - Added primarily as a desulfurizing and de-gassifying element for alloys containing nickel. 6-4. CHEMICAL COMPOSITION. - The chemical composition of the copper alloys (listed by commercial trade name) is listed in table 6-1. 6-5. HEAT TREATMENT AND NOT WORKING TEMPERATURE OF COPPER ALLOYS. NOTE Additional Heat Treatment information is discussed in Section IX. 6-6. During production and fabrication, copper alloys may be heated for homogenizing, hot working, stress relief for solution treatment, and precipitation hardening. The temperatures commonly used for heating, hot working and annealing af ter cold working are given in table 6-2. 6-7. STRESS RELIEF OF COPPER ALLOYS.

6-2. Most of the commercial coppers are ref ined to a purity of 99.90%, minimum copper plus silver. The two principal copper base alloys are brass and bronze, containing zinc and tin respectively, as the major alloying element. Alloy designations for wrought copper and copper alloys are listed in table 6-1, with the corresponding specif ication and common trade names. 6-3. COPPER ALLOYING ELEMENTS. ZINC - Added to copper to form a series of alloys known as brasses. They are ductile, malleable, corrosion resistant and have colors ranging from pink to yellow. TIN - Added to copper to form a series of alloys known as bronzes. Bronzes are a quality spring material, and are strong, ductile and corrosion resistant. LEAD - Added to copper in amounts up to 1% to form a machinable, high-conductivity copper rod. It is added to brasses or bronzes in amounts of 0.5 to 4% to improve machinability and in the range of 2 -4% to improve bearing properties. ALUMINUM - Added to copper as a predominating alloy element to form a series known as aluminum bronzes. These alloys are of high strength and corrosion resistance. IRON - Added to copper along with aluminum in some aluminum bronzes and with manganese in some manganese bronzes. PHOSPHOROUS - Added to copper principally as a deoxidizer and in some bronzes to improve spring properties. NICKEL - Added to copper for higher strength without loss of ductility. They have excellent corrosion resistance. SILICON - Added to copper to form the copper silicon series having high corrosion resistance combined with strength and superior welding qualities. Small amounts are used as deoxidizers. BERYLLIUM - Added to copper to form a series of age hardenable alloys. In the fully treated condition, it is the strongest of the copper base alloys

6-8. Table 6-3 below gives a list of typical stress relief treatments commonly used in industry. This table is listed in terms of chemical composition percents, and should be used as representing average stress relieving temperatures. 6-9. MACHINING COPPER AND COPPER ALLOYS. Free cutting brass is one of the most easily machined metals and serves as a standard for machinability ratings of copper alloys. The following table gives the machinability ratings and recommended speeds and feeds for use with high speed steel tools. 6-10. WROUGHT-COPPER-BERYLLIUM ALLOYS. The beryllium copper alloys are frequently used due to their ability to respond to precipitation or age hardening treatments and other beneficial characteristics. Some of the characteristics are; good electrical and thermal conductivity, high strength hardness, corrosion resistance, good wear resistance, non-magnetic qualities and very good fatigue strength.

6-1

T.O. 1-1A-9

Table 6-1.

Chemical Composition by Trade Name

COPPER ALLOY NO. 101

SPECIFICATION FEDERAL QQ-A-673, type II QQ-C-502 QQ-C-576 QQ-W-343 WW-P-377 QQ-A-673 Type II QQ-C-502 QQ-C-825 QQ-C-576 QQ-R-571, Class FS-RCu-1 QQ-W-343 WW-T-799 QQ-C-502 QQ-C-825 QQ-C-502 QQ-C-825 QQ-A-673, Type I QQ-C-502 QQ-C-825 QQ-C-576 QQ-C-502 QQ-C-576 QQ-C-502 QQ-C-576 QQ-C-530 QQ-C-533 QQ-W-321, comp 1 QQ-W-321, comp 2 QQ-B-613, comp 4 QQ-B-626, comp 4 QQ-W-321 comp 3 WW-P-351 Grade A WW-T-791 Grade 1 MIL-W-85C MIL-W-6712 MIL-W-3318 MIL-W-6712 MILITARY MIL-W-85C TRADE NAME Oxygen free certif ied copper.

102

MIL-W-85C MIL-W-6712A

Oxygen free copper.

104 105 110

Oxygen free with silver. Oxygen free with silver. Electrolyte Tough pitch copper.

128 130 170 172 210 220 230

Fire ref ined tough pitch with silver. Fire ref ined tough pitch with silver. Beryllium Copper Gilding, 95% Commercial bronze, 90%

Red Brass, 85%

6-2

T.O. 1-1A-9

Table 6-1.

Chemical Composition by Trade Name - Continued

COPPER ALLOY NO. 240

SPECIFICATION FEDERAL QQ-B-591 QQ-B-613 comp 3 QQ-B-626 comp 3 QQ-B-650 comp D QQ-W-321 comp 4 QQ-B-613 comp 2 and 11 QQ-B-626 comp 2 and 11 QQ-B-650 comp C QQ-W-321 comp 6 MILITARY TRADE NAME Low Brass, 80%

JAN-W-472 *MIL-S-22499 MIL-T-6945 comp II MIL-T-20219 Cartridge brass, 70%

260

*Laminated Shim Stock 261 262 Same as 260 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-613 comp 1 and 11 QQ-B-626 comp 1 and 11 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-W-321 comp 7 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-W-321 comp 8 Yellow brass, 66% (Sheet)

268

270

Yellow brass, 65% (rod and wire)

274

Yellow brass 63%

6-3

T.O. 1-1A-9

Table 6-1.

Chemical Composition by Trade Name - Continued

COPPER ALLOY NO. 280

SPECIFICATION FEDERAL QQ-B-613 comp 11 QQ-B-626 comp 11 WW-P-351 Grade C WW-T-791 Grade 3 QQ-B-650 comp A QQ-B-613 comp 11 QQ-B-626 Comp 11 WW-P-351 Grade B WW-T-791 Grade 2 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-R-571, Class FS-RW-1 QQ-W-343 WW-P-377 QQ-C-502 QQ-C-825 QQ-C-576 QQ-W-343 QQ-C-502 QQ-C-825 QQ-C-576 QQ-C-502 QQ-C-825 QQ-C-576 QQ-C-502 QQ-C-576 WW-P-377 WW-T-797 WW-T-799 MIL-W-85C Electrolytic Touch pitch anneal resist copper MIL-T-6945 comp III MILITARY TRADE NAME Muntz metal, 60%

298 330

Brazing Alloy Low leaded brass

331

110

111

114

Tough pitch with silver

116

Tough pitch with silver

120

Phosphorous deoxidized low residual phosphorus copper

6-4

T.O. 1-1A-9

Table 6-1.

Chemical Composition by Trade Name - Continued

COPPER ALLOY NO. 121 122

SPECIFICATION FEDERAL QQ-C-502 QQ-C-576 QQ-A-674, Type III QQ-C-502 QQ-C-576 WW-P-377 WW-T-797 QQ-C-502 QQ-C-576 QQ-C-502 QQ-C-576 QQ-C-502 QQ-C-576 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-613 comp 11 and 24 QQ-B-626 comp 11 and 24 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-613 comp 11 QQ-B-626 comp 11 Fire ref ined tough pitch copper Fire ref ined tough pitch with silver High leaded brass Phosphorus deoxidized high residual phosphorus copper MILITARY TRADE NAME

122

123 125 127 332

340

Medium leaded brass 641/2%

335

Low leaded brass

342

High leaded brass 641/2%

344

347

348

6-5

T.O. 1-1A-9

Table 6-1.

Chemical Composition by Trade Name - Continued

COPPER ALLOY NO. 350

SPECIFICATION FEDERAL QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-613 comp 11 QQ-B-626 comp 11 and 22 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-613 comp 11 QQ-B-626 comp 11 and 22 QQ-B-626 comp 21 WW-T-756 WW-T-756 WW-T-756 QQ-B-626 comp 11 QQ-B-637 comp 4 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-637 comp 1 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-637 comp 1 MIL-W-6712 MIL-T-6945 comp 1 MIL-W-6712 MIL-T-6945 comp 1 Naval brass, arsenical MILITARY TRADE NAME Medium leaded brass 62%

353

Extra High leaded brass

356

Extra High leaded brass

370

Free cutting muntz metal

360

Free cutting brass

377 443 444 445 462

Forging brass Admiralty, Arsenical Admiralty, Antimonial Admiralty, Phosphorized Naval Brass, 631/2%

464

Naval Brass

465

6-6

T.O. 1-1A-9

Table 6-1.

Chemical Composition by Trade Name - Continued

COPPER ALLOY NO. 466

SPECIFICATION FEDERAL QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-637 comp 1 QQ-B-613 comp 11 QQ-B-626 comp 11 QQ-B-637 comp 1 QQ-R-571 Class FS-RWZn-1 QQ-B 650 comp B QQ-B-626 comp 11 QQ-B-637 comp 2 QQ-B-626 comp 1 QQ-B-637 comp 3 QQ-B-750 comp A QQ-W-401 QQ-R-571, class FS-RCuSm -2 QQ-R-571 Class FS-RCu Sm-2 QQ-R-571 Class FS-Rcu Sm-2 QQ-B-750 Comp D QQ-B-750 QQ-C-450 comp 3 QQ-C-450 comp 4 MIL-B-13501 MIL-W-6712 MIL-T-6945 comp 1 MIL-W-6712 MIL-T-6945 comp 1 MILITARY MIL-W-6712 MIL-T-6945 comp 1 MIL-W-6712 MIL-T-6945 Naval Brass, phosphorized TRADE NAME Naval Brass, antimonial

467

470 472 482

Naval brass, welding and brazing rod Brazing Alloy Naval Brass, medium leaded

485

Naval Brass, High leaded

510

Phosphor Bronze A

518

Phosphor bronze

521

Phosphor Bronze C

524 544 606 612

Phosphor Bronze D Phosphor Bronze B-2

6-7

T.O. 1-1A-9

Table 6-1.

Chemical Composition by Trade Name - Continued

COPPER ALLOY NO. 614 618

SPECIFICATION FEDERAL QQ-C-450 comp 5 MIL-W-6712 MIL-R-18818 MIL-RUA1-2 MIL-R-18818 class MIL-RCA-B QQ-C-591 comp B QQ-C-591 comp A QQ-R-571 Class FS-RCuS1 MIL-T-8231 MIL-E13191 class MIL-EcuSi-A MIL-E-13191 class MIL-ECuSi-A QQ-C-591 comp D QQ-B-728 Class B QQ-B-728 Class A QQ-R-571 Class FS-RCu-Zn-3 QQ-R-571 class FS-RCuZn-2 QQ-C-591 Comp E QQ-R-571 Class FS-RCuNi QQ-C-585 comp 6 QQ-C-585 comp 5 QQ-C-586 comp 5 QQ-W-340 comp 5 Nickel Silver 65-10 Manganese Bronze B Manganese Bronze A Bronze Low Fuming (Nickel) Bronze, Low Fuming Silicon Brass Copper Nickel 30% Low silicon bronze B MILITARY TRADE NAME Aluminum Bronze D

622 651 655 656

High Silicon Bronze A

658 661 670 675 680 681 692 715 735 745

6-8

T.O. 1-1A-9

Table 6-1.

Chemical Composition by Trade Name - Continued

COPPER ALLOY NO. 752

SPECIFICATION FEDERAL QQ-C-585 comp 1 QQ-C-586 comp 1 QQ-W-340 comp 1 QQ-C-586 comp 3 QQ-W-340 comp 3 QQ-C-585 comp 7 QQ-C-585 comp 2 QQ-C-586 comp 2 QQ-W-340 comp 2 QQ-C-586 comp 4 QQ-W-340 comp 4
Table 6-2. Hot Working and Annealing Temperatures for Copper and Wrought Copper Alloys

MILITARY

TRADE NAME Nickel Silver 65-18

764

766 770

Nickel Silver 55-18

794

COMMERCIAL DESIGNATION Copper, commercially pure Gilding Metal Commercial Bronze Red Brass Low Brass Cartridge Brass Yellow Brass Muntz Metal Leaded Commercial Bronze Low Leaded Brass Medium Leaded Brass

CHEMICAL COMPOSITION 99,93 Cu 95 Cu, 5 Zn 90 Cu, 10 Zn 85 Cu, 15 Zn 80 Cu, 20 Zn 70 Cu, 30 Zn 65 Cu, 35 Zn 60 Cu, 40 Zn 89 Cu, 9.25 Zn, 1.75 Pb 64.5 Cu, 35 Zn, 0.5 Pb 64.5 Cu, 34.5 Zn, 1 Pb

HOT WORKING TEMP oF 1300 to 1650 1300 to 1650 1400 to 1600 1450 to 1650 1450 to 1650 1350 to 1550 (a) 1150 to 1450 (a) (a) (a)

ANNEALING TEMP o F 700 to 1200 800 to 1450 800 to 1450 800 to 1350 800 to 1300 800 to 1300 800 to 1300 800 to 1100 800 to 1200 800 to 1300 800 to 1200

6-9

T.O. 1-1A-9

Table 6-2.

Hot Working and Annealing Temperatures for Copper and Wrought Copper Alloys - Continued

COMMERCIAL DESIGNATION High Leaded Brass Extra High Leaded Brass Free Cutting Brass Leaded Muntz Metal Free Cutting Muntz Metal Forging Brass Architectural Bronze Admiralty Naval Brass Leaded Naval Brass Manganese Bronze Aluminum Brass Phosphor Bronze A Phosphor Bronze C Phosphor Bronze D Phosphor Bronze E Cupro-Nickel 30% Nickel Silver 18% (A) Nickel Silver 18% (B) High-Silicon Bronze (A) Low Silicon Bronze (b)

CHEMICAL COMPOSITION 62.5 Cu, 35.75 Zn, 1.75 Pb 62.5 Cu, 35 Zn, 2.5 Pb 61. 5 Cu, 35.5 Zn, 3 Pb 60 Cu, 39.5 Zn, 5 Pb 60.5 Cu, 38.4 Zn, 1.1 Pb 60 Cu, 38 Zn, 2 Pb 57 Cu, 40 Zn, 3 Pb 71 Cu, 28 Zn, 1 Sn 60 Cu, 39.25 Zn, 0.75 Sn 60 Cu, 37.5 Zn, 1.75 Sn 58.5 Cu, 39.2 Zn 1 Sn, 3Mn, 1Fe 76.Cu, 22Zn, Z al 95 Cu, 5 Sn 92 Cu, 8 Sn 90 Cu, 10 Sn 98- 75 Cu, 1.25 Sn 70 Cu, 30 Ni 65 Cu, 17 Zn, 18 Ni 55 Cu, 27 Zn, 18 Ni 94.8 Cu, 3 Si, 1.5 Mn, 0.7 Zn 96. Cu, 2 Si, 1.5 Zn, 0.5 Mn

HOT WORKING TEMP oF (a) (a) 1300 to 1450 1150 to 1450 1150 to 1450 1200 to 1500 1200 to 1400 1200 to 1500 1200 to 1400 1200 to 1450

ANNEALING TEMP o F 800 to 1100 800 to 1100 800 to 1100 800 to 1100 800 to 1100 800 to 1100 800 to 1100 800 to 1100 800 to 1100 800 to 1100

1250 to 1450 1450 to 1550 (a) (a) (a) 1450 to 1600 1700 to 2000 (a) (a) 1300 to 1650 1300 to 1650

800 to 1100 800 to 1100 900 to 1250 900 to 1250 900 to 1250 900 to 1200 1200 to 1600 1100 to 1500 1100 to 1400 900 to 1300 900 to 1250

(a) These alloys are usually hot extruded af ter casting, further hot working is uncommon. 6-11. Typical Engineering properties of alloys 170, Specif ication QQ-C-530 and 172, Specif ication QQ-C-533 are cited in Table 6-5. 6-12. HEAT TREATING PROCEDURES AND EQUIPMENT REQUIREMENTS.

6-10

T.O. 1-1A-9

NOTE SAE-AMS-H-7199, Heat Treatment of Wrought Copper-Beryllium Alloys, Process for (Copper Alloy numbers 170, 172 and 175), will be the control document for heat treatment of wrought copper-beryllium alloy, numbers 170, 172 and 175. For complete description of heat treat requirements for these alloys, refer to the latest issue of SAE-AMS-H-7199. 6-13. Furnaces for solution heat treating of copper-beryllium items/parts may be heated by electricity, gas or oil, with either controlled gas atmosphere or air (static or forced), used in the chamber, continuous or induction types. Molten salt baths shall not be used because of corrosive attack of beryllium alloys by the molten salts at solution heat treatment temperatures. Air atmosphere furnaces shall not be used when the loss of material due to excessive scaling is detrimental to the f inished part. 6-14. The furnace alloy shall be capable of maintaining a temperature in working zone with a normal load, of 20oF for solution heat treatment, or 5oF for aging, or precipitation heat treatment. In addition, the temperature in working zone shall not vary above the maximum or below the minimum specif ied for the alloy being treated, during the holding portion of the treatment cycles (See Table 6-6). 6-15. SOLUTION HEAT TREATMENT COPPER-BERYLLIUM. Normally solution heat treatment is not required because the material is furnished in a condition suitable for accomplishing
Table 6-3.

forming operations and then precipitation heat treating. An exception is when the material has been rendered unsuitable for precipitation or age hardening as result of welding, brazing or other fabrication operations or when, cold working requirements demand intermediate sof tening (annealing) treatment. 6-16. The solution heat treatment temperatures for alloys 170 and 172 shall be 1425o to 1460oF. The time the material is held at the temperature will determine the potential properties of the material. Insuff icient time will make it impossible to achieve maximum strength af ter precipitation hardening, while excessive time may cause grain growth with attendant harmful possibilities. Once the parts are brought up to temperature it is recommended that material be held at temperature for 1 hour per inch of thickness. For parts less than 1/2 inch in thickness, 1/6-1/2 hour may be suff icient. Test sample should be used to determine specif ic time or if laboratory facilities are available an examination of microstructure will conf irm the adequacy of the time selected. The part/material should be rapidly (10 seconds or under) quenched in water from the annealing temperature. An agitated quench should be used. Some oxidation will occur as a result of the annealing temperatures and it should be removed by pickling or other suitable cleaning process. 6-17. PRECIPITATION OR AGE HARDENING. Appreciable changes can be produced in both mechanical and physical by this treatment. The actual changes can be controlled by the time and temperature of hardening. Table 6-6 gives times and temperatures for obtaining various tempers.

Typical Stress-Relief Treatments for Certain Copper Alloys

ALLOY COMPOSITION Copper, commercially pure 90 Cu - 10 Zn 80 Cu - 20 ZN 70 Cu - 30 ZN 63 CU - 37 ZN 60 CU - 40 ZN 70 Cu - 29 ZN - 1 SN 85 Cu - 15 Ni 70 Cu - 30 Ni 64 Cu - 18 ZN - 18 Ni 95 Cu - 5 Sn 90 Cu - 10 Sn

TEMP oF 300 400 500 500 475 375 575 475 475 475 375 375

TIME, HOURS 1/2 1 1 1 1 1/2 1 1 1 1 1 1

Change 4

6-11

T.O. 1-1A-9

Table 6-4.

Standard Machinability Rating of Copper Alloys

ALLOY DESIGNATION

MACHINABILITY RATING 80 80 60 70 90 100 80 70 90 30 30 40 30 30 50 50 30 60 60 20 20 20 20 20 20 20 20

SURFACE SPEED FEET PER MINUTE 300 300 300 300 300 300 300 300 300 300 150 150 150 150 150 to to to to to to to to to to to to to to to 700 700 700 700 700 700 700 700 700 700 300 300 300 300 300

ROUGHING FEED, INCH

FINISHING FEED, INCH

Leaded Copper Leaded Commercial Bronze Low Leaded Brass Medium Leaded Brass High Leaded Brass Free Cutting Brass* Forging Brass Leaded Naval Brass Architectural Bronze Red Brass, 85% Low Brass, 80% Muntz Metal Naval Brass Manganese Bronze (A) Leaded Nickel Silver, 12% Leaded Nickel Silver 18% High Silicon Bronze (A) Leaded Silicon Bronze (d) Aluminum Silicon Bronze Electrolytic Tough pitch copper Commercial Bronze Phosphor Bronze Nickel Silver Cupro-Nickel Aluminum Bronze Beryllium Copper Chromium Copper

0.006 0.006 0.006 0.006 0.006 0.006 0.006 0.006 0.006 0.006 0.015 0.015 0.015 0.015 0.015

to to to to to to to to to to to to to to to

0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.035 0.035 0.035 0.035 0.035

0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.005 0.005 0.005 0.005 0.005

to to to to to to to to to to to to to to to

0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015

150 to 300 150 to 300 150 to 300 150 to 300 150 to 300 75 75 75 75 75 75 75 75 to to to to to to to to 150 150 150 150 150 150 150 150

0.015 to 0.035 0.015 to 0.035 0.015 to 0.035 0.015 to 0.035 0.015 to 0.035 0.015 0.015 0.015 0.015 0.015 0.015 0.015 0.015 to to to to to to to to 0.040 0.040 0.040 0.040 0.040 0.040 0.040 0.040

0.005 to 0.015 0.005 to 0.015 0.005 to 0.015 0.005 to 0.015 0.005 to 0.015 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.005 to to to to to to to to 0.020 0.020 0.020 0.020 0.020 0.020 0.020 0.020

* Table based on machining characteristics in comparison to this alloy.

6-12

T.O. 1-1A-9

Table 6-5.

Typical Engineering Properties

TENSILE STRENGTH KSI

YIELD STRENGTH 0.2% OFFSET

% ELONGATION IN 2 INCHES

FATIGUE (1) STRENGTH KSI

ROCKWELL HARDNESS

ELECTRICAL CONDUCTIVITY % OF 1 ACS 17-19 16-18 15-17 15-17 22-25 22-25 22-25 22-25

A- Annealed 1/4 Hard 1/2 Hard Hard AT 1/4 HT 1/2 HT HT

60-78 75-88 85-100 100-120 165-190 175-200 785-210 190-215

28-36,000 60-80,000 55-70,000 90-112,000 100-125,000 110-135,000 160-195,000 165-205,000

35-60 10-35 5-25 2-8 4-10 3-6 2-5 1-4

30-35 31-36 32-38 35-39 34-38 35-39 39-43 41-46

B45- 78 B68-90 B88-96 B96-102 C36-MIN C38-MIN C39-MIN C40-MIN

(1) Based on 100,000,000 load cycles.

Table 6-6. Age Hardening Time-Temperature Conditions and Material Temper Designations

MATERIAL FORM

TEMPER DESIGNATION BEFORE AGE HARDENING A 1/4 H 1/2 H H A H H

AGE HARDENING TIME TEMP HRS. (oF) 3 2-1/2 2 2 3 2 3 600 600 600 600 5 5 5 5

TEMPER DESIGNATION AFTER AGE HARDENING

Plate, Sheet or Strip Forgings Rod and Bar 3/4 Inch or Less Over 3/4 Inch Wire

AT 1/4 HT 1/2 HT HT AT HT HT

600 5 600 5 600 5

A 1/4 H 1/2 H 3/4 H

3 2 1-1/2 1

600 600 600 600

5 5 5 5

AT 1/4 HT 1/2 HT 3/4 HT

NOTE: For additional data see Specification SAE-AMS-H-7199.

Change 4

6-13/(6-14 blank)

T.O. 1-1A-9

SECTION VII TOOL STEELS

7-1. GENERAL. acts as an intensif ier. It improves the deep hardening and elevated temperature properties of steel. f. NICKEL - Nickel makes the steel more ductile. It is used in only a few applications and only in small amounts. g. SILICON - This element is present in all steels. In amounts of 1/4 to 1% it acts as a deoxidizer. Silicon is added to shock resisting and hot work steels to improve their impact characteristics and hardenability. It has a graphitizing inf luence and usually requires the addition of carbide stabilizing elements such as molybdenum and chromium. h. TUNGSTEN - One of the most important features of tungsten steels is their high red hardness. Tungsten steels are f ine grained and high strength, which means they hold good cutting edges. Tungsten content is usually 5 - 12% in heat resisting tool steels, 4 - 9% in tungsten - molybdenum high speed steels, and 14 - 20% in straight tungsten high speed steel. i. VANADIUM - This element forms stable carbides and has considerable effect on the hardenability of steels. Undissolved vanadium carbides inhibit grain growth and reduce hardenability. Dissolved carbides increase hardenability. Vanadium is also used as a deoxidizer. It is added to plain carbon tool steels to make them f ine grained and tough. It is added to high speed and hot working steels to resist grain growth and help maintain their hardness at elevated temperatures. 7-5. SPECIFICATIONS. The armed services procure tool steels under three different Federal Specifications, dependent upon its intended use. Table 7-1 lists these specif ications, and present and past classif ication of the tool steels. Army Specification 57-108A was superseded by three Army Ordnance Specif ications, QQ-S-778, QQ-S779, and QQ-S-780. which were then superseded by Federal Specif ications QQ-T-570, QQ-T-580 and QQ-T-590 respectively.

7-2. Tool steels are essential to the fabrication of aircraft parts. It is therefore necessary to provide guidance in the handling of these important metals. 7-3. Tool steels are produced and used in a variety of forms. The more common forms are bars, (round, square, hexagonal, or octaganal), drill rods, (round, square, or rectangular), f lats, and forged shapes. 7-4. ALLOYING ELEMENTS IN TOOL STEELS. (See Table 7-2, chemical composition table.) a. CARBON - Carbon is the most important single element in tool steel. Changing the carbon content a specif ic amount will change the physical properties a greater degree than the same amount of any other element. Degree of hardness of tool steel quenched from a suitable temperature is a function of carbon content alone. b. CHROMIUM - In amounts up to 1.80% the addition of chromium produced a marked increase in the hardenability (depth of hardness) of steels. Small amounts of chromium toughens the steel (greater impact strength), and increases its strength. Machine ability decreases as chromium increases. The addition of 5 to 15% chromium imparts hardening qualities to the steel. A degree of red hardness and resistance to wear and abrasion results from the addition of chromium to steel. c. COBALT - Cobalt is sometimes used in high speed tools. Addition of 5 to 8% increase the red hardness of these steels. d. MANGANESE - This element is present in all steels. In amounts of less than 1/2%, it acts as a deoxidizer and desulfurizer. In amounts greater than 15% it gives steel air hardening tendencies. In intermediate amounts it is necessary to have other alloying agents present with manganese because of its tendency to make the steel brittle. e. MOLYBDENUM - Always used in conjunction with other alloying elements, molybdenum

7-1

T.O. 1-1A-9

D - High carbon-high chromium types H - Hot work tool steels T - High speed tool steels M - Molybdenum Base types L - Special purpose, low alloy types F - Carbon tungsten tool steels Table 7-1. Tool Steel Specifications

SAE DESIGNATION

FEDERAL SPECIFICATION NUMBER CLASS W1-08 W1-09 W1-10 W1-12 W2-09 W2-10 W3-10 A2 A6 D2 D3 D5 D7 F3 H11 H12 H13 H21 T1 T2 T3 T4 T5 T6 T7 T8 M1 M2 M3 M4 M-10 M15 M30 M34 01 02 06 L6 L7 T15 S1 S2 S5 W5

SUPERSEDED SPECIFICATION NUMBER 57-108A 57-108A 57-108A 57-108A 57-108A 57-108A QQ-S-00779 (Army) 57-108A -----57-108A 57-108A QQ-S-00778 (Army) -----57-108A -----QQ-S-00778 (Army) -----QQ-S-00778 (Army) QQ-S-00780 (Army) QQ-S-00780 (Army) -----QQ-S-00780 (Army) QQ-S-00780 (Army) MIL-S-15046 (Ships) QQ-S-00780 (Army) QQ-S-00780 (Army) QQ-S-00780 (Army) QQ-S-00780 (Army) QQ-S-00780 (Army) -----57-108A -----57-108A QQ-S-00780 (Army) 57-108A.QQ-T-778 57-108A ----------QQ-S-00778 (Army) -----QQ-S-00778 (Army) QQ-S-00778 (Army) QQ-S-00778 (Army) QQ-S-00778 (Army) CLASSIFICATION A1 A2 A3 A4/A5 B1 B1 FS-W3-10 C1 -----C2 C3 FS-D5 -----D1 -----FS-H12 -----FS-H21 FS-T1 FS-T2 FS-T4 FS-T5 T6 FS-T7 FS-T8 FS-M1 FS-M2 FS-M3 -----F1 -----F3 FS-M34 B4 B3 ----------FS-L7 -----FS-S1 FS-S2 FS-S5 FS-W5

W1-.80 Carbon W1-.90 Carbon W1-1.0 Carbon W1-1.2 Carbon W2-.9 Carbon V W2-1.0 Carbon V W3-1.0 Carbon VV A2 A6 D2 D3 D5 D7 F3 H11 H12 H13 H21 T1 T2 T3 T4 T5 T6 T7 T8 M1 M2 M3 M4 M10 M15 M30 M34 01 02 06 L6 L7 T15 S1 S2 S5 W5

QQ-T-580 QQ-T-580 QQ-T-580 QQ-T-580 QQ-T-580 QQ-T-580 QQ-T-580 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-590 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-590 QQ-T-570 QQ-T-570 QQ-T-570 QQ-T-570

7-2

Table 7-2.

Chemical Composition, Tool Steel

SAE DESIGNATION W1-.80 Carbon W1-.90 Carbon W1-1.00 Carbon W1-1.20 Carbon W2-.90 Carbon-V W2-1.00 Carbon-V W3-1.00 Carbon VV A2-5% Chromium A6-Maganese D2 D3 D5 D7 F3 H11 H12 H-13 H21 T1 T2 T3 T4

C 0.70-0.85 0.85-0.95 0.95-1.10 1.10-1.30 0.85-0.95 0.95-1.10 0.95-1.10 0.95-1.05 0.65-0.75 1.40-1.60 2.00-2.35 1.40-1.60 2.15-2.50 1.25-1.40 0.30-0.40 0.30-0.40 0.30-0.40 0.30-0.40 0.65-0.75 0.75-0.85 1.00-1.10 0.70-0.80

MN 0.15-0.35 0.15-0.35 0.15-0.35 0.15-0.35 0.15-0.35 0.15-0.35 0.15-0.35 0.45-0.75 1.80-2.20 0.30-0.50 0.24-0.45 0.30-0.50 0.30-0.50 0.20-0.50 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40

SI 0.10-0.35 0.10-0.35 0.10-0.35 0.10-0.35 0.10-0.35 0.10-0.35 0.10-0.35 0.20-0.40 0.20-0.40 0.30-0.50 0.25-0.45 0.30-0.50 0.30-0.50 0.60-0.90 0.80-1.20 0.80-1.20 0.80-1.20 0.15-0.30 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40

CHEMICAL C0MPOSITION, PERCENT (TABLE II) CR V MO W 0.15 0.15 0.15 0.15 0.15 0.15 0.15 4.755.50 0.901.20 11.013.0 11.0 13.0 11.0 13.0 11.5 13.5 0.80 0.80 0.80 2.8-4.4 0.25 max 4.75 5.50 4.755.50 4.755.50 3.00 3.75 3.75-4.50 3.75-4.50 3.75-4.50 3.75-4.50 0.30-0.50 0.50 max 0.80-1.20 0.30-0.50 0.90-1.30 1.80-2.40 2.90-3.50 0.80-1.20 0.70-1.00 0.70-1.00 0.10-1.00 1.25-1.75 1.25-1.75 1.25-1.75 8.75 10.00 17.25-18.75 17.50-19.00 17.50-19.00 17.25-18.75 1.0-1.7 0.10 0.10 0.10 0.10 0.15-0.35 0.15-0.35 0.35-0.50 .40 0.10 0.10 0.90-1.40 0.90-1.40 0.70-1.20 0.80 0.70-1.20 0.70-1.20 3.00 4.50 0.15 0.15 0.15 0.10 0.10 0.10 0.10 0.15 0.15 0.15 0.15

CO

NI 0.20 0.20 0.20 0.20 0.20 0.20 0.20

CU 0.20 0.20 0.20 0.20 0.20 0.20 0.20

P 0.025 0.025 0.025 0.025 0.030 0.030 0.030

0.60

2.5-3.5

T.O. 1-1A-9

4.25 5.75

7-3

7-4
SAE DESIGNATION T5 T6 T7 T8 M1 M2 M3 M4 M10 M15 M30 M34 01 02 06 L6 L7 T15 S1 S2 S5 W5 C 0.75-0.85 0.75-0.85 0.70-0.76 0.75-0.85 0.75-0.85 0.78-0.88 1.00-1.25 1.25-1.40 0.85-0.95 1.50-1.60 0.77-0.85 0.85-0.92 0.85-0.95 0.85-0.95 1.35-1.55 0.65-0.75 0.95-1.05 1.50-1.60 0.45-0.55 0.45-0.55 0.50-0.60 1.05-1.25 MN 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.30 1.00-1.30 1.40-1.80 0.30-1.00 0.30-0.80 0.25-0.45 0.20-0.40 0.30-0.50 0.60-0.90 0.15-0.35

T.O. 1-1A-9

Table 7-2.

Chemical Composition, Tool Steel - Continued

SI 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.40 0.20-0.30 0.20-0.40 0.20-0.40 0.80-1.20 0.20-0.40 0.20-0.40 0.25-0.45 0.80-1.20 1.80-2.20 0.10-0.40

CHEMICAL C0MPOSITION, PERCENT (TABLE II) CR V MO W 3.75-4.75 4.00-4.75 3.75-4.25 3.75-4.50 3.75-4.50 3.75-4.50 3.75-4.50 4.00-4.75 3.75-4.50 4.00-5.00 3.50-4.25 3.50-4.25 0.40-0.60 0.35 1.80-2.40 1.50-2.10 1.80-2.20 1.80-2.40 0.90-1.30 1.60-2.20 2.35-3.25 3.90-4.50 1.80-2.20 4.50-5.25 1.00-1.40 1.90-2.30 0.30 max 0.20 0.30 0.20-0.30 0.65-0.85 1.25-1.75 3.75-4.50 1.25-1.75 0.20-0.35 0.20-0.35 0.30-0.50 4.75-5.25 0.15-0.30 0.25 0.30 0.40-0.60 0.25 0.25 max 0.40 0.40-0.60 0.30-0.50 0.30-0.50 12.00-13.00 1.0-3.0 0.70-1.00 0.70-1.00 0.70-1.00 0.70-1.00 7.75-9.25 4.50-5.50 4.75-6.25 4.50-5.50 7.75-9.00 2.75-3.50 7.75-9.00 8.00-9.20 6.00-6.75 1.30-2.30 1.30-2.30 0.40-0.60 17.50-19.00 18.50-21.25 13.50-14.50 13.25-14.75 1.15-1.85 5.50-6.75 5.50-6.75 5.25-6.50

CO 7.00 9.50 10.25 13.75 4.255.75

NI

CU

4.755.25 4.505.50 1.75 8.75

1.25 1.75 4.75-5.25

T.O. 1-1A-9

Table 7-3.

Tool Steel Selection

MATERIAL TO BE CUT Aluminum, copper and magnesium alloys Carbon and alloy steels, ferritic stainless Stainless steel, austenitic Spring steel, hardened, Rockwell C52max Electrical sheet, transformer grade Paper, gaskets, and similar sof t material Plastic sheet, not reinforced

TOTAL QUANTITY OF PARTS TO BE MADE 1,000 10,000 100,000 W1, AIS14140 W1, AIS14140 W1, A2 A2 A2 W1 01 W1, 01, A2 W1, 01, A2 W1, A2, D2 A2, D2 A2, D2 W1 01 01, A2 01, A2 A2, D2 D2 D2 W1, A2 01, A2

Table 7-3 is listed for use as a guide reference in the selection of tool steel types for specif ic applications.
Table 7-4. Tool Steel Hardening and Tempering Temperatures

STEEL

HARDENING TREATMENT 1450oF, Water 1450 F, Oil 1550 F, Oil 1600 F, Oil 1750oF, Oil 1775 F, Oil 1875 F, Oil 2350 F, Oil 2225oF, Oil
o o o o o o

TEMPERING TREATMENT 300oF 300 F 300 F 300 F 500oF 500 F 500 F 1050 F 1025oF
o o o o o o

SIZE CHANGE, IN/IN

W O L F S A D T M 7-6.

0.0017 - 0.0025 0.0014 - 0.0021 0.0014 - 0.0024 0.0011 - 0.0021 0.0010 - 0.0025 0.0005 - 0.0015 0.0005 - 0.0005 0.0006 - 0.0014 0.0016 - 0.0024

CLASS DESIGNATIONS.

W - Water hardening tool steels S - Shock resisting tool steels O - Cold work tool steels, oil hardening types A - Cold work tool steels, air hardening types 7-7. APPLICATIONS OF TOOL STEELS.

cutting tools require high hardness, high resistance to the sof tening effect of heat, and high wear resistance. Shearing tools require high wear resistance and fair toughness. Forming tools must possess high wear resistance or high toughness and strength. In battering tools, high toughness is most important. 7-9. SELECTION OF MATERIAL FOR A CUTTING TOOL. The selection of material for a cutting tool depends on several factors: the metal being machined, nature of cutting operation, condition of the machine tool, machining practice, size and design of tool, coolant to be used, and cost of tool material. Selection is usually based more on previous experience or applications than on an engineering or metallurgical analysis.

7-8. The majority of tool steel applications can be divided into a small number of groups: cutting, shearing, forming, drawing, extrusion, rolling and battering. Cutting tools include drills, taps, broaches, hobs, lathe tools, etc. Shearing tools include shears, blanking and trimming dies, punches, etc. Forming tools include draw, forging, cold heading and die casting dies. Battering tools include chisels and all forms of shock tools. Most

7-5

T.O. 1-1A-9

7-10. High speed cutting tools are usually manufactured from the class T or class M alloys. Four classes, T1, M1, M2 and M10 make up nearly 90% of the general purpose high speed steels. Certain special purpose steels in each class, such as T6, T7, T8 and T15 are advantageous for operations like milling cutters and prehardened forging die blocks. 7-11. High speed drills should possess high strength and toughness, notably M1, M2, M10 and T1. Classes T1 and M1 are used for tools subject to shock, while M2 and M10 are generally used where tools require less toughness and more abrasion resistance. 7-12. Material for reamers should be of high hardness and abrasion resistance, such as M1, M2, M10 and T1. The M3 and M15 and T15 classes possess greater abrasion resistance than the lowervanadium grades. 7-13. Material for taps is generally of the M1, M2 or M10 types. In tapping heat-resisting alloys or steels harder than Rockwell C35, M15 or T15 may be justif ied. 7-14. Milling cutters are usually made from the high speed steels. As the hardness of the workpiece increases beyond Rockwell C35, the cobalt high speed steels should be used. 7-15. Recommended punch and die material for blanking parts from 0.050 inch sheet materials are shown in following table. This table does not cover all operations, and is a sample table intended for use as a guide only. 7-16. HEAT TREAT DATA.

NOTE Additional Heat Treatment information is discussed in Section IX. 7-17. The thermal treatments listed in table 7-5 cover the generally used treatments for the forgings, normalizing, and annealing of tool and die steels. The thermal treatments listed in table 7-7 cover the usual ranges of temperatures for hardening and tempering tool and die steels. These tables are listed for use as a guide only, and test samples should be checked prior to use. 7-18. DISTORTION IN TOOL STEELS. Distortion is a general term encompassing all dimensional changes; the two main types being volume change or change in geometrical form. Volume change is def ined as expansion or contraction and geometric change is def ined as changes in curvature or angular relations. Table 7-4 shows an approximate range of size changes depending upon the type of tool steel, and also dependent on specif ic tempering and heat treatments. If a very close tolerance is required for a f inished tool, specif ic data covering this item should be obtained from a detailed source. 7-19. 7-20. 7-21. 7-22. 7-23. Deleted Deleted Deleted Deleted Deleted

7-6

Change 1

Table 7-5.

Forging, Normalizing and Annealing Treatments of Tool and Die Steels

FORGING/a SAE DESIGNATION W1 (0.8C) HEAT SLOWLY TO 1450 START FORGING AT 1800 1950 1800 1950 1800 1900 1800 1900 1800 1900 1800 1900 1800 1900 1850 2000 DO NOT FORGE BELOW 1500

NORMALIZING/b HEAT SLOWLY TO 1450 HOLD AT TEMPERATURE

ANNEALING/c MAX RATE OF COOLING F/HR 75 BRINELL HARDNESS APPROX. 159-202 ROCKWELL B, APPROX. 84-94

1500

1400-1450

W1 (0.9C)

1450

1500

1450

1500

1375-1425

75

159-202

84-94

W1 (1.0C)

1450

1500

1450

1550

1400-1450

75

159-202

84-94

W1 (1.2C)

1450

1500

1450

1625

1400-1450

75

159-202

84-94

W2 (0.9C)

1450

1500

1450

1500

1375-1425

75

159-202

84-94

W2 (1.0C)

1450

1500

1450

1550

1400-1450

75

159-202

84-94

W3 (1.0C)

1450

1500

1450

1550

1400-1450

75

159-202

84-94

A2

1600

1650

DO NOT NORMALIZE

1550-1600

40

202-229

94-98

A6 D2

1200-1300 1650 1850 2000 1850 2000 1850 2000 2050 2125 1800 2000 1650

DO NOT NORMALIZE DO NOT NORMALIZE 1600-1650 40

248 207-255

102 95-102

D3

1650

1650

DO NOT NORMALIZE

1600-1650

50

212-255

96-102

D5

1650

1650

DO NOT NORMALIZE

1600-1650

40

207-255

95-102

Change 1 7-7

D7

1650

1800

DO NOT NORMALIZE

1600-1650

50

235-262

99-103

T.O. 1-1A-9

F3

1550

1600

DO NOT NORMALIZE

1475

50

235

99

7-8 Change 1

T.O. 1-1A-9

Table 7-5.

Forging, Normalizing and Annealing Treatments of Tool and Die Steels - Continued

FORGING/a SAE DESIGNATION HEAT SLOWLY TO START FORGING AT DO NOT FORGE BELOW

NORMALIZING/b HEAT SLOWLY TO HOLD AT TEMPERATURE

ANNEALING/c MAX RATE OF COOLING F/HR BRINELL HARDNESS APPROX. ROCKWELL B, APPROX.

H11

1650

1950 2100 1950 2100 1950 2100 2000 2150 1950 2100 2000 2150 2025 2000 2150 2000 2150 1950 2150 1950 2150 2000 2150 1900 2050 1950 2100

1650

DO NOT NORMALIZE

1550-1600

50

192-229

92-98

H12

1650

1650

DO NOT NORMALIZE

1600-1650

50

192-229

92-98

H13

1650

1650

DO NOT NORMALIZE

1550-1600

50

192-229

92-98

H21

1600

1650

DO NOT NORMALIZE

1600-1650

50

202-235

94-99

T1

1600

1750

DO NOT NORMALIZE

1600-1650

50

217-255

96-102

T2

1600

1750

DO NOT NORMALIZE

1600-1650

50

223-255

97-102

T3 T4

1925 1600

1750 1750

DO NOT NORMALIZE DO NOT NORMALIZE

1650 1600-1650

50 50 229-255 98-102

T5

1600

1800

DO NOT NORMALIZE

1600-1650

50

248-293

102-106

T6

1600

1700

DO NOT NORMALIZE

1600-1650

50

248-293

102-106

T7

1600

1700

DO NOT NORMALIZE

1550-1625

50

217-250

96-102

T8

1600

1750

DO NOT NORMALIZE

1600-1650

50

229-255

98-102

M1

1500

1700

DO NOT NORMALIZE

1525-1600

50

207-248

95-102

M2

1500

1700

DO NOT NORMALIZE

1550-1625

50

217-248

96-102

Table 7-5.

Forging, Normalizing and Annealing Treatments of Tool and Die Steels - Continued

FORGING/a SAE DESIGNATION HEAT SLOWLY TO START FORGING AT DO NOT FORGE BELOW

NORMALIZING/b HEAT SLOWLY TO HOLD AT TEMPERATURE

ANNEALING/c MAX RATE OF COOLING F/HR BRINELL HARDNESS APPROX. ROCKWELL B, APPROX.

M3

1500

2000 2150 2000 2150 1900 2100 1900 2100 1900 2100 1900 2100 1750 1900 1750 1900 1750 1900 1800 2000 1800 2000 2000 2100 1800 2000

1700

DO NOT NORMALIZE

1550-1625

50

223-255

97-102

M4

1500

1700

DO NOT NORMALIZE

1550-1625

50

229-255

98-102

M10

1400

1700

DO NOT NORMALIZE

1600-1650

50

235-262

99-103

M15

1400

1700

DO NOT NORMALIZE

1600-1650

50

235-262

99-103

M30

1400

1600

DO NOT NORMALIZE

1600-1650

50

235-262

99-103

M34

1400

1600

DO NOT NORMALIZE

1600-1650

50

235-262

99-103

01

1500

1550

1500

1600

1425-1475

50

183-212

90-96

02

1500

1550

1500

1550

1375-1425

50

183-212

90-96

06

1500

1500

1500

1625

1425-1275

50

183-212

90-96

L6

1500

1600

1550

1650

1400-1450

50

183-212

90-96

L7

1500

1550

1550

1650

1450-1500

50

174-212

88-96

T15

1500

1600

DO NOT NORMALIZE

1600-1650

35

241-269

100-104

Change 1 7-9

T.O. 1-1A-9

S1

1500

1600

DO NOT NORMALIZE

1450-1500

50

192-235

92-99

7-10 Change 1

T.O. 1-1A-9

Table 7-5.

Forging, Normalizing and Annealing Treatments of Tool and Die Steels - Continued

FORGING/a SAE DESIGNATION S2 HEAT SLOWLY TO 1500 START FORGING AT 1900 2100 1900 2050 1700 1900 DO NOT FORGE BELOW 1600

NORMALIZING/b HEAT SLOWLY TO 1500HOLD AT TEMPERATURE 1400-1450

ANNEALING/c MAX RATE OF COOLING F/HR 50 BRINELL HARDNESS APPROX. 192-229 ROCKWELL B, APPROX. 92-98

1650

S5

1500

1600

1500

1600

1400-1450

50

192-229

92-98

W5

1200

1500

DO NOT NORMALIZE

1400-1425

50

192-212

92-96

a. The temperature at which to start forging is given as a range, the higher side of which should be used for large sections and heavy or rapid reductions, and the lower side for smaller sections and lighter reductions, as the alloy content of the steel increases, the time of soaking at forging temperature increases proportionately. Likewise, as the alloy content increases, it becomes more necessary to cool slowly from the forging temperature. With the very high alloy steels, such as high speed or air hardening steels, this slow cooling is imperative in order to prevent cracking and to leave the steel in a semi-soft condition. Either furnace cooling or burying in an insulating medium such as lime, mica, or silocel is satisfactory.

b. The length of time the steel is held af ter being uniformly heated through at the normalizing temperature, varies from about 15 minutes for a small section to about 1 hour for larger sizes. Cooling from the normalizing temperatures is done in still air. The purpose of normalizing af ter forging is to ref ine the grain structure and to produce a uniform structure throughout the forging. Normalizing should not be confused with low temperature (about 1200F) annealing used for the relief of redisual stresses resulting from heavy machining, bending and forming.

c. The annealing temperature is given as a range, the upper limit of which should be used for large sections, and the lower limit for smaller sections. The temperature varies from about 1 hour for light sections and small furnace charges of carbon or low alloy steel, to about 4 hours for heavy sections and large furnace charges of high alloy steel.

Table 7-6.

Thermal Treatment for Hardening and Tempering Tool Steel - General

CLASS W1-08 W1-09 W1-10 W1-12 W2-09 W2-10 W3-10 A2 A6 D2 D3 D5 D7 F3 H-11 H12 H13 H21 T1 T2 T3 T4 T5

QUENCH MEDIUM Water Water Water Water Water Water Water Air Air Air Oil Air Air Water Air Oil-Air Air Oil-Air Oil-AirSalt Oil-AirSalt Oil-Air Oil-AirSalt Oil-AirSalt

PREHEAT TEMPERATURE F -a -a -a -a -a -a -a 1200-1300 1200-1300 1200-1300 1200-1300 1200-1300 1200-1300 -a 1450-1500 1450-1500 1400-1450 1500-1550 1500-1550 1500-1550 1500-1550 1500-1550 1500-1550

HARDENING TEMPERATURE RANGE F 1420-1450 1420-1450 1420-1450 1420-1500 1420-1500 1420-1500 1420-1500 1725-1775 1525-1600 1800-1875 1750-1800 1800-1875 1850-1950 1550 1825-1875 1800-1900 1825-1575 2100-2150 2300-2375 2300-2375 2275-2325 2300-2375 2300-2400

HARDNESS AFTER QUENCHING ROCKWELL C 65-67 65-67 65-67 65-67 65-67 65-67 65-67 61-63 60 61-63 62-64 60-62 63-65 62-66 53-55 53-55 53-55 50-52 63-65 63-65

TEMPERING TEMPERATURE RANGE F 350-525 350-525 350-525 350-525 350-525 350-525 350-525 400-700

HARDNESS AFTER TEMPERING ROCKWELL C 65-56 65-56 65-56 65-56 65-56 65-56 65-56 60-57

DECARBURIZATION (PREVENTION OF DURING HEAT TREATMENT) -b -b -b -b -b -b -b -c

400-700 400-700 400-700 300-500 850-1000 300-500 1000-1100 1000-1100 1000-1100 950-1150 1025-1100 1025-1100 1000-1050

60-58 62-58 59-57 65-63 62-58 66-62 51-43 51-43 51-43 50-47 65-63 63-65 67-60 65-63 65-63

-c -c -c -c -c -c -c -c -c -c -c -c -c -c

63-65 63-65

1026-1100 1050-1100

T.O. 1-1A-9

7-11

7-12
CLASS T6 T7 T8 M1 M2 M3 M4 M10 M15 M30 M34 01 02 06 L6 L7 T15 S1 QUENCH MEDIUM Oil Oil Oil-AirSalt Oil-AirSalt Oil-AirSalt Oil-AirSalt Oil-AirSalt Oil Oil Oil Oil Oil Oil Oil Oil Oil Oil-Air Oil -a -a -a -a -a

T.O. 1-1A-9

Table 7-6.

Thermal Treatment for Hardening and Tempering Tool Steel - General - Continued

PREHEAT TEMPERATURE F 1600 1600 1500-1550 1400-1500 1450-1500 1450-1500 1450-1500 1400 1400 1400 1400

HARDENING TEMPERATURE RANGE F 2350 2325 2300-2375 2150-2250 2175-2250 2150-2225 2150-2225 2220 2220 2220 2220 1450-1500 1420-1450 1450-1500 1500-1600 1525-1550 2250-2300 1650-1800

HARDNESS AFTER QUENCHING ROCKWELL C 60-65 60-65 63-65 63-65 63-65 63-65 63-65 60-65 60-65 60-65 60-65 63-65 63-65 63-65 62-64 63-65 65-66 57-59

TEMPERING TEMPERATURE RANGE F 1000-1100 1000-1100 1025-1100 1025-1100 1025-1075 1025-1075 1025-1075 1000-1100 1000-1100 1000-1100 1000-1100 300-800 375-500 300-800 400-800 350-500 1025-1100 300-1000

HARDNESS AFTER TEMPERING ROCKWELL C 65-60 65-60 65-63 65-63 65-63 65-63 65-63 65-60 65-60 65-60 65-60 62-50 62-57 63-50 62-48 62-60 66-68 57-45

DECARBURIZATION (PREVENTION OF DURING HEAT TREATMENT) -c -c -c -c -c -c -c -c -c -c -c -b -b -b -b -b -c -c

1500-1600 1200-1300

Table 7-6.

Thermal Treatment for Hardening and Tempering Tool Steel - General - Continued

CLASS S2 S5

QUENCH MEDIUM Water-oil Water Oil

PREHEAT TEMPERATURE F -A

HARDENING TEMPERATURE RANGE F 1550-1575 1660-1625 1550-1600 1600-1675

HARDNESS AFTER QUENCHING ROCKWELL C 60-62 58-60 60-62 58-60 65-66

TEMPERING TEMPERATURE RANGE F 300-500 300-500 300-650 300-650 300-400

HARDNESS AFTER TEMPERING ROCKWELL C 60-54 58-54 60-54 58-54 62-65

DECARBURIZATION (PREVENTION OF DURING HEAT TREATMENT) -b -b -b -b -b

W5

Water

1100-1200

1400-1550

a. For large tools and tools having intricate sections, preheating at 1050o to 1200o is recommended. b. Use moderately oxidizing atmosphere in furnace or a suitable neutral salt bath. c. Use protective pack from which volatile matter has been removed, carefully balanced neutral salt bath or atmosphere controlled furnaces. In the latter case, the furnace atmosphere should be in equilibrium with the carbon content of the steel being treated. Furnace atmosphere dew point is considered a reliable method of measuring and controlling this equilibrium.

T.O. 1-1A-9

7-13

T.O. 1-1A-9

Table 7-7.

Comparison of Tool Steel Properties

CLASS

NON DEFORMING PROPERTIES

TOUGHNESS

RESISTANCE TO SOFTENING EFFECT OF HEAT Poor Poor Poor Poor Poor Poor Poor Fair Poor Fair Fair Fair Fair Poor Good Good Good Good Good Good Good Best Best Good Good Best Good Good Good Good Good Good Good Good Poor

WEAR RESISTANCE

MACHINE ABILITY

W1-08 W1-09 W1-10 W1-12 W2-09 W2-10 W3-10 A2 A6 D2 D3 D5 D7 F3 H11 Hl2 Hl3 H21 T1 T2 T3 T4 T5 T6 T7 T8 M1 M2 M3 M4 M10 M15 M30 M34 01

Poor Poor Poor Poor Poor Poor Poor Best Good Best Good Best Best Poor Good Good Good Good Good Good Good Good Good Good Good Good Good Good Good Good Good Good Good Good Good

Good Good Good Good Good Good Good Fair Fair Fair Poor Fair Poor Poor Good Good Good Good Poor Poor Poor Poor Poor Fair Poor Poor Poor Poor Poor Poor Poor Poor Poor Poor Fair

Fair Fair Good Good Fair Good Good Good Good Best Best Best Best Best Fair Fair Fair Fair Good Good Good Good Good Best Best Good Good Good Best Best Best Best Best Best Good

Best Best Best Best Best Best Best Fair Fair Poor Poor Poor Poor Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Fair Good

7-14

T.O. 1-1A-9

Table 7-7.

Comparison of Tool Steel Properties - Continued

CLASS

NON DEFORMING PROPERTIES

TOUGHNESS

RESISTANCE TO SOFTENING EFFECT OF HEAT Poor Poor Poor Poor Best Fair Fair Poor Poor

WEAR RESISTANCE

MACHINE ABILITY

02 06 L6 L7 T15 S1 S2 S5 W5

Good Fair Fair Fair Good Fair W-Poor O-Fair W-Poor O-Fair Poor

Fair Fair Fair Fair Poor Good Best Good Good

Good Good Fair Good Best Fair Fair Fair Fair

Good Best Fair Fair Fair Fair Good Best Best

7-15/(7-16 blank)

T.O. 1-1A-9

SECTION VIII TESTING AND INSPECTION HARDNESS TESTING

8-1. GENERAL. d. A release mechanism with micrometer eyepiece for calculating the area of the impression. 8-7. Making The Brinell Test. The test is preformed as follows: a. Prepare the sample by f iling, grinding, and polishing to remove all scratches and variations that may affect the reading. b. Place the sample on the anvil of the machine and elevate until the hardened ball contacts the surface to be tested. c. Apply the load by pumping handle. NOTE A load of 3,000 kilograms is required for steel, while 500 kilograms is used when testing the sof ter metals, such as aluminum alloy, brass, and bronze. Normally, the load should be applied for 30 seconds. Although this period may be increased to 1 minute for extremely hard steels, in order to produce equilibrium. d. Release the pressure and measure the area of impression with the calibrated microscope. e. Calculate the Brinell number, completing the test. 8-8. ROCKWELL HARDNESS TEST. The Rockwell hardness test is based on the degree of penetration of a specif ically designed indentor into a material under a given static load. The indentor/penetrator used may be either a diamond or hardened steel ball. The diamond indentor called a brale is precision ground and polished and the shape is spheroconica. The steel ball for normal use is 1/16 inch diameter, however, other larger diameter steel balls such as 1/8, 1/4 or 1/2 inch may be used for testing sof t metals. The selection of the ball is based on the hardness range of the type of materia1 to be tested. 8-9. The Rockwell machine/tester for accomplishing the hardness test applies two loads to obtain the controlled penetration and indicates results on a graduated dial (see Figure 8-2). A minor load of 10 kilograms is f irst applied to seat the penetrator in the surface of the test specimen. The actual penetration is then produced by applying a major

8-2. Hardness testing is used to determine the results of heat treatment as well as the state of the metal prior to heat treatment. Its application in determining the approximate tensile strength of the material by use of a hardness-tensile strength table is very limited and should only be used in the case of ferrous (steel) alloys. Table 8-1 should be used only as a conversion table for converting the various hardness values from one type of test to another, and should not be used as an indication of tensile strength for alloys other than ferrous. In addition, it should be realized that values given in Table 8-1 are only approximate. Whenever a specif ic type of hardness test is given in a drawing, specif ication, etc., necessary hardness readings should be made by that test whenever possible, rather than by other means, and a conversion made. In obtaining hardness values, precaution must be taken to assure removal of cladding and decarburized surface layers from area to be tested. 8-3. METHODS OF HARDNESS TESTING.

8-4. The methods of hardness testing in general use are: Brinell, Rockwell, Vickers (British), Tukon and Shore scleroscope. 8-5. BRINELL HARDNESS TEST. This test consists of pressing a hardened steel ball into a f lat surface of the metal being tested by the application of a known pressure. The impression made by the ball is measured by means of a microscope with a micrometer eyepiece. The Brinell number is obtained by dividing the load in kilograms by the area of the spherical impression made by the ball, measured in square millimeters. The thickness of all samples used for testing must be sufficient to prevent bulging on the under side. 8-6. Brinell Tester. The Brinell tester (Figure 81) consists of the following major parts: a. An elevating screw and anvil for bringing the sample into contact with the ball. b. A manually operated hydraulic pump for applying the pressure to the hardened steel ball, which is mounted on its actuating member. c. A pressure gage for determining the applied pressure.

8-1

T.O. 1-1A-9

load, subsequently, releasing and then reading hardness number from the dial. The dial reading is related to the depth of penetration, load and the penetrator used. The shallower the penetration, the higher the hardness value number for given indentor and load. The normal major load is 150 kilograms (C Scale) when using the diamond penetrator and 100 kilograms (BScale) when using a 1/16 inch steel ball. A hardness value indicated by a number alone is incomplete. The number must be pref ixed with a letter to indicate the load and indentor used to obtain the number. There is a variety of combinations of indentors and loads used to obtain a hardness value in accordance with hardness range of various material. The combinations are listed in Table 8-2 which is based on Specif ication ASTM E-18. 8-10. Review of Table 8-2 will reveal that the Red Dial Numerals B scale are used for steel ball indentors regardless of size of ball or load and Black Figure C scales are used for the diamond penetrator. When the readings fall below the hardness value, C20 (B98) the material is considered too sof t for the diamond cone and 1/16 inch or larger hardened ball should be used. The diamond cone must be used for all hard materials (those above 100 on the Bscale) as the steel ball may be deformed by the test. If in doubt about the hardness of a material start with the diamond penetrator and switch to the steel ball if the material is below C20-C22. 8-11. Rockwell Test Procedure: The procedure for making the Rockwell test is outlined as follows: (See Figure 8-2 for machine illustrations.) a. Prepare the sample by removing (f ile, grind and polish) scale, oxide f ilms, pits, variations and foreign material that may affect the reading. The surface should be f lat, of one thickness and no bludge should be opposite the indentation. NOTE Do not perform test closer than 1/8 from edge of specimen to assure accurate reading. b. Select the proper anvil and penetrator and place proper weight on the weight pan.

c. Check trip lever for proper location. Lever should be located in the OFF LOAD position. d. Place the test specimen on the anvil and by turning the hand wheel, raise it slowly (do not crash) until contact is made with the penetrator. On the older model continue turning until pointer of the indicator has made three revolutions and is within f ive divisions (plus or minus) of the upright position. On the newer model af ter contact, continue turning hand wheel until the small pointer is nearly vertical and slightly to right of the dot. Then watching the long pointer, raise specimen until long pointer is approximately upright within three degrees (plus or minus) of C-0. K the C=+3 degrees position is overshot, lower the specimen and start over. When the pointer is within three divisions of C-0, set dial to zero. Af ter this step is complete, the minor load has been applied. e. Apply the major load by tripping the trip lever. Trip the lever, do not push. f. When the trip lever comes to rest and there is no further movement of pointer, return lever to the original position and read the hardness number indicated by the dial. When dial pointer indicates a fraction, use next lower whole number for the reading. 8-12. All hardness tests should be made on a single thickness to obtain accurate results. In testing curved specimens, the concave side should face the indentor; if reversed, an inaccurate reading will result due to f latening of the piece on the anvil. Specimens that do not balance on the anvil because of overhang should be properly supported to obtain accurate readings and to prevent damaging the penetrator. Also to obtain a true indication of hardness of a given part, several readings (3-6 is usually sufficient) at different points should be taken and averaged. If it is necessary to determine the condition of the interior, parts should be cut by some method that does not appreciably change the temper/ condition, such as using a water-cooled saw-off wheel. When testing clad material; the clad coat shall be removed. Specimen samples of clad and other materials should be provided when possible. It is not desirable to accomplish the test on the f inished part.

8-2

T.O. 1-1A-9

Table 8-1.

Hardness Conversion Chart

8-3

T.O. 1-1A-9

working order before making any test. The table on which the Rockwell tester is mounted must be rigid and not subject to any vibration if accurate results are to be obtained. 8-14. The accuracy of the Rockwell hardness tester should be checked regularly. Test blocks are available for testing all ranges of hardness. If the error in the tester is more than 2 hardness numbers, it should be re-calibrated. The dashpot should be checked or oil and properly adjusted for completion of travel. The ball indentor and diameter should also be checked regularly for bluntness and chipping and replaced as required. 8-15. VICKERS PYRAMID HARDNESS TEST. The Vickers pyramid hardness test(Figure 8-4) covers a normal range of loading from 2.5 to 127.5 kilograms. However, for special applications such as the hardness testing of thin, sof t materials, loads as low as 50 to 100 grams may be used. This test is made by pressing a square base diamond indentor into a f lat surface of the metal being tested by the application of known pressure. The indentation lef t by the indentor is a square, the diagonal of which remains the hardness of the metal. The diagonal of the square impression is measured by a microscope which reads directly to 0.001 millimeters on a large micrometer drum. With the standard pyramidal diamond indentor (Figure 8-5) having an angle of 136o between opposite face of the pyramid, the pyramidal hardness number is determined by dividing the applied load in kilograms by the pyramidal area of the impression in square millimeters by the formula, Hardness 1.854 applied load in kilograms square of the diagonal of impression or from correlation tables accompanying the tester. Rapid readings may be taken by means of three knife edges in the f ield of the eye-piece. The f irst knife edge is f ixed; the second knife is movable through a micrometric screw connected to a counter. The third knife edge, moved by means of a special screw, may be used if rapid reading of values to specif ied limits is desired. This method of testing is highly f lexible and permits testing for very high hardness values. In the Amsler-Vickers variation of this hardness tester the surface of the material to be tested, at which the indentor contacts may be thrown on a ground-glass screen directly in front of the operator, allowing the length of the diagonals to be read directly.

Figure 8-1.

Brinell Hardness Tester

8-13. The Rockwell testers are equipped with various anvils and indentors. Typical anvils and attachments are shown in Figure 8-3. The anvil(s) should be properly selected to accomplish the job. The tester should also be properly set and in good

8-4

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Figure 8-2.

Rockwell Hardness Tester

8-5

T.O. 1-1A-9

Figure 8-3.

Attachments for Rockwell Tester

8-16. Vickers Tester. The Vickers tester consists of the following major parts: a. Table for supporting the metal to be tested.

a. Prepare the sample by smooth grinding or polishing to remove all scratches and variations that may affect the readability of the indentation. b. Place the test piece (6) on the testing table (5) and turn the table elevating wheel (1) until the indentor (7) fails to contact the metal being tested.

b. A lever with a 20 to 1 ratio through which a load is applied through a rod to an indentor at the end of a tube moving up and down in a vertical position. c. A frame containing a control in which a plunger moves up and down vertically under the inf luence of a cam which applies and releases the test load. The cam is mounted on a drum and when the starting handle is depressed, the whole is rotated by a weight attached to a f lexible cable, the speed of rotation being controlled by a piston and dashpot of oil. The mechanism provides for a slow and diminishing rate of application for the last portion of the load. d. A foot pedal, which when depressed, returns the cam, drum and weight to their original positions, thus cocking the mechanism and preparing the instrument for another test. e. A tripper, which supports the beam during the return of the cam, weight and drum. The tripper also released the lever for load applications. f. A medium-power compound microscope for measuring the indentation across the diagonal of a square. 8-17. Making The Vickers Test. The test is applied as follows (See f igure 8-4):

CAUTION Sudden contact of the indentor and the material under test should be avoided to prevent possible injury to the diamond point. c. Depress the load trip level (8) applying the load. The duration of the load application is f ixed by the manufacturers at 10 to 30 seconds, the time being determined by the rate at which oil is allowed to bleed out of the dashpot. The load is fully applied, the indentor is automatically released. d. Elevate the indentor by turning the wheel. Lower the testing table by reversing the table elevating wheel. e. Swing the microscope (10) into place until locked. f. View the impression of the indentation in the form of a square in the f ield shown by the eyepiece.

8-6

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Figure 8-4.

Vickers Pyramid Hardness Tester

8-7

T.O. 1-1A-9

8-18. SHORE SCLEROSCOPE HARDNESS TEST. The Shore scleroscope is not a precision instrument as the others discussed in preceding paragraphs. It is used to give approximate values for comparative hardness readings. Testing hardness with the scleroscope consists of dropping a diamond tipped hammer upon the test specimen from a def inite height and measuring the rebound produced. In one type of tester, the height of the rebound must be measured directly on the scale of the machine, while on another the amount is indicated on a dial. 8-19. The Scleroscope Tester. The tester (Figure 8-6) consists of the following major parts: a. A base, provided with leveling screws, end a clamping arrangement to hold the sample to be tested.

Figure 8-5.

Standard Pyramid Diamond Indentor

g. Bring the lef t corner of the impression, by means of the centering screws (13) to a point where it touches the lef t hand f ixed knife edge. Adjust the right hand movable knife edge by means of the micrometric screw connected to the counter until it touches the right hand corner of the impression. The counter (15) will then show an ocular reading which is transposed to the Vickers pyramid numeral by use of correlation tables accompanying the tester. h. Where specif ied hardness limits are desired the third knife edge is used. This is moved by means of special screws to correspond to the smaller dimension or maximum hardness, while the micrometer-controlled knife edge is adjusted to correspond to the minimum hardness or larger dimension. When the settings of the second and third knife edges are made, it is only necessary when taking readings to set the f ixed knife edge to the lef t hand corner of the impression in the usual way. If the right hand corner of the impression appears between the second and third knife edges, the material has the proper hardness for the range desired.

Figure 8-6.

Shore Scleroscope

b. A vertical glass tube, mounted to the base and containing the cylindrical diamond point hammer.

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c. A suction heat and bulb for lif ting and releasing the hammer. d. A scale, visible through the glass tube, for determining the height of the rebound. e. A magnif ier hammer with a larger contact area is supplied for use with extremely sof t metals. 8-20. TESTING WITH THE SCLEROSCOPE. The test is made as follows: a. Level the instrument by means of the adjusting screws (1). (See f igure 8-6). The level position is determined by means of the plumb rod (2). b. Prepare the test specimen as described for the Brinell and Rockwell tests in preceding paragraphs and clamp it on the base. This is done by raising the lever (3) inserting the sample and exerting the pressure on the clamping shoe (4). c. Raise the hammer (5) by squeezing and releasing the bulb (6) d. Release the hammer by again squeezing the bulb and observing its rebound. e. Several tests should be made at different points of a specimen, and an average reading taken to reduce visual error. 8-21. TENSILE TESTING. The terms tension test and compression test are usually taken to refer to tests in which a prepared specimen is subjected to a gradually increasing load applied axially until failure occurs . For the purpose of tensile testing implied by this technical order this type of setting would apply to determining the mechanical properties desired in a material. For this test, the following test specimens are listed. (See Figure 8-7.) This does not exclude the use of other test specimens for special materials or forms of material. The tensile strength shall be determined by dividing the maximum load on the specimen during a tension test by the original crosssectional area of the specimen. a. Diameter of the reduced section may be smaller at center than at ends. Difference shall not exceed 1% of diameter at ends.

b. When an extensometer is required to determine elastic properties, dimensions C and L may be modif ied. In all cases the percentage of elongation shall be based on dimension G. c. The type R1 test specimen is circular in cross section and is used for bars, rods, forgings, plates, shapes, heavy-walled tubing, and castings. Types R2, R3, R4, and R5 are circular in cross-section and are used for material of dimensions insufficient for type R1. (1) The ends of the reduced section shall not differ in width by more than 0.004 inch. (2) The ends of the specimen shall be symmetrical with the center line of the reduced section within 0.10 inch. (3) When material is over 2 inches thick, machine to 3/4 inch or use type R1 test specimen. For more detailed information, refer to Federal Test Method Standard No. 151. 8-22. DECARBURIZATION MEASUREMENT. 8-23. Decarburization is the loss of carbon at the surface of ferrous materials which have been heated for fabricating, welding, etc., or when heated to modify mechanical properties. Effective decarburization is any measurable loss of carbon content which results in mechanical properties below the minimum acceptable specif ications for hardened materials. The most common methods used to measure decarburization are microscopic, hardness and chemical. The microscopic method is sufficiently accurate for most annealed and hot rolled material for small amounts of decarburization in high carbon (over 0.60%), high hardness steels. The hardness method is insensitive in this case, and recourse must be taken to chemical analysis. In this technical order, only the hardness method is covered. When precise measurements are required, publications giving detailed measurements must be consulted.

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Table 8-2.

Rockwell Scales, Loads and Prefix Letters

SCALE PREFIX LETTERS A B* C* D E F G H K L M P R S V

INDENTOR/PENETRATOR Diamond 1/16 in Steel Ball Diamond Diamond 1/8 in Ball 1/16 in Ball 1/16 in Ball 1/8 in Ball 1/8 in Ball 1/4 in Ball 1/4 in Ball 1/4 in Ball 1/2 in Ball 1/2 in Ball 1/2 in Ball

MAJOR LOAD KILOGRAMS 60 100 150 100 100 60 150 60 150 60 100 150 60 100 150

DIAL NUMBERS Black Red Black Black Red Red Red Red Red Red Red Red Red Red Red

* Most Commonly Used Scales. 8-24. HARDNESS METHOD. readings are made on steps which are known distances below the surface. These steps should be ground at pre-determined depths below the surfaces, and of sufficient areas to allow several hardness readings on each f lat. 8-26. The f ile method is of ten suitable for detecting decarburization of hardened materials during shop processing, but not for accurate measurement. Base metals expected to harden above RC60 and found to be f ile sof t are probably decarburized. Decarburization of base metal that will not harden to RC60 can not be detected by this method unless specially prepared f iles are used. The extent and severity of any decarburization detected by this method should be verif ied by either of the other methods.

8-25. Taper or Step Grind - The specimen containing the surface on which decarburization is to be measured is prepared so that it can be manipulated on a Rockwell superf icial or Vickers hardness tester. If the specimen is not in the hardened condition, it is recommended that it be hardened by quenching from heating equipment under conditions which avoid further change in carbon distribution. For the taper grind procedure, a shallow taper is ground through the case, and hardness measurements are made along the surface. The angle is chosen so that readings spaced equal distances apart will represent the hardness at the desired increments below the surface of the case. The step grind procedure is essentially the same as the taper grind, except that hardness

8-10

T.O. 1-1A-9

Figure 8-7.

Test Specimens

8-11

T.O. 1-1A-9

Table 8-3.

Approximate Hardness - Tensile Strength Relationship of Carbon and Low Alloy Steels

Rockwell C 150 Kg Load 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 B 100 Kg Load 1/16 Ball

Vickers Diamond Pyramid 50 Kg Load 918 884 852 822 793 765 740 717 694 672 650 630 611 592 573 556 539 523 508 493 479 465 452 440 428 417 406 396 386 376 367 357 348 339 330 321 312 304 296 288 281 274 267 261 255 250 245 240 Tungsten Carbide Ball 820 796 774 753 732 711 693 675 657 639 621 604 588 571 554 538 523 508 494 479 465 452 440 427 415 405 394 385 375 365 356 346 337 329 319 310 302 293 286 278 271 264 258 252 246 241 236 231

Brinell3 300 Kg Load - 10mm Ball Steel Ball 717 701 686 671 656 642 628 613 600 584 574 561 548 536 524 512 500 488 476 464 453 442 430 419 408 398 387 377 367 357 347 337 327 318 309 301 294 286 279 272 265 259 253 247 241 235 230 225

Tensile Strength 1000 lb per sq in.

121.3 120.8 120.2 119.6 119.1 118.5 117.9 117.4 116.8 116.2 115.6 115.0 114.4 113.8 113.3 112.7 112.1 111.5 110.9 110.4 109.7 109.1 108.5 107.8 107.1 106.4 105.7 105.0 104.3 130.7 102.9 102.2 101.5 100.8 100.2 99.5 98.9

283 273 264 256 246 237 231 221 215 208 201 194 188 181 176 170 165 160 155 150 147 142 139 136 132 129 126 123 120 118 115 112 110 107

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Table 8-3.

Approximate Hardness - Tensile Strength Relationship of Carbon and Low Alloy Steels - Continued

Rockwell C 150 Kg Load 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 B 100 Kg Load 1/16 Ball 98.1 97.5 96.9 96.2 95.5 94.9 94.1 93.4 92.6 91.8 91.2 90.3 89.7 89 88.3 87.5 87 86 85.5 84.5 83.2 82 80.5 79 77.5 76 74 72 70 68 66 64 61 58 55 51 47 44 39 35 30 24 20 11 0

Vickers Diamond Pyramid 50 Kg Load 235 231 227 223 219 215 211 207 203 199 196 192 189 186 183 179 177 173 171 167 162 157 153 149 143 139 135 129 125 120 116 112 108 104 99 95 91 88 84 80 76 72 69 65 62 Tungsten Carbide Ball 226 222 218 214 210 206 202 199 195 191 187 184 180 177 174 171 169 165 163 159 153 148 144 140 134 130 126 120 116 111 107 104 100 95 91 86 83 80 76 72 67 64 61 57 54

Brinell3 300 Kg Load - 10mm Ball Steel Ball 220 215 210 206 201 197 193 190 186 183 180 177 174 171 168 165 162 160 158 154 150 145 140 136 131 127 122 117 113 108 104 100 96 92 87 83 79 76 72 68 64 60 57 53 50

Tensile Strength 1000 lb per sq in. 104 103 102 100 99 97 95 93 91 90 89 88 87 85 84 83 82 81 80 78 76 74 72 70 68 66 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28

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8-27. NONDESTRUCTIVE INSPECTION METHODS. 8-28. Radiographic inspection will show internal and external structural details of all types of parts and materials. It is accomplished by passing penetrating radiation (usually X or gamma rays) through the part or assembly being inspected to expose a f ilm. Af ter developing, interpretation of the radiograph will indicate defects or damage. All radiographic inspections shall be accomplished in accordance with T.O. 33B-1-1, MIL-STD-453, and MIL-STD-410. 8-29. Penetrant inspection is a nondestructive inspection method that is used to detect discontinuities open to the surface of nonporous material. It is accomplished by treating the inspection area with a f luid (penetrant) that penetrates the surface discontinuity. Surplus penetrant remaining on the surface is removed and an absorbent material (developer) is applied to the surface. The developer acts as a blotter and draws some of the penetrant from the discontinuity to the surface. Discontinuities are visible due to color contrast between the penetrant drawn out and the background surface. Only f luorescent penetrants are approved for Air Force use. All penetrant inspection materials shall conform to MIL-I-25135. All penetrant inspections shall be accomplished in accordance with T.O. 33B-1-1 and MIL-STD-410. 8-30. Ultrasonic inspection uses a high frequency sound wave to detect discontinuities in materials. The pulser in the ultrasonic instrument sends an electrical impulse to a piezoelectric material in the search unit (transducer). The transducer changes the electrical impulse into mechanical vibrations (sound) and transmits them into the material being inspected. Any marked change in acoustic properties, such as a f law or interface in the material, ref lects the sound back to the transducer. Examination of the ref lections on a cathode ray tube will reveal discontinuities in the material. All ultrasonic inspections shall be accomplished in accordance with T.O. 33B-1-1, MIL-I-8950, and MIL-STD-410. 8-31. Magnetic particle inspection is used to detect discontinuities in ferromagnetic materials, principally iron and steel. Magnetic particle inspection is accomplished by inducing a magnetic field into the material being inspected. A discontinuity will interrupt this f ield, creating north and

south poles which will attract magnetic particles applied to the material. Discontinuities are visible due to color contrast between the magnetic particles and the background surface. All magnetic particle inspections shall be accomplished in accordance with T.O. 33B-1-1 and MIL-STD-410. 8-32. Eddy current inspection is used to detect discontinuities in materials that are conductors of electricity. An eddy current is the circulating electrical current induced in a conductor by an alternating magnetic f ield, which is produced by a small test coil in contact with or close to the material being inspected. Discontinuities in the material being tested cause variations in the induced eddy current. The test coil measures the variations which reveal discontinuities in the material. All eddy current inspections shall be in accordance with T.O. 33B-1-1 and MIL-STD-410. 8-33. CHEMICAL ANALYSIS. Chemical analysis methods are those in which the elements present in metals are determined by the use of reagents in solution, by combustion methods, or by other none-mission methods. Sample metal from any piece shall be such that it represents as nearly as possible the metal of the entire piece. Drilling, milling and other machining operations for sample metal shall be performed without the use of water, oil, or other lubricants, and cutting speeds shall be such that no burning takes place to cause alternation of the chemical composition of the test metal. Method III.I of Federal Method Standard 151A is the controlling document for chemical analysis. 8-34. SPECTROCHEMICAL ANALYSIS. Spectrochemical analysis includes all methods in which measurements of electromagnetic radiations produced by a sample metal are employed to determine the chemical composition. Samples shall be so selected as to be representative of the entire quantity of metal under inspection. Cutting speeds in all machining operations shall be such that no burning takes place to cause alteration of the chemical composition of the test metal. Method 112.1 of Federal Test Method Standard 151A governs this type of analysis. The result of spectrochemical analysis shall be determined to the number of decimal places shown in the chemical requirements for the material.

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SECTION IX HEAT TREATMENT

9-1. GENERAL. 9-8. Some typical material applications are listed in Table 9-1 for general guidance only. Cycle for which an alloy type is listed may not necessarily be specif ied for that material. 9-9. SPECIAL HEAT TREATMENT INFORMATION. 9-10. CADMIUM PLATED PARTS. All cadmium plate shall be stripped from parts (SPOP 21) and cadmium plated detail parts shall be removed from assemblies prior to subjecting the part or assemblies to any furnace temperature in excess of 500oF (260oC). At temperatures above 500oF (260oC), stress alloying of molten cadmium will occur with potentially harmful results on the base materials. 9-11. TINT TEST FOR DETERMINING COATING REMOVAL FROM NICKEL BASE AND COBALT BASE ALLOYS. 9-12. Perform test as follows: a. Remove coating from parts using applicable stripping procedure. b. Heat parts and an uncoated, vapor blasted test panel of the same material as the parts at 1075o 25oF (579o 14oC) for 45 to 75 minutes in air. c. A uniform color match between the part and the test piece will indicate complete removal of the coating.

9-2. Controlled atmosphere ovens are not required for heat treatment operations unless specified for a particular part. 9-3. A cold oven is def ined as any oven where the temperature is not over 500oF (260oC). Loading and unloading a cold oven is possible without further lowering the temperature. 9-4. Parts that are prone to distortion during heat treatment shall be properly supported and temperature raised gradually by steps. Coat f ixturing at part contact points and threaded details with PMC 2264 boron nitride coating prior to installing part and before heat treatment. Cooling of these parts shall also be done gradually. Cycles with A suffix are recommended for this purpose. 9-5. Parts that are not prone to distortion during heat treatment may be loaded into and withdrawn from a hot oven. 9-6. Temperature and time are the most critical factors in heat treatment. Time required at each specified temperature begins only af ter all sections of parts have reached that temperature. Furnace operator shall make allowance for size of part, number of parts, and furnace input capacities. 9-7. Optimum temperatures are given for each cycle, with tolerances included for practical use. However, it is best to hold to basic temperatures listed.
Table 9-1.

Typical Heat Treatment Application

Cycle No. 1, 1A

Type* STR

SPOP No. 455-1, 455-2

Possible Alloy Application Low alloy steel, as AMS 6322 and AMS 6415; martensitic stainless steel, as Type 410 (AMS 5504 and AMS 5613) and Greek Ascoloy (AMS 5508 and AMS 5616) Aluminum Inconel X Nickel alloys: B-1900 (PWA 663 and PWA 1455); Inconel 713 (PWA 655) Cobalt alloys: Stellite 31 (AMS 5382); WI-52 (PWA 653); MAR-M509 (PWA 647) Greek Ascoloy (AMS 5508 and AMS 5616) (martensitic stainless steel)

2 3 4, 4A 5, 5A

STR STR STR STR

456 457 458-1, 458-2 459-1, 459-2

6, 6A

STR

460-1, 460-2

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Table 9-1.

Typical Heat Treatment Application - Continued

Cycle No. 7 8 9 11 12, 12A 13 14 15 17 20 21

Type* STR STR STR STR PRE STR STR PRE PRE SOL SOL

SPOP No. 461 455-3 459-3 464 471, 465 466 467 468 470 480 481

Possible Alloy Application Waspaloy, Udimet 700 Inconel 600 (nickel alloy); Nimonic 75 (PWA 673) (nickel alloy); stainless steel, as Types 310, 316, 321, and 347 Titanium Inconel 718 (nickel alloy), as AMS 5596, AMS 5662, and AMS 5663 17-7PH (stainless steel - austenite conditioning); Type 430 (ferritic stainless steel), welded with Type 430 f iller metal Type 430 (ferritic stainless steel), welded with AMS 5680 (Type 347 stainless steel) A-286 (modif ied Tinidur) stainless steel, as AMS 5525, AMS 5731, AMS 5732, and AMS 5737 Incoloy 901 (nickel alloy), as AMS 5660 and AMS 5661 HASTELLOY X (nickel alloy) Nickel alloy: HASTELLOY X (AMS 5536 and AMS 5754) Cobalt alloys: STELLITE 31 (AMS5382); Haynes 188 (AMS 5608, AMS 5772, and PWA 1042); L-605 (AMS 5537 and AMS 5759) Nickel alloys: Inconel 600 (AMS 5540 and AMS 5665); Inconel 625 (AMS 5599 and AMS 5666); HASTELLOY N; HASTELLOY X (AMS 5536, AMS 5754, and PWA 1038); HASTELLOY W Cobalt alloys: STELLITE 31 (AMS 5382); Haynes 188 (AMS 5608, AMS 5772, and PWA 1042); L-605 (AMS 5537 and AMS 5759); MAR-M509 (PWA 647) Waspaloy (nickel alloy), as AMS 5544, AMS 5706, and AMS 5707 Waspaloy (nickel alloy), as AMS 5544, AMS 5706, and AMS 5707 Waspaloy (nickel alloy), as AMS 5544, AMS 5706, AMS 5707, AMS 5708, and AMS 5709 Waspaloy (nickel alloy), as AMS 5596, AMS 5706, AMS 5707, AMS 5708, and AMS 5709 Inconel 718 (nickel alloy), as AMS 5596, AMS 5662, and AMS 5663 Inconel 718 (nickel alloy, as AMS 5596, AMS 5662, and AMS 5663

22

STR

482

101 102 103 104 105 106

SOL SOL STA PRE SOL SOL

761 762 763 764 765 766

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Table 9-1.

Typical Heat Treatment Application - Continued

Cycle No. 10

Type* PRE

SPOP No. 767

Possible Alloy Application Nickel alloys: Inconel 718, as AMS 5596, AMS 5662, and AMS 5663; Inconel X-750, as AMS 5598, AMS 5670, and AMS 5671

* PRE = Precipitation SOL = Solution STA = Stabilization STR = Stress-relief

9-13.

TITANIUM ALLOY PARTS. NOTE AMS 4901 and 4921 are the only commercially pure titanium material types used widely in the fabrication of P&W engine parts. Virtually all other titanium materials used are titanium alloys and are subject to these instructions. WARNING Alkaline rust remover causes burns. Protect eyes and skin from contact.

9-14. GENERAL. All titanium alloy parts shall be cleaned by the following procedure prior to stress-relief. Otherwise, certain impurities that may be present on the parts during the heating cycle could cause stress alloying of the parts. The thin, hard, blue-gray oxide coating sometimes occurring on titanium alloy surfaces and unaffected by this cleaning procedure is harmless in this respect and may be disregarded.

. .

NOTE Parts shall be immersed only long enough to obtain optimum results. Refer to Section V. CLEANING, for solution make-up.

b. Soak in alkaline rust remover (SPS 2, SPS 5, SPS 7, SPS 12, SPS 25, SPS 27, or PS 240) at 180o to 200oF (82o to 93oC) for 1 to 4 minutes maximum. c. Pressure rinse over tank with cold water, then dip rinse in cold water, following with a cold water pressure rinse. d. Rinse in hot PMC 1737 deionized water at 150o to 200oF (66o to 93oC). Air dry; do not use compressed air. e. Immediately af ter completing step d., protect the parts from all contamination, such as dirt, dust, oil mist, f ingerprints, etc. Cover parts with clear plastic sheet or store them in clear plastic bags until furnace or other operation is begun. Use clean white gloves for all handling. 9-15. Type 6A1-4V Titanium Alloy Parts (AMS 4911, 4928, 4930, 4935, 4954, 4956, 4967, and PWA 1213, 1215, 1262). Parts fabricated of these titanium alloys may be stress-relieved in air only to 1015o15oF (546o8oC). See Cycles 1 and 1A. At any higher temperatures, an inert atmosphere shall be used regardless of any contrary instructions stipulated in a particular repair. 9-16. SOLUTION, STABILIZATION, OR PRECIPITATION HEAT TREATMENT.

WARNING Methyl ethyl ketone (MEK) is f lammable and harmful to eyes, skin, and breathing passages. Keep ignition sources away, provide adequate ventilation, and wear protective clothing. NOTE Since only light f ilms of oil or grease will be removed by the cleaning solution, it is essential that as much surface contamination as possible be removed before immersing parts into the cleaning solution. a. Remove any visible concentrations of oil, grease, dirt, and any other contaminants by wiping with a clean, lint-free cloth dampened with methyl ethyl ketone TT-M-261 or acetone O-A-51.

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9-17. GENERAL. Solution heat treatment of material (particularly HASTELLOY X) is performed to improve ductility and weldability prior to resizing and repair. Long-time exposure to high temperature engine operating environment causes precipitation of carbides into the grain boundaries. Carbides, particularly chromium carbides, are thus precipitated into the grain boundaries of parts fabricated of HASTELLOY X material and subjected for long periods to temperatures of 1200o to 1700oF (649o to 927oC). The solution treatment dissolves these carbides and puts them back into metallic solution. The cooling cycle, therefore, shall be rapid enough to maintain carbides or precipitation hardeners in solution. Replication and metallurgical examination may be necessary to verify whether f ixturing and cooling rate are adequate to obtain desired microstructure and prevent cracking. 9-18. Stabilization heat treatment is maintaining a part at a selected temperature long enough to rearrange the atoms into an improved structure. 9-19. Precipitation heat treatment is a selected temperature and duration that produces benef icial hardening in certain alloys. It is sometimes referred to as Aging, or Age Hardening. 9-20. When a sequence of solution, stabilization, or precipitation heat treatment is applied to a given part, various temperatures are used. The f inal condition obtained is a combined effect of this sequence.
Table 9-2.

9-21. The expressions AIR COOL and AIR COOL OR FASTER mean that parts shall be cooled quickly enough to prevent metal structure changes that can happen in certain alloys if cooling is too slow. It does not mean to quench in a liquid. Circulating fans may be used, but f ixturing may be required if distortion is a problem. a. AIR COOL is def ined as rate of cooling of part obtained by removing that part from furnace at prescribed temperature and allowing it to cool in room temperature still air. Def inition has been broadened to include the following situations. (1) In vacuum furnace, by force cooling in protective atmosphere. (2) In protective atmosphere furnace, by shutting off heat and maintaining atmospheric f low rates. (3) In retort furnace, by removing retort from furnace and fan cooling. (4) In pit furnace, by removing parts from furnace and cooling in room temperature still air. b. AIR COOL OR FASTER is def ined as cooling not less than 40oF (22oC) per minute to 1100oF (593oC) and not less than 15oF (8oC) from 1100o to 1000oF (538oC). 9-22. Cycle number, type of heat treatment, SPOP number, and maximum temperature are listed in Table 9-2.

Cross-Index for Solution, Stabilization, or Precipitation Heat Treatments

Cycle No. 12 12A 15 17 20 21 101 102 103 104 105 106 107

Type Precipitation Precipitation Precipitation Precipitation Solution Solution Solution Solution Stabilization Precipitation Solution Solution Precipitation

SPOP No. 471 465 468 470 480 481 761 762 763 764 765 766 767

Peak Temp., oF(oC)* 1350 1350 1325 1450 2050 2150 1825 1825 1550 1400 1750 1750 1325 (732) (732) (718) (788) (1121) (1177) (996) (996) (843) (760) (954) (954) (718)

* (disregarding tolerance) 9-23. Solution heat treatment Cycles 20 and 21 are used for various HASTELLOY X parts. Reference to these cycles will be made in the repair instructions, as necessary, by cycle or SPOP number.

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NOTE These cycles apply only to the repair of HASTELLOY X parts that require using one of the following solution heat treatments. The specif ic cycle required will be included in the repair procedure. 9-24. CYCLE 20 (SPOP 480). Perform as follows:

manufacture. The benef icial properties derived from this lower temperature treatment could be lost permanently if subjected to a temperature higher than 1800oF (982oC). For regular Hastelloy material, solution heat treat shall be performed in accordance with Cycle 20 (SPOP 480), unless otherwise directed by a specif ic repair procedure. a. Heat part to 2150o 25oF (1177o 14oC) and hold for 7 to 10 minutes.

CAUTION Do not use this cycle for solution heat treating PWA 1038 HASTELLOY X material. This material was solution treated at 1950oF (1066oC) at its manufacture. The benef icial properties derived from this lower temperature treatment could be lost permanently if subjected to a temperature higher than 1800oF (982oC). For other HASTELLOY alloys, solution heat treat shall be performed per this cycle unless otherwise directed by a specific repair procedure. a. Heat part to 2050o 25oF (1121o 14oC) and hold for 7 to 10 minutes. NOTE Hydrogen, argon, or air are acceptable atmospheres; however, when solution treating is to be followed by weld repair that requires complete prior removal of oxides, hydrogen is preferred because of its characteristic and benef icial cleaning action over the entire part. Hydrogen cleaning removes oxides from all surfaces, including those difficult to clean mechanically, and to some extent, from the inside of cracks to be welded. b. Air cool or faster. b. NOTE Hydrogen, argon, or air are acceptable atmospheres. However, when solution treating is to be followed by weld repair that requires complete prior removal of oxides, hydrogen is preferred because of its characteristic and benef icial cleaning action over the entire part. Hydrogen cleaning removes oxides from all surfaces including those difficult to clean mechanically, and to some extent, from the inside of cracks to be welded. Air cool or faster. 9-26. The following solution, stabilization, or precipitation heat treatment cycles apply primarily to certain age-hardenable alloys such as WASPALOY and INCONEL materials, for stress-relief, and to dissolve precipitated carbides and intermetallics (hardeners). NOTE These cycles apply only when specif ically invoked in repair procedures in engine publications. Parts that are susceptible to distortion during heat treatment shall be adequately supported, and temperature raised and lowered stepwise. The Suffix A following a cycle number indicates a stepwise cycle. Step cycles shall not be used for solution heat treatments. Refer to cautions in solution heat treat cycles. 9-27. CYCLE 12 (SPOP 471). Perform as follows: NOTE This is a short-term precipitation (aging) heat treatment for INCONEL 718 or other part material specif ied in engine publication.

9-25. CYCLE 21 (SPOP 481). Perform as follows:

CAUTION Do not use this cycle for solution heat treating PWA 1038 HASTELLOY X material. This material was solution treated at 1950oF (1066oC) at its

9-5

T.O. 1-1A-9

a. Place part in oven and heat to 1350o15oF (732o8oC). b. Hold at 1350oF (732oC) for 4 hours. c. Cool to 1200o 15oF (649o 8oC) at approximately 100oF (56oC) per hour. Hold at temperature for a total of 3 hours, including cool-down time from 1350oF (732oC). d. Air cool to room temperature. 9-28. CYCLE 12A (SPOP 465). Perform as follows: NOTE This is a short-term precipitation (aging) heat treatment for INCONEL 718 or other part material specif ied in engine publication. a. Place part in cold oven. b. Heat to 600oF (316oC) and hold for 30 minutes. c. Increase to 800oF (427oC) and hold for 30 minutes. d. Increase to 1000oF (538oC) and hold for 30 minutes. e. Increase to 1200oF (649oC) and hold for 30 minutes. f. Increase to 1350o 15oF (732o 8oC) and hold for 4 hours. g. Cool to 1200o 15oF (649o 8oC) at approximately 100oF (56oC) per hour. Hold at temperature for a total of 3 hours, including cool-down time from 1350oF (732oC). h. Air cool to room temperature. 9-29. CYCLE 15 (SPOP 468). Perform as follows: NOTE Heating and cooling rates are optional. Air is an acceptable atmosphere. a. Heat part to 1325o 25oF (718o 14oC) and hold for 4 hours. b. Air cool. 9-30. CYCLE 17 (SPOP 470). Perform as follows: NOTE Hydrogen, argon, or a blend of hydrogen and argon, or vacuum, are acceptable atmospheres.

a. Heat part to 1450o 15oF (788o 8oC) and hold for 4 hours. b. Cool to 500oF (260oC) at a rate equivalent to air cool. c. Heat part to 1325o 15oF (718o 8oC) and hold for 14 hours. d. Cool at a rate equivalent to air cool. 9-31. CYCLE 101 (SPOP 761). Perform as follows: CAUTION Heating or cooling rate between 1000oF (538oC) and 1850oF (1010oC) shall be at least 40oF (22oC) per minute to prevent cracking and to control aging characteristics. NOTE This is a solution heat treatment using an argon atmosphere. a. Place part with thermocouples in retort, and seal retort. b. Purge retort at approximately 150 CFH argon until dew point reaches -40oF (-40oC) or lower at retort exhaust. c. Insert retort into furnace. NOTE Furnace may initially be set higher than 1850oF (1010oC). d. Heat to 1825o 25oF (996o 14oC) using lower thermocouple for controlling. Do not exceed 1850oF (1010oC) on higher thermocouple. Hold at temperature for 2 hours unless otherwise specified. e. Remove retort from furnace and cool with forced argon to 1000oF (538oC) in no longer than 18 minutes; then complete cooling with argon or air. 9-32. CYCLE 102 (SPOP 762). Perform as follows:

9-6

T.O. 1-1A-9

CAUTION Heating or cooling rate between 1000oF (538oC) and 1850oF (1010oC) shall be at least 40oF (22oC) per minute to prevent cracking and to control aging characteristics. a.

NOTE This is a precipitation heat treatment using air, argon, or vacuum. Place part in cold furnace.

b. Heat to 1400o 15oF (760o 8.3oC) for 16 hours. c. Air cool.

. .
a.

NOTE This is a solution heat treatment using vacuum. Heat cycle shall be completed in the 0.010 torr range or lower. Furnace system shall provide for argon forced cooling, in order to satisfy cooling rate requirement. Place part, with thermocouples, in furnace.

9-35. CYCLE 105 (SPOP 765). Perform as follows:

CAUTION Heating or cooling rate between 1000oF (538oC) and 1775oF (968oC) shall be at least 40oF (22oC) per minute to prevent cracking and to control aging characteristics. NOTE This is a solution heat treatment using an argon atmosphere. a. Place part with thermocouples in retort, and seal retort. b. Purge retort at approximately 150 CFH argon until dew point reaches -40oF (-40oC) or lower, at retort exhaust. c. Insert retort into furnace. NOTE Furnace may initially be set higher than 1775oF (968oC). d. Heat to 1750o 25oF (954o 14oC), using lower thermocouple for controlling. Do not exceed 1775oF (968oC) on higher thermocouple. Hold at temperature for 1 hour unless otherwise specif ied. e. Remove retort from furnace and cool with forced argon to 1000oF (538oC) in no longer than 16 minutes; then complete cooling with argon or air. 9-36. CYCLE 106 (SPOP 766). Perform as follows:

b. Evacuate to 0.009 torr or lower. Static leak rate shall not exceed 50 microns per hour. NOTE Furnace may initially be set higher than 1850oF (1010oC). c. Heat to 1825o 25oF (996o 14oC) using lower thermocouple for controlling. Do not exceed 1850oF (1010oC) on higher thermocouple. Hold at temperature for 2 hours unless otherwise specified. d. Cool at required rate using forced argon.

9-33. CYCLE 103 (SPOP 763). Perform as follows: NOTE This is a stabilization heat treatment using air, argon, or vacuum. a. Place part in cold furnace.

b. Heat to 1550o 15oF (843o 8.3oC) for 4 hours. c. Air cool.

9-34. CYCLE 104 (SPOP 764). Perform as follows:

9-7

T.O. 1-1A-9

CAUTION Heating or cooling rate between 1000oF (538oC) and 1775oF (968oC) shall be at least 40oF (22oC) per minute to prevent cracking and to control aging characteristics.

NOTE Local stress-relief of engine parts following minor repairs is authorized only if procedure has been developed to be compatible with applicable parts, material, size, and operating environment, and is approved by the cognizant engineering authority. 9-39. GENERAL. Parts that have been repaired by fusion welding shall ordinarily be stressrelieved. CAUTION The required stress-relief (Cycle 1 or 1A) af ter welding or brazing Type 410 or Greek Ascoloy materials eliminates the brittleness in the joint areas. To avoid cracking, parts shall be handled carefully until stress-relief is accomplished. NOTE On certain parts, experience has indicated that stress-relief is not required. This permissible omission will be included in appropriate manual repair section for such parts. 9-40. The following stress-relief cycles are used throughout manual for various parts. Reference to these cycles will be made, as necessary, by cycle or SPOP number.

. .
a.

NOTE This is a solution heat treatment using vacuum. Heat cycle shall be completed in the 0.010 torr range or lower. Furnace system shall provide for argon forced cooling, in order to satisfy cooling rate requirement. Place part, with thermocouples, in furnace.

b. Evacuate to 0.009 torr or lower. Static leak rate shall not exceed 0.05 torr per hour. NOTE Furnace may initially be set higher than 1775oF (968oC). c. Heat to 1750o 25oF (954o 14oC), using lower thermocouple for controlling. Do not exceed 1775oF (968oC) on higher thermocouple. Hold at temperature for 1 hour unless otherwise specif ied. d. Cool at required rate using forced argon. 9-37. CYCLE 107 (SPOP 767). Perform as follows: NOTE This is a precipitation heat treatment using air or argon. a. Place part in cold furnace. b. Heat to 1325o 15oF (718o 8.3oC) for 8 hours. c. Furnace cool at a rate not to exceed 100oF (56 C) per hour to 1150o 15oF (621o 8.3oC); hold for 8 hours.
o

. .

NOTE Parts may require a cycle different from one of the following. This will result in cycle being included in specif ic repair procedure. Parts that are susceptible to distortion during heat treatment shall be adequately supported, and temperature raised and lowered stepwise. The Suff ix A following a cycle number indicates a stepwise cycle.

d. 9-38.

Air cool. STRESS-RELIEF AFTER WELDING.

9-41. Cycle number, SPOP number, and maximum temperature are listed in Table 16-3.

9-8

T.O. 1-1A-9

Table 9-3.

Cross-Index for Stress-Relief Heat Treatments

Cycle No. 1 1A 2 3 4 4A 5 5A 6 6A 7 8 9 11 13 14 22

SPOP No. 455-1 455-2 456 457 458-1 458-2 459-1 459-2 460-1 460-2 461 455-3 459-3 464 466 467 482

Peak Temp., oF(oC)* 1015 1015 350 900 1300 1300 1600 1600 1050 1050 1500 1010 1600 1150 1400 1500 1800 (546) (546) (177) (482) (704) (704) (871) (871) (566) (566) (816) (543) (871) (621) (760) (816) (982)

* (disregarding tolerance) 9-42. CYCLE 1 (SPOP 455-1). Heat part to 1015oF 15oF (546o 8oC) and hold for 2 hours. NOTE To minimize distortion, use Cycle 1A as an alternate. Other cycles are permissible provided stress-relief requirement of 1015o 15oF (546o 8oC) for 2 hours is met. 9-43. CYCLE 1A (SPOP 455-2). Perform as follows: a. Put part in cold oven. b. Heat to 600oF (316oC) and hold for 30 minutes. c. Increase to 800oF (427oC) and hold for 30 minutes. d. Increase to 1015o 15oF (546o 8oC) and hold for 2 hours. e. Cool to 500oF (260oC) not faster than 100oF o (56 C) every 15 minutes. 9-44. CYCLE 2 (SPOP 456). Heat part to 350o 10oF (177o 6oC) and hold for 1 hour. 9-45. a. CYCLE 3 (SPOP 457). Perform as follows: Put part in cold oven. d. Cool to 500oF (260oC) not faster than 100oF (56oC) every 15 minutes. 9-46. CYCLE 4 (SPOP 458-1). Heat part to 1300o 25oF (704o 14oC) and hold for 2 hours. NOTE To minimize distortion, temperature may be raised and cooled gradually in accordance with Cycle 4A. Other cycles are permissible provided stressrelief requirement of 1300o 25oF (704o 14oC) for 2 hours is met. 9-47. CYCLE 4A (SPOP 458-2). Perform as follows: a. Put part in cold oven.

b. Heat to 600oF (316oC) and hold for 30 minutes. c. Increase to 800oF (427oC) and hold for 30 minutes. d. Increase to 1100oF (593oC) and hold for 30 minutes. e. Increase to 1300oF 25oF (704o 15oC) and hold for 2 hours. f. Cool to 500oF (260oC) not faster than 100oF (56 C) every 15 minutes.
o

b. Heat to 600oF (316oC) and hold for 30 minutes. c. Increase to 900o 15o(482o 8oC) and hold for 4 hours.

9-48. CYCLE 5 (SPOP 459-1). Heat part to 1600o25oF (871o 14oC) and hold for 2 hours.

9-9

T.O. 1-1A-9

NOTE To minimize distortion, temperature may be raised and lowered gradually in accordance with Cycle 5A. Other cycles are permissable provided stress-relief requirement of 1600o 25oF (871o 14oC) for 2 hours is met. 9-49. CYCLE 5A (SPOP 459-2). Perform as follows: a. Put part in cold oven. b. Heat to 700oF (371oC) and hold for 30 minutes. c. Increase to 1000oF (538oC) and hold for 30 minutes. d. Increase to 1300oF (704oC) and hold for 30 minutes. e. Increase to 1600o 25oF (871o 14oC) and hold for 2 hours. f. Cool to 500oF (260oC) not faster than 100oF (56 C) every 15 minutes.
o

c. Increase to 800oF (427oC) and hold for 30 minutes. d. Increase to 1010oF (543o8oC) and hold for 30 minutes. e. Cool to 500oF (260oC) not faster than 100oF (56 C) every 15 minutes.
o

9-54. CYCLE 9 (SPOP 459-3). Heat part to 1600o 25oF (871o 14oC) and hold for 1 hour. 9-55. CYCLE 11 (SPOP 464). Perform as follows:

CAUTION

. .

For titanium parts, a vacuum of 0.5 microns mercury, maximum, or argon or helium with a dew point no higher than -60oF (-51oC) shall be used. Longer heat treatment at specif ied temperature, or shorter heat treatment at higher temperature may be required by engine publication for certain parts.

9-50. CYCLE 6 (SPOP 460-1). Heat part to 1050o 15oF (566o 8oC) for 2 hours. NOTE To minimize distortion, temperature may be raised and lowered gradually in accordance with Cycle 6A. Other cycles are permissible provided stressrelief requirement of 1050o 15oF (566o 8oC) for 2 hours is met. 9-51. CYCLE 6A (SPOP 460-2). Perform as follows: a. Put part in cold oven. b. Heat to 600oF (316oC) and hold for 30 minutes. c. Increase to 800oF (427oC) and hold for 30 minutes. d. Increase to 1050o 15oF (566o 8oC) and hold for 2 hours. e. Cool to 500oF (260oC) not faster than 100oF (56 C) every 15 minutes.
o

a. Heat part to 1150o 15oF (621o 8oC) and hold for 1 hour. NOTE For materials other than titanium, air or argon may be used. b. Air cool.

9-56. CYCLE 13 (SPOP 466). Perform as follows: a. Heat part to 1400o 25oF (760o 14oC) in air and hold for 2 hours. b. Air cool, or faster.

9-57. CYCLE 14 (SPOP 467). Perform as follows: a. Heat part to 1500o 25oF (816o 14oC) and hold for 30 minutes. NOTE A protective atmosphere is suggested. b. Furnace cool at a rate of 50oF (28oC) per hour to 1100o (593oC), then air cool or faster. 9-58. CYCLE 22 (SPOP 482). Previously designated Cycle 10.

9-52. CYCLE 7 (SPOP 461). Heat part to 1500oF 25oF (815o14oC) and hold for 4 hours. 9-53. CYCLE 8 (SPOP 455-3). Perform as follows: a. Put part in cold oven. b. Heat to 600oF (316oC) and hold for 30 minutes.

9-10

T.O. 1-1A-9

CAUTION Parts shall be thoroughly cleaned before entering oven. NOTE Hydrogen, argon, vacuum, or air are acceptable atmospheres; however, when heat treatment is to be followed by weld repair, hydrogen is preferable because of its cleaning action on oxides and impurities difficult to clean mechanically, as within cracks or cavities. a. Place part in cold oven; however, this step may be omitted for thin sheet metal parts. b. Heat part to 1800o 25oF (982o 14oC) and hold for 1 hour. c. 9-59. Air cool. LOCAL STRESS-RELIEF.

9-65. Choice of method depends upon size and shape of joint, part conf iguration, and accessibility. Resistance blankets and quartz lamps can be used to 1350oF (732oC); induction heaters and radiant gas burners can be used to 1825oF (996oC).

CAUTION Thermocouples shall not be tack welded to titanium parts. 9-66. Temperature prof ile shall be monitored with tack welded thermocouples to provide accurate readout for manual or automatic control during heat treat cycle. Thermocouples shall be located every 2 inches of area that is to be stressrelieved. Following the cycle, thermocouples are broken or ground off, and part blended to original contour. 9-67. Stress-relief duration and temperature shall be the same as for a corresponding furnace heat treat, unless otherwise specif ied in applicable engine technical orders. 9-68. DESCRIPTION OF METHODS. Local stress-relief methods are def ined in the following paragraphs. 9-69. Resistance. Heaters consist of nichrome wire elements insulated with ceramic f iber and contained within a f lexible wire jacket. These components are woven into a thermal blanket, which shall be held in close contact with surface to be stress-relieved. Supplementary f lexible heaters may be added to ensure that adjacent parts do not conduct heat away in such a manner as to make heat distribution non-uniform. 9-70. Induction. Requirements include a high frequency generator, with a water-cooled copper induction coil of sufficient number of turns to be positioned over entire area to be heat treated, such as a welded patch. Coils shall be insulated from metal contact, which will produce electrical arcing. Typical applications include small weld repair of holes or bosses, or replacement of small detail parts. 9-71. Quartz Lamp. Radiant lamp provides intense infrared heat, which can be easily directed toward part being stress-relieved. Temperature can be controlled by pulsing lamp on and off. Typical applications include inlet guide vanes, exhaust struts, intermediate cases, door assemblies, accessory housing, and thrust reversers.

9-60. GENERAL. Local stress-relief is the application of a heat treatment cycle, using a portable heating system, to a part that has been weld repaired, usually without disassembly. Elaborate fixturing is avoided when stress-relieving minor areas of large components. 9-61. Approval for local stress-relief is governed in part by accessibility, temperature requirement, and conf iguration and material of part. 9-62. Local stress-relief is especially useful when applied to parts on a mounted or partly disassembled engine. 9-63. Besides avoiding disassembly, local stressrelief provides signif icant cost and time savings. 9-64. Typical local stress-relief methods include the following: a. b. c. Resistance Induction Quartz lamp CAUTION Gas burner shall not be used to stress-relieve titanium parts. Exhaust gases can produce harmful surface reaction. d. Gas burner radiant heater.

9-11

T.O. 1-1A-9

CAUTION Gas burner shall not be used to stress-relieve titanium parts. Exhaust gases can produce harmful surface reaction.

9-72. Radiant Gas Burner. Good heating patterns and temperature control are permitted by using as burners. Heat treat of several areas can be accomplished simultaneously. Radiant gas burners are fueled with a mixture of air and natural gas.

9-12

T.O. 1-1A-9

APPENDIX A SUPPLEMENTAL DATA

Table A-1. Chemical Symbols

ELEMENT

SYMBOL

ATOMIC NO. 13 51 18 33 56 4 83 5 35 48 55 20 6 58 17 24 27 -29 66 68 63 9 64 31 32 79 72 2 67 1 49 53 77 26 36 57 82 3 71 12 25 80 42

ELEMENT

SYMBOL

ATOMIC NO. 60 10 28 7 76 8 46 15 78 84 19 59 91 8 86 75 45 37 44 62 21 34 14 47 11 38 16 73 52 65 81 90 69 50 22 74 92 23 54 70 39 30 40

Aluminum Al Antimony Sb Argon A Arsenic As Barium Ba Beryllium Be Bismuth Bi Boron B Bromine Br Cadmium Cd Cesium Cs Calcium Ca Carbon C Cerium Ce Chlorine Cl Chromium Cr Cobalt Co Columbium (Niobium) Cb(Nb) Copper Cu Dysprosium Dy Erbium Er Europium Eu Fluorine F Gadolinium Gd Gallium Ga Germanium Ge Gold Au Hafnium Hf Helium He Holmium Ho Hydrogen H Indium In Iodine I Iridium Ir Iron Fe Krypton Kr Lanthanum La Lead Pb Lithium Li Lutecium Lu Magnesium Mg Manganese Mn Mercury Hg Molybdenum Mo

Neodymium Nd Neon Ne Nickel Ni Nitrogen N Osmium Os Oxygen O Palladium Pd Phosphorus P Platinum Pt Polonium Po Potassium K Praseodymium Pr Protactinium Pa Radium Ra Radon(radium emanation) Rn Rhemium Re Rhodium Rh Rubedium Rb Ruthenium Ru Samarium Sm Scandium Sc Selenium Se Silicon Si Silver Ag Sodium Na Strontium Sr Sulphur S Tantalum Ta Tellurium Te Terbium Tb Thallium Tl Thorium Th Thulium Tm Tin Sn Titanium Ti Tungsten W Uranium U Vanadium V Xenon Xe Ytterbium Yb Yttrium Yo Zinc Zn Zirconium Zr

A-1

T.O. 1-1A-9

Table A-2.

Decimal Equivalents

INCH

Mm.

DRILL SIZE NO. OR LTR 80 79

DECIMALS OF AN INCH 0.0135 0.0145 0.015625 0.15748 0.016 0.018 0.019685 0.02 0.021 0.021653 0.0225 0.023622 0.024 0.025 0.02559 0.026 0.027559 0.028 0.02925 0.029527 0.031 0.03125 0.031496 0.032 0.033 0.033464 0.035 0.035433 0.036 0.037 0.037401 0.038 0.039 0.03937 0.04 0.041 0.041338 0.042 0.043 0.043307 0.045275 0.0465 0.046875 0.047244 0.049212 0.051181 0.052 0.053149 0.055 0.055118 0.057086 0.059055 0.0595

INCH

Mm. 1.7

DRILL SIZE NO. OR LTR 51

DECIMALS OF AN INCH 0.066929 0.067 0.068897 0.07 0.070866 0.072834 0.073 0.074803 0.076 0.076771 0.078125 0.0785 0.07874 0.080708 0.081 0.082 0.082877 0.084645 0.086 0.086614 0.088582 0.089 0.090551 0.092519 0.0935 0.09375 0.094488 0.096 0.096456 0.098 0.098425 0.0995 0.1015 0.102362 0.104 0.106299 0.1065 0.108267 0.109375 0.11 0.110236 0.111 0.113 0.114173 0.116 0.11811 0.12 0.122047 0.125 0.125984 0.127952 0.1285 0.129921

1/64 0.4 78 77 0.5 76 75 0.55 74 0.6 73 72 0.65 71 0.7 70 69 0.75 68 1/32 0.8 67 66 0.85 65 0.9 64 63 0.95 62 61 1.0 60 59 1.05 58 57 1.1 1.15 56 3/64 1.2 1.25 1.3 55 1.35 54 1.4 1.45 1.5 53

1.75 50 1.8 1.85 49 1.9 48 1.95 5/64 47 2.0 2.05 46 45 2.1 2.15 44 2.2 2.25 43 2.3 2.35 42 3/32 2.4 41 2.45 40 2.5 39 38 2.6 37 2.7 36 2.75 7/64 35 2.8 34 33 2.9 32 3.0 31 3.1 1/8 3.2 3.25 30 3.3

A-2

T.O. 1-1A-9

Table A-2.

Decimal Equivalents - Continued

INCH 1/16

Mm. 1.55 1.6

DRILL SIZE NO. OR LTR

DECIMALS OF AN INCH 0.061023 0.0625 0.062992 0.635 0.06496 0.141732 0.144 0.145669 0.147 0.147637 0.1495 0.149606 0.152 0.153543 0.154 0.15625 0.157 0.15748 0.159 0.161 0.161417 0.165354 0.166 0.167322 0.169291 0.1695 0.171875 0.173 0.173228 0.177 0.177165 0.18 0.181102 0.182 0.185 0.185039 0.187007 0.1875 0.188976 0.189 0.191 0.192913 0.1935 0.196 0.19685 0.199 0.200787 0.201 0.203125 0.204 0.204724 0.2055 0.206692

INCH

Mm. 3.4

DRILL SIZE NO. OR LTR 29

DECIMALS OF AN INCH 0.133858 0.136 0.137795 0.1405 0.140625 0.234 0.234375 0.23622 0.238 0.240157 0.242 0.244094 0.246 0.246062 0.248031 0.25 0.251968 0.255905 0.257 0.259842 0.261 0.263779 0.265625 0.265747 0.266 0.267716 0.271653 0.272 0.27559 0.277 0.279527 0.281 0.28125 0.283464 0.285432 0.287401 0.29 0.291338 0.295 0.295275 0.296875 0.299212 0.302 0.303149 0.305117 0.307086 0.311023 0.3125 0.31496 0.316 0.318897 0.322834 0.323

3.5 28 9/64 A 15/64 6.0 B 6.1 C 6.2 D 6.25 6.3 1/4 6.4 6.5 F 6.6 G 6.7 17/64 6.75 H 6.8 6.9 I 7.0 J 7.1 K 9/32 7.2 7.25 7.3 L 7.4 M 7.5 19/64 7.6 N 7.7 7.75 7.8 7.9 5/16 8.0 O 8.1 8.2 P E

52 1.65 3.6 27 3.7 26 3.75 25 3.8 24 3.9 23 5/32 22 4.0 21 20 4.1 4.2 19 4.25 4.3 18 11/64 17 4.4 16 4.5 15 4.6 14 13 4.7 4.75 3/16 4.8 12 11 4.9 10 9 5.0 8 5.1 7 13/64 6 5.2 5 5.25

A-3

T.O. 1-1A-9

Table A-2.

Decimal Equivalents - Continued

INCH

Mm. 5.3

DRILL SIZE NO. OR LTR 4

DECIMALS OF AN INCH 0.208661 0.209 0.212598 0.213 0.216535 0.21875 0.220472 0.221 0.224409 0.226377 0.228 0.228346 0.232283 0.350393 0.35433 0.358 0.358267 0.359375 0.362204 0.364172 0.366141 0.368 0.370078 0.374015 0.375 0.377 0.377952 0.381889 0.383857 0.385826 0.386 0.389763 0.390625 0.3937 0.397 0.404 0.40625 0.413 0.413385 0.421875 0.43307 0.4375 0.452755 0.453125 0.46875 0.47244 0.484375 0.492125 0.5 0.51181 0.515625 0.53125 0.531495

INCH

Mm. 8.25 8.3

DRILL SIZE NO. OR LTR

DECIMALS OF AN INCH 0.324802 0.326771 0.328125 0.330708 0.332 0.334645 0.338582 0.339 0.342519 0.34375 0.344487 0.346456 0.348 0.71875 0.728345 0.734375 0.74803 0.75 0.765625 0.767715 0.78125 0.7874 0.796875 0.807085 0.8125 0.82677 0.828125 0.84375 0.846455 0.859375 0.86614 0.875 0.885825 0.890625 0.90551 0.90625 0.921875 0.925195 0.9375 0.94488 0.953125 0.964565 0.96875 0.98425 0.984375 1.0

5.4 3 5.5 7/32 5.6 2 5.7 5.75 1 5.8 5.9 8.9 9.0 T 9.1 23/64 9.2 9.25 9.3 U 9.4 9.5 3/8 V 9.6 9.7 9.75 9.8 W 9.9 25/64 10.0 X Y 13/32 Z 10.5 27/64 11.0 7/16 11.5 29/64 15/32 12.0 31/64 12.5 1/2 13.0 33/64 17/32 13.5

21/64 8.4 Q 8.5 8.6 R 8.7 11/32 8.75 8.8 S 23/32 18.5 47/64 19.0 3/4 49/64 19.5 25/32 20.0 51/64 20.5 13/16 21.0 53/64 27/32 21.5 55/64 22.0 7/8 22.5 57/64 23.0 29/32 59/64 23.5 15/16 24.0 61/64 24.5 31/32 25.0 63/64 1

A-4

T.O. 1-1A-9

Table A-2.

Decimal Equivalents - Continued

INCH 35/64

Mm. 14.0

DRILL SIZE NO. OR LTR

DECIMALS OF AN INCH 0.546875 0.55118 0.5625 0.570865 0.578125 0.59055 0.59375 0.609375 0.610235 0.625 0.62992 0.640625 0.649605 0.65625 0.66929 0.671875 0.6875 0.688975 0.703125 0.70866

INCH

Mm.

DRILL SIZE NO. OR LTR

DECIMALS OF AN INCH

9/16 14.5 37/64 15.0 19/32 39/64 15.5 5/8 16.0 41/64 16.5 21/32 17.0 43/64 11/16 17.5 45/64 18.0

A-5

T.O. 1-1A-9

Table A-3.

Engineering Conversion Factors

LENGTH 1 1 1 1 1 1 1 1 inch = 2.54 Centimeters = 0.0833 Foot = 0.0278 Yard foot = 0.305 Meter = 0.333 Yard yard = 0.914 Meter = 3 Feet Rod = 16 1/2 Feet = 5 1/2 Yards Mile = 1.609 Kilometers = 5280 Feet = 1760 Yards Centimeter = 0.3937 Inch = 0.0328 Foot Meter = 39.37 Inches = 3.281 Feet = 1.094 Yards Kilometer = 1000 Meters = 3280.83 Feet = 1093.61 Yards = 0.62137 Mile

AREA 1 1 1 1 1 1 1 1 1 Sq. Inch = 6.452 Sq. Centimeters Sq. Foot = 144 Sq. Inches = 929.032 Sq. Centimeters Sq. Yard = 1296 Sq. Inches = 9 Sq. Feet = 0.836 Sq. Meter Sq. Rod = 272 1/4 Sq Feet = 30 1/4 Sq. Yards Acre = 43,560 Sq. Feet = 160 Sq. Rods Sq. Mile = 640 Acres Sq. Centimeter = 0.155 Sq. Inch Sq. Meter = 1550 Sq. Inches = 10.764 Sq. Feet = 1.196 Sq. Yards Sq. Kilometer = 0.3861 Sq. Miles = 247.104 Acres

VOLUME 1 1 1 1 1 1 1 Cu. Inch = 16.39 Cu. Centimeters = 0.00433 Gallons* Cu. Foot = 1728 Cu. Inches = 7.48 Gallons* = 28.317 Liters = 0.037 Cu. Yards Cu. Yard = 27 Cu. Feet = 0.7646 Cu. Meter = 202 Gallons* Cu. Centimeter = 0.001 Liter = 0.061 Cu. Inch Cu. Meter = 35.31 Cu. Feet = 1.308 Cu. Yards = 264.2 Gallons* Quart* = 0.25 Gallons* = 57.75 Cu. Inches = 0.946 Liter = 2 Pints* Gallon* = 0.832702 Imperial Gallon = 231 Cu. Inches = 0.1377 Cu. Feet = 3.785 Liters = 3785 Cu. Centimeters 1 Gallon, Imperial = 1.20091 U.S. Gallons 1 Barrel (Std.) = 31 1/2 Gallons 1 Barrel (Oil) = 42 Gallons *U.S. Measure WEIGHT 1 1 1 1 1 1 1 Ounce = 16 Drams = 437.5 Grains = 0.0625 Pound = 28.35 Grams = 0.9155 Ounce (Troy) Pound = 16 0unces = 453.593 Grams = 0.453593 Kilogram Ton (Short) = 2000 Pounds = 907.185 Kilograms = 0.892857 Long Ton = 0.907185 Metric Ton Ton (Metric) = 2204.62 Pounds = 0.98421 Long Ton = 1.10231 Short Tons Ton (Long) = 2240 Pounds = 1016.05 Kilograms = 1.120 Short Tons = 1.01605 Metric Tons Gram = 15.43235 Grains = 0.001 Kilogram Kilogram = 2.20462 Pounds

COMPOUND UNITS 1 1 1 1 gram per square millimeter kilogram per square millimeter kilogram per square centimeter kilogram per square meter = = = = = 1.422 pounds per square inch 1.422.32 pounds per square inch 14.2232 pounds per square inch 0.2048 pound per square foot 1.8433 pounds per square yard

A-6

T.O. 1-1A-9

Table A-3.

Engineering Conversion Factors - Continued

COMPOUND UNITS (Cont) 1 1 1 1 1 1 1 1 1 1 1 kilogram meter kilogram per meter pound per square inch pound per square foot pound per square foot pound per cubic inch pound per cubic foot kilogram per cubic meter foot per second meter per second meter per second = = = = = = = = = = = 7.2330 foot pounds 0.6720 pound per foot 0.07031 kilogram per square centimeter 0.0004882 kilogram per square centimeter 0.006944 pound per square inch 27679.7 kilograms per cubic meter 16.0184 kilograms per cubic meter 0.06243 pound per cubic foot 0.30480 meter per second 3.28083 feet per second 2.23693 miles per hour

MULTIPLES Circumference of Circle Area of Circle Area of Triangle Surface of Sphere Volume of Sphere Area of Hexagon Area of Octagon ENGINEERING UNITS 1 Horsepower = 33,000 foot pounds per minute 550 foot pounds per second 746 watts 0.746 kilowatts 1 Horsepower Hour = 0.746 Kilowatt hours 1,980,000 foot pounds 2,545 heat units (B.T.U) 1 Kilowatt = 1,000 watts 1.34 horsepower 737.3 foot pounds per second 44.240 foot pounds per minute 56.9 heat units (B.T.U) per minute 1 kilowatt Hour = 1,000 watt hours 1.34 horsepower hours 2,655,220 foot pounds 3,412 heat units (B.T.U) 1 British Thermal Unit = 1,055 watt seconds 778 foot pounds 0.000293 kilowatt hour 0.000393 horsepower hour 1 Watt = 1 joule per second 0.00134 horsepower 3.3412 heat units (B.T.U.) per hour 0.7373 foot pounds per second 44.24 foot pounds per minute = Diameter X 3.1416 = Square of Diameter X 0.7854, or Square of Radius X 3.1416, or Square of Circumference X 0.07958 = Base X one-half altitude = Circumference X diameter, or Square of diameter X 3.1416 = Surface X one-sixth diameter, or Cube of diameter X 0.5236 = Square of Diameter of Inscribed Circle X 0.866 = Square of Diameter of Inscribed Circle X 0.828

A-7

T.O. 1-1A-9

The following weights are approximate and variations must be expected in practice. Table A-4. Bars-Flat Size Lbs Per Linear Ft 1/2 x 1 .......................................0.578 1/2 x 2 .......................................1.174 3/4 x 2 .......................................1.7604 3/4 x 3 .......................................2.6408 1 x 2 ..........................................2.3472 1 x 3 ..........................................3.5208 1 1/2 x 2 ....................................3.5208 1 3/4 x 3 1/2..............................7.1883 2 x 3 ..........................................7.0416 2 3/4 x 4 ..................................12.9096 3 x 4 ........................................14.350 Bars-Hexagon Size Lbs Per Linear Ft 3/8 .............................................0.147 7/16 ...........................................0.20 1/2 .............................................0.262 9/16 ...........................................0.331 5/8 .............................................0.409 3/4 .............................................0.639 1 ................................................1.047 1 1/4 ..........................................1.620 1 1/2 ..........................................2.340 Rods-Round Size Lbs Per Linear Ft 3/16 ...........................................0.032 1/4 .............................................0.058 5/16 ...........................................0.090 3/8 .............................................0.129 7/16 ...........................................0.176 1/2 .............................................0.230 9/16 ...........................................0.291 5/8 .............................................0.360 11/14 .........................................0.435 3/4 .............................................0.518 13/16 .........................................0.608 7/8 .............................................0.705 15/16 .........................................0.809 1 ................................................0.921 1 1/4 ..........................................1.439 1 3/8 ..........................................1.741 1 1/2 ..........................................2.072 1 3/4 ..........................................2.820 2 ................................................3.683 2 1/2 ..........................................5.755 2 3/4 ..........................................6.964 3 ................................................8.287 3 1/2 ........................................11.550 4 ..............................................15.200 Sheets Thickness Lbs Per Sq Ft .0126 .........................................0.1797 .016 ...........................................0.2253 .020 ...........................................0.2817 .0253 .........................................0.3570 .032 ...........................................0.4501 .0359 .........................................0.5055 Table of Weights - Aluminum and Aluminum Alloy .0403 .........................................0.5676 .0508 .........................................0.7158 .0641 .........................................0.9026 .0808 .........................................1.1382 .0907 .........................................1.2781 .128 ...........................................1.8099 .156 ...........................................2.202 .1875 .........................................2.6481 .250 ...........................................3.5215 .375 ...........................................5.2822 .500 ...........................................7.212 Tubing-Round Size Lbs Per Linear Ft 1/4 x .028 ..................................0.025 1/4 x .032 ..................................0.027 1/4 x .035 ..................................0.03 1/4 x .049 ..................................0.036 1/4 x .058 ..................................0.044 1/4 x .065 ..................................0.047 5/16 x .025 ................................0.027 5/16 x .028 ................................0.032 5/16 x .035 ................................0.039 5/16 x .065 ................................0.061 3/8 x .025 ..................................0.033 3/8 x .028 ..................................0.037 3/8 x .035 ..................................0.0435 3/8 x .042 ..................................0.053 3/8 x .049 ..................................0.063 7/16 x .035 ................................0.054 7/16 x .049 ................................0.075 1/2 x .032 ..................................0.056 1/2 x .035 ..................................0.063 1/2 x .042 ..................................0.073 1/2 x .049 ..................................0.086 1/2 x .065 ..................................0.11 9/16 x .032 ................................0.067 5/8 x .035 ..................................0.08 5/8 x .042 ..................................0.093 5/8 x .049 ..................................0.11 5/8 x .058 ..................................0.13 5/8 x .065 ..................................0.14 11/16 x .049 ..............................0.105 3/4 x .035 ..................................0.096 3/4 x .049 ..................................0.1245 3/4 x .058 ..................................0.15 3/4 x .065 ..................................0.17 3/4 x .083 ..................................0.21 13/16 x .032 ..............................0.095 13/16 x .049 ..............................0.13 7/8 x .028 ..................................0.09 7/8 x .035 ..................................0.11 7/8 x .049 ..................................0.16 15/16 x .032 ..............................0.11 15/16 x .049 ..............................0.17 15/16 x .083 ..............................0.27 1 x .032 .....................................0.12 1 x .035 .....................................0.13 1 x .042 .....................................0.16 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 2 x .049 .....................................0.18 x .058 .....................................0.210 x .065 .....................................0.23 x .083 .....................................0.29 1/16 x .032 .............................0.13 1/16 x .083 .............................0.31 1/8 x .035..............................0.15 1/8 x .049..............................0.20 1/8 x .058..............................0.24 1/8 x .065..............................0.27 3/16 x .083 .............................0.35 1/4 x .035..............................0.16 1/4 x .049..............................0.2134 1/4 x .058..............................0.27 1/4 x .065..............................0.30 1/4 x .083..............................0.37 5/16 x .083 .............................0.39 3/8 x .032..............................0.17 3/8 x .049..............................0.25 3/8 x .058..............................0.29 3/8 x .065..............................0.33 3/8 x .083..............................0.41 3/8 x .120..............................0.58 7/16 x .095 .............................0.48 1/2 x .035..............................0.19 1/2 x .049..............................0.27 1/2 x .058..............................0.32 1/2 x .065..............................0.36 1/2 x .083..............................0.45 5/8 x .065..............................0.39 5/8 x .125..............................0.72 11/14 x .095...........................0.58 3/4 x .035 ...............................0.23 3/4 x .049 ...............................0.32 3/4 x .065 ...............................0.3934 3/4 x .083 ...............................0.53 3/4 x .125 ...............................0.79 x .042 .....................................0.29 7/8 x .049 ...............................0.34 x .049 .....................................0.36 x .065 .....................................0.48 x .083 .....................................0.61 x .125 .....................................0.92 1/4 x .025 ...............................0.2052 1/2 x .065 ...............................0.61 Tubing-Streamline Size Lbs Per Linear Ft 1.500 x .250 x .020...................0.082 1.500 x .375 x .020...................0.085 1.625 x .375 x .025...................0.115 1.875 x .375 x .035...................0.16 2.00 x .875 x .049....................0.27 2.01563 x .375 x .025...............0.12 2.625 x .375 x .035...................0.22 3.00 x .375 x .035....................0.25 3.125 x .375 x .032...................0.25 3.350 x 1.50 x .065...................0.61 4.0625 x 1.71 x .065.................0.73

A-8

T.O. 1-1A-9

Table A-5. Bars-Flat Size Lbs Per Linear Ft 1/8 x 1/2 ............................. 0.238 1/8 x 3/4 ............................. 0.358 1/8 x 1 ................................ 0.475 1/8 x 1 3/4.......................... 0.815 1/8 x 2 ................................ 0.935 6/32 x 1 .............................. 0.625 3/16 x 3/4 ........................... 0.535 3/16 x 1 .............................. 0.715 3/16 x 1 1/4 ........................ 0.895 3/16 x 1 1/2 ........................ 1.00 3/16 x 1 3/4 ........................ 1.175 3/16 x 2 .............................. 1.385 3/16 x 2 1/2 ........................ 1.785 3/16 x 3 .............................. 2.055 1/4 x 1 ................................ 0.9575 1/4 x 1 1/8.......................... 1.075 1/4 x 1 1/4.......................... 1.185 1/4 x 1 3/4.......................... 1.585 1/4 x 2 ................................ 1.885 1/4 x 2 1/2.......................... 2.375 1/4 x 3 ................................ 2.815 1/4 x 6 ................................ 5.65 5/16 x 3/4 ........................... 0.957 5/16 x 1 .............................. 1.075 5/16 x 1 1/4 ........................ 1.475 5/16 x 1 1/2 ........................ 1.975 5/16 x 1 3/4 ........................ 2.075 5/16 x 2 .............................. 2.375 5/16 x 2 1/2 ........................ 3.075 5/16 x 3 .............................. 3.875 5/16 x 4 .............................. 5.125 5/16 x 6 .............................. 8.75 3/8 x 1 ................................ 1.285 3/8 x 1 1/4.......................... 1.575 3/8 x 1 1/2.......................... 2.00 3/8 x 1 3/4.......................... 2.275 3/8 x 2 ................................ 2.675 3/8 x 2 1/2.......................... 3.475 3/8 x 3 ................................ 4.175 3/8 x 4 ................................ 5.725 3/8 x 6 ................................ 8.325 1/2 x 1 ................................ 1.795 1/2 x 1 1/2.......................... 2.685 1/2 x 2 ................................ 3.675 1/2 x 2 1/2.......................... 4.675 1/2 x 3 ................................ 5.675 1/2 x 4 ................................ 7.705 1/2 x 6 .............................. 11.10 5/8 x 1 ................................ 2.156 5/8 x 2 ................................ 4.250 3/4 x 1 ................................ 2.875 3/4 x 2 ................................ 5.750 7/8 x 2 1/2.......................... 8.325 1 x 1 1/4 ............................. 4.525 1 x 2 ................................... 7.705 Bars-Hexagon Size Lbs Per Linear Ft 3/16 .................................... 0.1123 1/4 ...................................... 0.1997 5/16 .................................... 0.3120

Table of Weights - Brass 13/16 .................................. 1.913 7/8 ...................................... 2.218 18/14 .................................. 2.546 1 ......................................... 2.897 1 1/8 ................................... 3.667 1 3/14 ................................. 4.086 1 1/4 ................................... 4.527 1 5/16 ................................. 4.991 1 3/8 ................................... 5.478 1 7/16 ................................. 5.987 1 1/2 ................................... 6.519 1 9/16 ................................. 7.073 1 5/8 ................................... 7.651 1 11/16 ............................... 8.250 1 3/4 ................................... 8.873 1 13/14 ............................... 9.518 1 7/8 ................................. 10.19 1 15/16 ............................. 10.88 2 ....................................... 11.59 2 1/4 ................................. 14.67 2 1/2 ................................. 18.11 2 3/4 ................................. 21.91 2 7/8 ................................. 23.95 3 ....................................... 26.08 3 1/2 ................................. 36.75 4 ....................................... 46.93 5 ....................................... 74.25 6 ..................................... 108.25 Sheet Thickness Lbs Per Sq Ft .0031 .................................. 0.1393 .0035 .................................. 0.1564 .004 .................................... 0.1756 .0045 .................................. 0.1972 .005 .................................... 0.2214 .0056 .................................. 0.2486 .0063 .................................. 0.2792 .0071 .................................. 0.3135 .008 .................................... 0.3521 .0089 .................................. 0.3953 .010 .................................... 0.4439 .0113 .................................. 0.4985 .0126 .................................. 0.5598 .0142 .................................. 0.6286 .0159 .................................. 0.7059 .0179 .................................. 0.7927 .0201 .................................. 0.8901 .0226 .................................. 0.9995 .0253 .................................. 1.122 .0285 .................................. 1.260 .032 .................................... 1.415 .0359 .................................. 1.589 .0403 .................................. 1.785 .0453 .................................. 2.004 .0508 .................................. 2.251 .0571 .................................. 2.527 .0641 .................................. 2.838 .072 .................................... 3.187 .0808 .................................. 3.578 .0907 .................................. 4.018 .1019 .................................. 4.512 .1144 .................................. 5.067

3/8 ...................................... 0.4493 7/16 .................................... 0.6115 1/2 ...................................... 0.7987 9/16 .................................... 1.001 5/8 ...................................... 1.248 11/16 .................................. 1.510 3/4 ...................................... 1.797 12/16 .................................. 2.109 7/8 ...................................... 2.446 15/16 .................................. 2.808 1 ......................................... 3.195 1 1/8 ................................... 4.043 1 3/16 ................................. 4.505 1 1/4 ................................... 4.992 1 5/16 ................................. 5.503 1 3/8 ................................... 6.040 1 1/2 ................................... 7.188 1 9/16 ................................. 7.800 1 5/8 ................................... 8.436 1 11/14 ............................... 9.097 1 3/4 ................................... 9.784 1 13/16 ............................. 10.50 1 7/8 ................................. 11.23 1 15/16 ............................. 11.99 2 ....................................... 12.78 2 1/2 ................................. 19.97 3 ....................................... 26.41 Bars-Square Size Lbs Per Linear Ft 3/16 .................................... 0.1297 1/4 ...................................... 0.2306 9/16 .................................... 0.3602 3/8 ...................................... 0.5188 7/16 .................................... 0.7061 1/2 ...................................... 0.9222 5/8 ...................................... 1.441 3/4 ...................................... 2.075 1 ......................................... 3.689 1 1/4 ................................... 5.764 1 1/2 ................................... 8.300 2 ....................................... 14.76 Rods-Round Size Lbs Per Linear Ft 1/16 .................................... 0.01132 3/32 .................................... 0.03625 1/8 ...................................... 0.04527 6/32 .................................... 0.0915 3/16 .................................... 0.1019 7/32 .................................... 0.1475 1/4 ...................................... 0.1811 9/32 .................................... 0.2375 9/14 .................................... 0.2829 11/32 .................................. 0.3480 3/8 ...................................... 0.4074 28/64 .................................. 0.4185 12/32 .................................. 0.4866 7/16 .................................... 0.5546 1/2 ...................................... 0.7243 9/16 .................................... 0.9167 5/8 ...................................... 1.132 11/14 .................................. 1.369 3/4 ...................................... 1.630

A-9

T.O. 1-1A-9

Table A-5. .1285 .................................. 5.690 .1443 .................................. 6.389 .162 .................................... 7.175 .1819 .................................. 8.057 .2043 .................................. 9.047 .2294 ................................ 10.16 .2576 ................................ 11.41 .2893 ................................ 12.81 .3249 ................................ 14.39 .3648 ................................ 16.15 .4096 ................................ 18.14 .460 .................................. 20.37 Shim Stock Thickness No. Of Ozs Per Sq Ft .002 .................................... 1.40 .004 .................................... 2.75 .006 .................................... 4.50 .008 .................................... 6.00 .010 .................................... 6.75 .012 .................................... 9.00 Tubing-Round Size Lbs Per Linear Ft 1/8 x .020 ........................... 0.024 1/8 x .032 ........................... 0.034 3/16 x .028 ......................... 0.052 1/4 x .032 ........................... 0.081 1/4 x .049 ........................... 0.114 5/16 x .032 ......................... 0.104 3/8 x .028 ........................... 0.112 3/8 x .032 ........................... 0.127 3/8 x .042 ........................... 0.162 3/8 x .065 ........................... 0.233 7/14 x .028 ......................... 0.133 1/2 x .032 ........................... 0.173 1/2 x .035 ........................... 0.188 1/2 x .065 ........................... 0.327 5/8 x .032 ........................... 0.220 5/8 x .049 ........................... 0.327 5/8 x .065 ........................... 0.421 3/4 x .025 ........................... 0.210 3/4 x .032 ........................... 0.266 3/4 x .049 ........................... 0.397 7/8 x .032 ........................... 0.312 7/8 x .049 ........................... 0.468

Table of Weights - Brass - Continued .0035 .................................. 0.00003596 .004 .................................... 0.00004535 .0045 .................................. 0.00005718 .005 .................................... 0.00007210 .0056 .................................. 0.00009092 .0063 .................................. 0.0001146 .0071 .................................. 0.0001446 .008 .................................... 0.0001823 .0089 .................................. 0.0002299 .010 .................................... 0.0002898 .0113 .................................. 0.0003655 .0126 .................................. 0.0004609 .0142 .................................. 0.0005812 .0159 .................................. 0.0007328 .0179 .................................. 0.0009241 .0201 .................................. 0.001165 .0226 .................................. 0.001469 .0254 .................................. 0.001853 .0285 .................................. 0.002336 .032 .................................... 0.002946 .0359 .................................. 0.003715 .0403 .................................. 0.004684 .0453 .................................. 0.005907 .0508 .................................. 0.007449 .0571 .................................. 0.009393 .0641 .................................. 0.01184 .072 .................................... 0.01493 .0800 .................................. 0.01883 .0907 .................................. 0.02375 .1019 .................................. 0.02994 .1144 .................................. 0.03776 .1285 .................................. 0.04761 .1443 .................................. 0.06004 .162 .................................... 0.07571 .1819 .................................. 0.09547 .2043 .................................. 0.1204 .2294 .................................. 0.1518 .2576 .................................. 0.1914 .2893 .................................. 0.2414 .3249 .................................. 0.3044 .3648 .................................. 0.3838 .4096 .................................. 0.4839 .460 .................................... 0.6102

7/8 x .065 ........................... 0.609 1 x .032 .............................. 0.358 1 x .035 .............................. 0.391 1 x .049 .............................. 0.567 1 x .065 .............................. 0.703 1 1/8 x .032 ........................ 0.404 1 1/8 x .049 ........................ 0.610 1 1/8 x .058 ........................ 0.716 1 1/8 x .065 ........................ 0.797 1 1/8 x .095 ........................ 1.132 1 1/8 x .134 ........................ 1.1537 1 1/4 x .020 ........................ 0.285 1 1/4 x .032 ........................ 0.451 1 1/4 x .049 ........................ 0.681 1 1/4 x .058 ........................ 0.800 1 1/4 x .065 ........................ 0.891 1 1/4 x .072 ........................ 0.981 1 3/8 x .035 ........................ 0.543 1 3/8 x .049 ........................ 0.752 1 3/8 x .065 ........................ 0.935 1 1/2 x .032 ........................ 0.544 1 1/2 x .049 ........................ 0.823 1 1/2 x .065 ........................ 1.08 1 5/8 x .032 ........................ 0.590 1 5/8 x .049 ........................ 0.893 1 5/8 x .065 ........................ 1.173 1 3/4 x .032 ........................ 0.636 1 3/4 x .049 ........................ 0.964 1 3/4 x .065 ........................ 1.267 1 7/8 x .049 ........................ 1.035 2 x .032 .............................. 0.729 2 x .035 .............................. 0.796 2 x .065 .............................. 1.455 2 1/4 x .049 ........................ 1.248 2 1/4 x .065 ........................ 1.643 2 3/8 x .035 ........................ 0.9275 2 1/2 x .035 ........................ 0.998 2 1/2 x .065 ........................ 1.831 2 7/8 x .1875 ...................... 5.875 3 x .032 .............................. 1.200 Wire Size Lbs Per Linear Ft .0010 .................................. 0.000002884 .0031 .................................. 0.00002852 Table A-6. Table of Weights - Bronze

Bars-Hexagon Size Lbs Per Linear Ft 5/16 ...........................................0.3081 3/8 .............................................0.4437 7/16 ...........................................0.6039 1/2 .............................................0.7888 9/16 ...........................................0.9983 5/8 .............................................1.232 3/4 .............................................1.775 1 ................................................3.155 Rods-Round Size Lbs Per Linear Ft 1/8 .............................................0.04471 3/16 ...........................................0.1006 1/4 .............................................0.1788

9/16 ...........................................0.2794 3/8 .............................................0.4024 1/2 .............................................0.7154 9/16 ...........................................0.9054 5/8 .............................................1.118 11/16 .........................................1.353 3/4 .............................................1.610 13/14 .........................................1.889 7/8 .............................................2.191 1 ................................................2.862 1 1/8 ..........................................3.622 1 3/16 ........................................4.035 1 1/4 ..........................................4.471 1 3/8 ..........................................5.410 1 7/14 ........................................5.913

1 1/2 ..........................................6.438 1 3/4 ..........................................8.763 2 ..............................................11.45 2 1/8 ........................................12.92 2 1/2 ........................................17.88 3 ..............................................25.75 3 1/2 ........................................35.05 4 ..............................................45.78 Sheet Thickness Lbs Per Sq Ft .010 ...........................................0.4406 .012 ...........................................0.5552 .0159 .........................................0.7006 .0201 .........................................0.8857 .0253 .........................................1.115

A-10

T.O. 1-1A-9

Table A-6. .032 ...........................................1.410 .0359 .........................................1.582 .0403 .........................................1.776

Table of Weights - Bronze - Continued .0907 .........................................3.997 .1285 .........................................5.662

.050 ...........................................2.238 .0641 .........................................2.825 .0808 .........................................3.567 Table A-7. Table Of Weights - Copper

Bars-Flat Size Lbs Per Linear Ft 1/16 x 3/4 ..................................0.1809 1/8 x 1 .......................................0.4823 1/8 x 2 .......................................0.9646 1/4 x 1 .......................................0.9646 1/4 x 2 .......................................1.929 1/4 x 3 .......................................3.894 1/4 x 4 .......................................3.858 3/8 x 1 .......................................1.447 3/8 x 2 .......................................2.894 1/2 x 3/4 ....................................1.425 1/2 x 1 .......................................1.929 5/8 x 1 1/2.................................3.675 Rods-Round Size Lbs Per Linear Ft 1/4 .............................................0.1894 9/16 ...........................................0.2959 3/8 .............................................0.4261 7/16 ...........................................0.580 1/2 .............................................0.7576 5/8 .............................................1.184 3/4 .............................................1.705 7/8 .............................................2.320 1 ................................................3.030 1 1/8 ..........................................3.835 1 1/4 ..........................................4.735 1 1/2 ..........................................6.818 1 3/4 ..........................................9.281 2 ..............................................12.12 2 1/2 ........................................18.94 3 ..............................................27.27 Sheet Thickness Lbs Per Sq Ft .002 ...........................................0.125 .003 ...........................................0.1434 .005 ...........................................0.2312 .006 ...........................................0.2914 .010 ...........................................0.4625 .0126 .........................................0.5827 .0142 .........................................0.6567 .0159 .........................................0.7353 .0201 .........................................0.9296 .0226 .........................................1.0452 .0253 .........................................1.170 .032 ...........................................1.4799 .0359 .........................................1.6602 .0403 .........................................1.8637 .0453 .........................................2.0950 .0508 .........................................2.3493 .0571 .........................................2.6407 .0641 .........................................2.9644 .0808 .........................................3.7367 .0907 .........................................4.1946 .1285 .........................................5.9427 Tubing-Round

Size Lbs Per Linear Ft 1/8 x .020 ..................................0.026 1/8 x .025 ..................................0.030 1/8 x .028 ..................................0.033 1/8 x .032 ..................................0.036 1/8 x .049 ..................................0.045 3/16 x .022 ................................0.044 3/16 x .028 ................................0.055 3/16 x .032 ................................0.061 3/16 x .035 ................................0.065 3/16 x .042 ................................0.075 3/16 x .049 ................................0.083 7/22 x .065 ................................0.132 1/4 x .028 ..................................0.076 1/4 x .032 ..................................0.085 1/4 x .035 ..................................0.092 1/4 x .042 ..................................0.106 1/4 x .049 ..................................0.120 1/4 x .065 ..................................0.146 9/22 x .042 ................................0.122 3/16 x .025 ................................0.088 5/16 x .028 ................................0.097 5/16 x .032 ................................0.110 5/16 x .035 ................................0.119 5/16 x .042 ................................0.139 5/16 x .049 ................................0.158 5/16 x .058 ................................0.180 5/16 x .065 ................................0.196 3/8 x .025 ..................................0.106 3/8 x .028 ..................................0.118 3/8 x .032 ..................................0.134 3/8 x .035 ..................................0.145 3/8 x .042 ..................................0.170 3/8 x .049 ..................................0.194 3/8 x .065 ..................................0.245 3/8 x .083 ..................................0.295 3/8 x .095 ..................................0.325 7/16 x .032 ................................0.158 7/16 x .035 ................................0.171 7/16 x .042 ................................0.202 7/16 x .049 ................................0.232 7/16 x .065 ................................0.295 1/2 x .028 ..................................0.161 1/2 x .032 ..................................0.182 1/2 x .035 ..................................0.198 1/2 x .042 ..................................0.234 1/2 x .049 ..................................0.269 1/2 x .058 ..................................0.312 1/2 x .065 ..................................0.344 1/2 x .120 ..................................0.554 1/2 x .134 ..................................0.596 9/16 x .032 ................................0.207 9/16 x .035 ................................0.225 9/16 x .042 ................................0.266 9/16 x .049 ................................0.306 9/16 x .120 ................................0.645

9/16 x .134 ................................0.704 5/8 x .032 ..................................0.231 5/8 x .035 ..................................0.251 5/8 x .042 ..................................0.298 5/8 x .049 ..................................0.343 5/8 x .065 ..................................0.443 5/8 x .083 ..................................0.547 5/8 x .120 ..................................0.737 11/14 x .120 ..............................0.812 3/4 x .025 ..................................0.220 3/4 x .028 ..................................0.246 3/4 x .032 ..................................0.280 3/4 x .035 ..................................0.304 3/4 x .042 ..................................0.362 3/4 x .049 ..................................0.418 3/4 x .058 ..................................0.488 3/4 x .065 ..................................0.542 3/4 x .083 ..................................0.673 3/4 x .120 ..................................0.920 3/4 x .134 ..................................1.00 13/16 x .042 ..............................0.396 13/16 x .049 ..............................0.452 7/8 x .028 ..................................0.289 7/8 x .032 ..................................0.328 7/8 x .035 ..................................0.358 7/8 x .049 ..................................0.492 7/8 x .058 ..................................0.576 7/8 x .095 ..................................0.901 7/8 x .109 ..................................1.02 7/8 x .120 ..................................1.10 1 x .025 .....................................0.297 1 x .028 .....................................0.331 1 x .032 .....................................0.377 1 x .035 .....................................0.411 1 x .042 .....................................0.489 1 x .049 .....................................0.567 1 x .065 .....................................0.739 1 x .120 .....................................1.29 1 1/16 x .032 .............................0.403 1 1/16 x .035 .............................0.438 1 1/8 x .032 ...............................0.425 1 1/8 x .042 ...............................0.553 1 1/8 x .049 ...............................0.641 1 1/8 x .065 ...............................0.838 1 1/8 x .148 ...............................1.759 1 3/16 x .032 .............................0.453 1 1/4 x .032 ...............................0.474 1 1/4 x .035 ...............................0.517 1 1/4 x .049 ...............................0.716 1 1/4 x .065 ...............................0.937 1 1/4 x .072 ...............................1.03 1 1/4 x .148 ...............................1.98 1 5/16 x .032 .............................0.498 1 5/16 x .042 .............................0.648 1 5/16 x .049 .............................0.758 1 3/8 x .028 ...............................0.459

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T.O. 1-1A-9

Table A-7. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3/8 x .032 ...............................0.523 3/8 x .035 ...............................0.570 3/8 x .042 ...............................0.681 3/8 x .049 ...............................0.790 3/8 x .065 ...............................1.036 3/8 x .148 ...............................2.209 7/16 x .035.............................0.597 1/2 x .032 ...............................0.571 1/2 x .042 ...............................0.745 1/2 x .049 ...............................0.865 1/2 x .058 ...............................1.017 1/2 x .065 ...............................1.135 1/2 x .148 ...............................2.434 5/8 x .032 ...............................0.620 5/8 x .042 ...............................0.809 5/8 x .049 ...............................0.939 5/8 x .058 ...............................1.106 5/8 x .065 ...............................1.238 5/8 x .148 ...............................2.659 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2

Table Of Weights - Copper - Continued 2 1/2 x .065 ...............................1.93 2 3/4 x .095 ...............................3.07 3 x .120 .....................................4.20 Wire Size No. of Ft Per Lb .020 .......................................826.9 .0253 .....................................516.7 .032 .......................................323.0 .0359 .....................................256.6 .0403 .....................................203.7 .0508 .....................................128.2 .0625 .......................................84.67 .064 .........................................80.75 .072 .........................................63.80 .0808 .......................................50.66 .0907 .......................................40.21 .1019 .......................................31.85 .1285 .......................................20.03 .2576 .........................................4.984

3/4 x .032 ...............................0.669 3/4 x .042 ...............................0.873 3/4 x .049 ...............................1.014 3/4 x .065 ...............................1.332 3/4 x .148 ...............................2.884 7/8 x .032 ...............................0.717 7/8 x .042 ...............................0.937 7/8 x .049 ...............................1.088 7/8 x .065 ...............................1.431 7/8 x .148 ...............................3.109 x .032 .....................................0.766 x .035 .....................................0.837 x .042 .....................................1.00 x .049 .....................................1.163 x .065 .....................................1.530 x .083 .....................................1.936 x .095 .....................................2.202 1/4 x .049 ...............................1.31 1/4 x .065 ...............................1.73 Table A-8. Table of Weights - Iron

Angle Size Lbs Per Linear Ft 1 1/16 x 1 x 1............................0.40 1/8 x 3/4 x 3/4...........................0.59 1/8 x 1 x 1.................................0.80 1/8 x 1 1/2 x 1 1/2 ....................1.23 1/8 x 1 3/4 x 1 3/4 ....................1.44 1/8 x 2 x 2.................................1.65 3/16 x 1 x 1...............................1.16 3/16 x 1 1/4 x 1 1/4 ..................1.48 3/16 x 1 1/2 x 1 1/2 ..................1.80 3/16 x 1 1/2 x 2.........................2.12 3/16 x 2 x 2 1/2.........................2.75 3/16 x 2 1/2 x 2 1/2 ..................3.07 1/4 x 1 1/4 x 1 1/4 ....................1.92 1/4 x 1 1/2 x 1 1/2 ....................2.34 1/4 x 2 x 2.................................3.19 1/4 x 2 1/2 x 2 1/2 ....................4.10 1/4 x 3 x 3.................................4.9 1/4 x 4 x 4.................................6.6 5/16 x 2 1/2 x 3.........................5.6

5/16 x 3 x 3...............................6.1 3/8 x 1 1/2 x 1 1/2 ....................3.35 3/8 x 2 1/2 x 2 1/2 ....................5.90 5/8 x 6 x 6...............................24.2 Sheet-Black Thickness Lbs Per Sq Ft .0156 .........................................0.625 .0188 .........................................0.75 .025 ...........................................1.00 .032 ...........................................1.25 .0375 .........................................1.50 .0438 .........................................1.723 .050 ...........................................2.00 .0625 .........................................2.55 .0781 .........................................3.2 .093 ...........................................3.757 .125 ...........................................5.1 .156 ...........................................6.4 .1875 .........................................7.56 .250 .........................................10.2 .375 .........................................15.178 Table A-9. Table of Weights - Lead

.500 .........................................20.4 Sheet-Galvanized Thickness Lbs Per Sq Ft .0156 .........................................0.781 .0188 .........................................0.906 .025 ...........................................1.156 .032 ...........................................1.406 .0375 .........................................1.656 .0438 .........................................1.9064 .050 ...........................................2.156 .0625 .........................................2.62 .0938 .........................................3.9603 .125 ...........................................5.1563 Sheet-Terne Plate Size Lbs Per Sq Ft .0156 .........................................0.6377 .0186 .........................................0.7685 .025 ...........................................1.022 .0313 .........................................1.2795 .037 ...........................................1.5329 .050 ...........................................2.044

Sheet Thickness Lbs Per Sq Ft 1/32 ...........................................2.10 Table A-10. Bars-Flat Size Lbs Per Linear Ft 1/2 x 1 .......................................0.372 1/2 x 2 .......................................0.756 3/4 x 2 .......................................1.135 3/4 x 3 .......................................1.700 1 x 2 ..........................................1.513 1 x 3 ..........................................2.270 1 1/2 x 2 ....................................2.290 1 3/4 x 3 1/2..............................4.630

1/16 ...........................................4.25 3/52 ...........................................6.031

1/8 .............................................7.812 3/16 .........................................11.720

Table of Weights - Magnesium and Magnesium Alloy 2 x 3 ..........................................4.535 2 3/4 x 4 ....................................8.320 3 x 4 ..........................................9.240 Bars-Hexagon Size Lbs Per Linear Ft 3/8 .............................................0.095 7/16 ...........................................0.129 1/2 .............................................0.169 9/16 ...........................................0.213 5/8 .............................................0.263 3/4 .............................................0.412 1 ................................................0.674 1 1/4 ..........................................1.043 1 1/2 ..........................................1.510 Rods-Round Size Lbs Per Linear Ft 3/16 ...........................................0.021 1/4 .............................................0.037 3/16 ...........................................0.058 3/8 .............................................0.083

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T.O. 1-1A-9

Table A-10. 7/16 ...........................................0.114 1/2 .............................................0.148 3/16 ...........................................0.188 5/8 .............................................0.232 11/16 .........................................0.280 3/4 .............................................0.334 13/16 .........................................0.392 7/8 .............................................0.454 15/16 .........................................0.522 1 ................................................0.593 1 1/4 ..........................................0.927 1 3/8 ..........................................1.122 1 1/2 ..........................................1.348

Table of Weights - Magnesium and Magnesium Alloy - Continued 1 3/4 ..........................................1.818 2 ................................................2.385 2 1/2 ..........................................3.710 2 3/4 ..........................................4.480 3 ................................................5.340 3 1/2 ..........................................7.450 4 ................................................9.800 Sheets Thickness Lbs Per Sq Ft .0126 .........................................0.1158 .020 ...........................................0.1814 .016 ...........................................0.1451 .0253 .........................................0.230 .032 ...........................................0.290 .0359 .........................................0.3258 .0403 .........................................0.366 .0508 .........................................0.462 .0641 .........................................0.582 .0808 .........................................0.733 .128 ...........................................1.167 .0907 .........................................1.823 .156 ...........................................1.418 .1875 .........................................1.708 .250 ...........................................2.270 .375 ...........................................3.405 .500 ...........................................4.650

Table A-11. Rods-Round Size Lbs Per Linear Ft 1/4 .............................................0.182 3/16 ...........................................0.285 3/8 .............................................0.409 1/2 .............................................0.728 3/4 .............................................1.638 1 ................................................2.912 1 1/4 ..........................................4.55 1 1/2 ..........................................6.553 2 ..............................................11.651 2 1/2 ........................................18.203 Sheets Thickness Lbs Per Sq Ft .018 ...........................................0.84 .025 ...........................................1.11 .032 ...........................................1.39 .037 ...........................................1.65 .043 ...........................................1.91 .050 ...........................................2.22 .0625 .........................................2.76 .093 ...........................................4.14 .125 ...........................................5.56 .156 ...........................................6.94 .1875 .........................................8.32

Table of Weights - Nickel Chromium Iron Alloy (Inconel) .250 .........................................11.12 Tubing Size Lbs Per Linear Ft 1/4 x .028 ..................................0.071 1/4 x .035 ..................................0.088 1/4 x .049 ..................................0.113 1/4 x .065 ..................................0.139 5/16 x .028 ................................0.091 5/16 x .035 ................................0.113 5/16 x .049 ................................0.150 5/16 x .065 ................................0.188 3/8 x .028 ..................................0.113 3/8 x .035 ..................................0.139 3/8 x .049 ..................................0.188 3/8 x .058 ..................................0.217 3/8 x .065 ..................................0.236 1/2 x .035 ..................................0.191 1/2 x .049 ..................................0.257 1/2 x .058 ..................................0.299 1/2 x .065 ..................................0.329 5/8 x .049 ..................................0.329 5/8 x .065 ..................................0.424 3/4 x .035 ..................................0.292 3/4 x .049 ..................................0.400 3/4 x .058 ..................................0.468 3/4 x .065 ..................................0.519 7/8 x .035 ..................................0.343 7/8 x .049 ..................................0.472 7/8 x .058 ..................................0.552 7/8 x .065 ..................................0.613 1 x .035 .....................................0.393 1 x .049 .....................................0.543 1 x .058 .....................................0.636 1 x .065 .....................................0.708 1 1/4 x .049 ...............................0.686 1 1/4 x .065 ...............................0.897 1 3/8 x .049 ...............................0.757 1 3/8 x .065 ...............................0.988 1 1/2 x .035 ...............................0.597 1 1/2 x .049 ...............................0.828 1 1/2 x .065 ...............................1.09 1 3/4 x .049 ...............................0.969 1 3/4 x .065 ...............................1.28 2 x .049 .....................................1.11 2 x .065 .....................................1.46 2 1/4 x .049 ...............................1.26 2 1/4 x .065 ...............................1.65 2 1/2 x .049 ...............................1.40 2 1/2 x .065 ...............................1.84 3 1/4 x .120 ...............................4.38

Table A-12. Rods-Round Size Lbs Per Linear Ft 1/4 .............................................0.190 3/16 ...........................................0.309 3/8 .............................................0.428 1/2 .............................................0.761 3/4 .............................................1.172

Table of Weights - Nickel Copper Alloy Thickness Lbs Per Sq Ft .018 ...........................................0.86 .025 ...........................................1.15 .032 ...........................................1.44 .037 ...........................................1.72 .125 ...........................................5.75

1 ................................................3.044 1 1/4 ..........................................4.756 1 1/2 ..........................................6.849 2 ..............................................12.178 2 1/2 ........................................19.027 Sheets

Table A-13. Bars-Flat Lbs Per Linear Ft 1/2 ..................................0.106 3/4 ..................................0.1594 1 .....................................0.212 1 1/2 ...............................0.319 2 .....................................0.425 2 1/2 ...............................0.531

Table of Weights - Steel 3/16 3/16 3/16 3/16 3/16 3/16 3/16 3/16 x x x x x x x x 1/2 ..................................0.319 3/4 ..................................0.478 1 .....................................0.638 1 1/4 ...............................0.797 1 1/2 ...............................0.956 2 .....................................1.28 2 1/2 ...............................1.59 3 .....................................1.91

Size 1/14 1/14 1/14 1/14 1/14 1/14

x x x x x x

1/14 x 3 .....................................0.638 1/8 x 1/2 ....................................0.2125 1/8 x 3/4 ....................................0.3188 1/8 x 1 .......................................0.425 1/8 x 1 1/2.................................0.638 1/8 x 2 .......................................0.850 1/8 x 2 1/2.................................1.06 1/8 x 3 .......................................1.27

A-13

T.O. 1-1A-9

Table A-13. 1/4 x 1/2 ....................................0.425 1/4 x 3/4 ....................................0.636 1/4 x 1 .......................................0.850 1/4 x 1 1/4.................................1.06 1/4 x 1 1/2.................................1.28 1/4 x 1 3/4.................................1.49 1/4 x 2 .......................................1.70 1/4 x 2 1/2.................................2.13 1/4 x 3 .......................................2.55 3/16 x 1/2 ..................................0.531 3/16 x 3/4 ..................................0.797 5/16 x 1 .....................................1.06 5/16 x 1 1/4 ...............................1.33 5/16 x 1 1/2 ...............................1.59 5/16 x 1 3/4 ...............................1.86 5/16 x 2 .....................................2.13 5/16 x 2 1/4 ...............................2.39 5/16 x 2 1/2 ...............................2.66 5/16 x 2 3/4 ...............................2.92 5/16 x 3 .....................................3.19 3/8 x 1/2 ....................................0.638 3/8 x 1 .......................................1.28 3/8 x 1 1/4.................................1.59 3/8 x 1 1/2.................................1.91 3/8 x 2 .......................................2.55 3/8 x 2 1/2.................................3.19 3/8 x 3 .......................................3.83 3/8 x 3 1/2.................................4.46 3/8 x 4 .......................................5.10 3/8 x 6 .......................................7.65 1/2 x 1 .......................................1.70 1/2 x 1 1/4.................................2.13 1/2 x 1 1/2.................................2.55 1/2 x 2 .......................................3.40 1/2 x 2 1/2.................................4.25 1/2 x 3 .......................................5.10 1/2 x 3 1/2.................................5.95 1/2 x 4 .......................................6.80 1/2 x 4 1/2.................................7.65 1/2 x 5 .......................................8.50 1/2 x 6 .....................................10.20 5/8 x 2 .......................................4.25 5/8 x 2 1/2.................................5.31 5/8 x 3 .......................................6.38 5/8 x 3 1/2.................................7.44 5/8 x 4 .......................................8.50 5/8 x 6 .....................................12.75 3/4 x 1 .......................................2.55 3/4 x 1 1/2.................................3.85 3/4 x 2 .......................................5.10 3/4 x 2 1/2.................................6.38 3/4 x 3 .......................................7.65 3/4 x 4 .....................................10.20 3/4 x 5 .....................................12.75 3/4 x 6 .....................................15.30 1 x 2 ..........................................6.80 1 x 2 1/2 ....................................8.50 1 x 3 ........................................10.20 1 x 4 ........................................13.60 1 x 5 ........................................17.00 1 x 6 ........................................20.40 1 1/4 x 2 ....................................8.50 1 1 1 1 1 2 2 2 2 3

Table of Weights - Steel - Continued 5/32 ...........................................0.065 3/16 ...........................................0.094 7/32 ...........................................0.128 1/4 .............................................0.167 9/32 ...........................................0.211 5/16 ...........................................0.261 11/22 .........................................0.316 3/8 .............................................0.376 7/16 ...........................................0.511 1/2 .............................................0.668 9/16 ...........................................0.845 5/8 .............................................1.043 11/16 .........................................1.262 3/4 .............................................1.502 13/16 .........................................1.763 7/8 .............................................2.044 15/16 .........................................2.347 1 ................................................2.670 1 1/16 ........................................3.015 1 1/8 ..........................................3.380 1 3/16 ........................................3.766 1 1/4 ..........................................4.172 1 3/8 ..........................................5.049 1 7/16 ........................................5.518 1 1/2 ..........................................6.008 1 5/8 ..........................................7.051 1 3/4 ..........................................8.178 1 7/8 ..........................................9.388 2 ..............................................10.68 2 1/4 ........................................13.52 2 5/16 ......................................14.28 2 3/8 ........................................15.06 2 1/2 ........................................16.69 2 3/4 ........................................20.19 3 ..............................................24.03 3 1/4 ........................................28.21 3 1/2 ........................................32.71 3 3/4 ........................................37.55 4 ..............................................42.73 4 1/2 ........................................54.07 5 ..............................................66.76 5 1/2 ........................................80.78 6 ..............................................96.13 7 ............................................130.8 8 ............................................170.9 Sheets Thickness Lbs Per Sq Ft .0156 .........................................0.6377 .020 ...........................................0.8952 .025 ...........................................1.022 .03125 .......................................1.2795 .0375 .........................................1.5329 .050 ...........................................2.044 .0625 .........................................2.5549 .0781 .........................................3.1928 .093 ...........................................3.8344 .109 ...........................................4.4557 .125 ...........................................5.1096 .156 ...........................................6.377 .1875 .........................................7.6851 .250 .........................................10.219 Tubing-Round

1/4 x 3 ..................................12.75 1/4 x 4 ..................................17.00 1/2 x 2 ..................................10.20 1/2 x 3 ..................................15.30 1/2 x 5 ..................................25.50 x 2 1/2 ..................................17.00 x 3 ........................................20.40 x 4 ........................................27.20 1/2 x 3 ..................................25.50 x 4 ........................................40.80 Bars-Hexagon Size Lbs Per Linear Ft 1/4 .............................................0.195 5/16 ...........................................0.29 3/8 .............................................0.43 7/16 ...........................................0.56 1/2 .............................................0.73 9/16 ...........................................0.93 5/8 .............................................1.15 11/16 .........................................1.40 3/4 .............................................1.66 13/16 .........................................1.91 7/8 .............................................2.25 13/16 .........................................2.58 1 ................................................2.94 1 1/16 ........................................3.33 1 1/8 ..........................................3.73 1 1/4 ..........................................4.60 1 5/16 ........................................5.07 1 3/8 ..........................................5.57 1 1/2 ..........................................6.62 1 3/4 ..........................................9.00 2 ..............................................11.78 Bars-Square Size Lbs Per Linear Ft 1/8 .............................................0.053 3/16 ...........................................0.120 1/4 .............................................0.212 5/16 ...........................................0.332 3/8 .............................................0.478 7/16 ...........................................0.651 1/2 .............................................0.850 9/16 ...........................................1.076 5/8 .............................................1.328 3/4 .............................................1.913 7/8 .............................................2.603 1 ................................................3.40 1 1/8 ..........................................4.303 1 1/4 ..........................................5.313 1 5/16 ........................................5.857 1 3/8 ..........................................6.428 1 1/2 ..........................................7.650 1 3/4 ........................................10.41 2 ..............................................13.60 2 1/4 ........................................17.21 2 1/2 ........................................21.25 3 ..............................................30.60 Rods-Rounds Size Lbs Per Linear Ft 1/16 ...........................................0.010 3/32 ...........................................0.023 1/8 .............................................0.042

A-14

T.O. 1-1A-9

Table A-13. Size Lbs Per Linear Ft 3/16 x .028 ................................0.0476 3/16 x .035 ................................0.0569 1/4 x .028 ..................................0.0663 1/4 x .035 ..................................0.0803 1/4 x .049 ..................................0.1051 1/4 x .058 ..................................0.1188 1/4 x .065 ..................................0.1283 5/16 x .028 ................................0.0850 5/16 x .035 ................................0.1036 5/16 x .049 ................................0.1378 5/16 x .058 ................................0.1575 5/16 x .065 ................................0.1716 5/16 x .095 ................................0.2204 3/8 x .028 ..................................0.1037 3/8 x .035 ..................................0.1270 3/8 x .049 ..................................0.1704 3/8 x .058 ..................................0.1962 3/8 x .065 ..................................0.2150 3/8 x .083 ..................................0.2586 3/8 x .095 ..................................0.2838 7/16 x .028 ................................0.1223 7/16 x .035 ................................0.1503 7/16 x .049 ................................0.2030 7/16 x .065 ................................0.2583 7/16 x .083 ................................0.3139 7/16 x .095 ................................0.3471 1/2 x .028 ..................................0.1410 1/2 x .035 ..................................0.1736 1/2 x .042 ..................................0.2052 1/2 x .049 ..................................0.2358 1/2 x .058 ..................................0.2735 1/2 x .065 ..................................0.3017 1/2 x .083 ..................................0.3693 1/2 x .095 ..................................0.4105 9/16 x .035 ................................0.1969 9/16 x .049 ................................0.2684 9/16 x .065 ................................0.3450 9/16 x .095 ................................0.4738 5/8 x .028 ..................................0.1783 5/8 x .035 ..................................0.2203 5/8 x .049 ..................................0.3011 5/8 x .058 ..................................0.3509 5/8 x .065 ..................................0.3883 5/8 x .083 ..................................0.480 5/8 x .095 ..................................0.5372 5/8 x .120 ..................................0.6465 11/14 x .035 ..............................0.2437 11/14 x .049 ..............................0.3338 11/14 x .065 ..............................0.4317 11/14 x .095 ..............................0.6005 3/4 x .028 ..................................0.2157 3/4 x .035 ..................................0.2670 3/4 x .049 ..................................0.3665 3/4 x .058 ..................................0.4282 3/4 x .065 ..................................0.4750 3/4 x .083 ..................................0.5906 3/4 x .095 ..................................0.6639 3/4 x .120 ..................................0.8066 13/14 x .035 ..............................0.2903 13/16 x .049 ..............................0.3991 13/16 x .058 ..............................0.4669

Table of Weights - Steel - Continued 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1/2 x .065 ...............................0.9951 1/2 x .083 ...............................1.255 1/2 x .095 ...............................1.424 1/2 x .120 ...............................1.767 1/2 x .1875 .............................2.626 9/16 x .049 .............................0.7912 9/16 x .065 .............................1.038 9/16 x .095 .............................1.487 5/8 x .049 ...............................0.8239 5/8 x .058 ...............................0.9697 5/8 x .065 ...............................1.082 5/8 x .083 ...............................1.365 5/8 x .095 ...............................1.551 5/8 x .120 ...............................1.927 11/16 x .049...........................0.8566 11/16 x .065...........................1.125 11/16 x .095...........................1.614 3/4 x .035 ...............................0.6404 3/4 x .049 ...............................0.8892 3/4 x .058 ...............................1.047 3/4 x .065 ...............................1.169 3/4 x .083 ...............................1.476 3/4 x .095 ...............................1.677 3/4 x .120 ...............................2.087 3/4 x .125 ...............................2.167 3/4 x .1875 .............................3.126 13/16 x .049...........................0.9219 13/16 x .065...........................1.212 13/16 x .095...........................1.741 7/8 x .049 ...............................0.9546 7/8 x .058 ...............................1.124 7/8 x .065 ...............................1.255 7/8 x .095 ...............................1.804 7/8 x .120 ...............................2.247 15/16 x .049...........................0.9873 15/16 x .065...........................1.299 15/16 x .095...........................1.867 x .035 .....................................0.7338 x .049 .....................................1.020 x .058 .....................................1.202 x .065 .....................................1.340 x .083 .....................................1.698 x .095 .....................................1.931 x .120 .....................................2.407 x .125 .....................................2.501 x .1875 ...................................3.626 1/8 x .035 ...............................0.7804 1/8 x .049 ...............................1.085 1/8 x .058 ...............................1.279 1/8 x .065 ...............................1.429 1/8 x .095 ...............................2.057 1/8 x .120 ...............................2.567 1/4 x .035 ...............................0.8271 1/4 x .049 ...............................1.151 1/4 x .058 ...............................1.356 1/4 x .065 ...............................1.515 1/4 x .083 ...............................1.919 1/4 x .095 ...............................2.184 1/4 x .120 ...............................2.727 1/4 x .125 ...............................2.834 1/4 x .1875 .............................4.126 3/8 x .049 ...............................1.216

13/16 x .065 ..............................0.5184 7/8 x .028 ..................................0.2530 7/8 x .035 ..................................0.3137 7/8 x .049 ..................................0.4318 7/8 x .058 ..................................0.5056 7/8 x .065 ..................................0.5617 7/8 x .095 ..................................0.7906 7/8 x .120 ..................................0.9666 15/16 x .035 ..............................0.3370 15/16 x .049 ..............................0.4645 15/16 x .065 ..............................0.6051 15/16 x .083 ..............................0.7567 1 x .028 .....................................0.2904 1 x .035 .....................................0.3603 1 x .049 .....................................0.4972 1 x .058 .....................................0.5829 1 x .065 .....................................0.6484 1 x .083 .....................................0.8120 1 x .095 .....................................0.9173 1 x .120 .....................................1.127 1 1/16 x .035 .............................0.3837 1 1/16 x .049 .............................0.5298 1 1/16 x .065 .............................0.6917 1 1/8 x .035 ...............................0.4070 1 1/8 x .049 ...............................0.5625 1 1/8 x .058 ...............................0.6603 1 1/8 x .065 ...............................0.7351 1 1/8 x .083 ...............................0.9227 1 1/8 x .095 ...............................1.044 1 1/8 x .120 ...............................1.287 1 3/16 x .035 .............................0.4304 1 3/16 x .049 .............................0.5952 1 3/16 x .065 .............................0.7784 1 3/16 x .095 .............................1.107 1 3/16 x .120 .............................1.367 1 1/4 x .028 ...............................0.3650 1 1/4 x .035 ...............................0.4537 1 1/4 x .049 ...............................0.6279 1 1/4 x .058 ...............................0.7376 1 1/4 x .065 ...............................0.8218 1 1/4 x .083 ...............................1.034 1 1/4 x .095 ...............................1.171 1 1/4 x .120 ...............................1.447 1 1/4 x .125 ...............................1.500 1 1/4 x .134 ...............................1.595 1 5/16 x .035 .............................0.4770 1 5/16 x .049 .............................0.6605 1 5/16 x .065 .............................0.8651 1 5/16 x .095 .............................1.234 1 5/16 x .120 .............................1.527 1 3/8 x .035 ...............................0.5004 1 3/8 x .049 ...............................0.6932 1 3/8 x .058 ...............................0.8150 1 3/8 x .065 ...............................0.9085 1 3/8 x .083 ...............................1.144 1 3/8 x .120 ...............................1.607 1 7/16 x .049 .............................0.7259 1 7/16 x .065 .............................0.9518 1 7/16 x .095 .............................1.361 1 1/2 x .035 ...............................0.5470 1 1/2 x .040 ...............................0.7585 1 1/2 x .058 ...............................0.8923

A-15

T.O. 1-1A-9

Table A-13. 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3/8 x .065 ...............................1.602 3/8 x .095 ...............................2.311 3/8 x .120 ...............................2.887 1/2 x .049 ...............................1.281 1/2 x .065 ...............................1.689 1/2 x .083 ...............................2.140 1/2 x .095 ...............................2.438 1/2 x .120 ...............................3.047 1/2 x .125 ...............................3.167 3/4 x .083 ...............................2.362 3/4 x .095 ...............................2.691 3/4 x .120 ...............................3.367 3/4 x .125 ...............................3.501 x .095 .....................................2.944 x .120 .....................................3.687 3/4 x .120 ...............................4.647 3/4 x .15625...........................5.991 3/4 x .1875.............................7.127 Tubing-Streamline Size Lbs Per Linear Ft 1.697 x .707 x .049...................0.6279 1.70 x .70 x .035.......................0.4537 1.874 x .781 x .035...................0.5004 1.875 x .786 x .049...................0.6932 2.047 x .854 x .049...................0.7585

Table of Weights - Steel - Continued .024 .......................................650.9 .025 .......................................599.9 .028 .......................................478.2 .031 .......................................383.9 .032 .......................................366.1 .035 .......................................306.1 .036 .......................................289.3 .040 .......................................234.3 .041 .......................................223. .045 .......................................182.7 .047 .......................................166.2 .049 .......................................156.2 .0508 .....................................145.3 .054 .......................................128.6 .058 .......................................111.5 .0625 .......................................95.98 .0641 .......................................91.25 .071 .........................................72.32 .080 .........................................58.58 .0907 .......................................45.58 .101 .........................................36.11 .118 .........................................26.04 .1285 .......................................22.71 .162 .........................................14.29

2.047 x .854 x .058...................0.8923 2.215 x .823 x .035...................0.5937 2.21875 x .921 x .049...............0.8239 2.386 x .994 x .049...................0.8892 2.386 x .994 x .058...................1.047 2.386 x .994 x .065...................1.169 2.726 x 1.136 x .035.................0.7338 3.00 x .375 x .035.....................0.7338 3.067 x 1.278 x .049.................1.151 3.067 x 1.278 x .065.................1.515 3.748 x 1.563 x .083.................2.362 Wire Thickness No. of Ft Per Lb .006 ................................... 10415. .008 .....................................5858. .009 .....................................4629. .010 .....................................3749. .011 .....................................2936. .012 .....................................2604. .013 .....................................2218. .014 .....................................1913. .016 .....................................1465. .018 .....................................1157. .020 .......................................937.3

Table A-14. Sheet Thickness Lbs Per Sq Ft .018 ...........................................0.67

Table of Weights - Zinc .0508 .........................................1.87 .109 ...........................................3.98

.032 ...........................................1.20 .045 ...........................................1.68 .049 ...........................................1.87

A-16

T.O. 1-1A-9

Table A-15.

Temperature Conversion Chart

A-17

T.O. 1-1A-9

Table A-16.

Standard Bend Radii for 90o Cold Forming-Flat Sheet

A-18

T.O. 1-1A-9

Table A-16.

Standard Bend Radii for 90o Cold Forming-Flat Sheet - Continued

Table A-17.

Metal Bending and Bend Radii Bend Allowances Sheet Metal Bend Allowances Per Degree of Bend Aluminum Alloys

Stock Thickness BEND RADIUS 1/32 1/16 3/32 1/8 5/32 3/16 7/32 1/4 9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2 17/32 9/16 19/32 0.022 0.00072 0.00126 0.00180 0.00235 0.00290 0.00344 0.00398 0.00454 0.00507 0.00562 0.00616 0.00671 0.00725 0.00780 0.00834 0.00889 0.00943 0.00998 0.01051 0.032 0.00079 0.00135 0.00188 0.00243 0.00297 0.00352 0.00406 0.00461 0.00515 0.00570 0.00624 0.00679 0.00733 0.00787 0.00842 0.00896 0.00951 0.01005 0.01058 0.040 0.00086 0.00140 0.00195 0.00249 0.00304 0.00358 0.00412 0.00467 0.00521 0.00576 0.00630 0.00685 0.00739 0.00794 0.00848 0.00903 0.00957 0.01012 0.01065 0.051 0.00094 0.00149 0.00203 0.00258 0.00312 0.00367 0.00421 0.00476 0.00530 0.00584 0.00639 0.00693 0.00748 0.00802 0.00857 0.00911 0.00966 0.01020 0.01073 0.064 0.00104 0.00159 0.00213 0.00268 0.00322 0.00377 0.00431 0.00486 0.00540 0.00595 0.00649 0.00704 0.00758 0.00812 0.00867 0.00921 0.00976 0.01030 0.01083 0.091 0.00125 0.00180 0.00234 0.00289 0.00343 0.00398 0.00452 0.00507 0.00561 0.00616 0.00670 0.00725 0.00779 0.00834 0.00888 0.00943 0.00997 0.01051 0.01105 0.128 0.00154 0.00209 0.00263 0.00317 0.00372 0.00426 0.00481 0.00535 0.00590 0.00644 0.00699 0.00753 0.00808 0.00862 0.00917 0.00971 0.01025 0.01080 0.01133 0.187 0.00200 0.00255 0.00309 0.00364 0.00418 0.00473 0.00527 0.00582 0.00636 0.00691 0.00745 0.00800 0.00854 0.00908 0.00963 0.01017 0.01072 0.01126 0.01179

Bend Allowance per One Degree

A-19

T.O. 1-1A-9

Table A-17.

Metal Bending and Bend Radii Bend Allowances Sheet Metal Bend Allowances Per Degree of Bend Aluminum Alloys Continued

Stock Thickness BEND RADIUS 5/8 21/32 11/16 23/32 3/4 0.022 0.01107 0.01161 0.01216 0.01269 0.01324 0.032 0.01114 0.01170 0.01223 0.01276 0.01332 0.040 0.01121 0.01175 0.01230 0.01283 0.01338 0.051 0.01129 0.01183 0.01238 0.01291 0.01347 0.064 0.01139 0.01193 0.01248 0.01301 0.01357 0.091 0.01160 0.01214 0.01268 0.01322 0.01378 0.128 0.01189 0.01245 0.01298 0.01351 0.01407 0.187 0.01235 0.01289 0.01344 0.01397 0.01453

Bend Allowance per One Degree

Example: To determine bend allowance Given: Stock = 0.064 aluminum alloy, Bend Radius = 1/8, Bend Angle = 50o Find bend allowance for 1o in column for 0.064 Aluminum opposite 1/8 in column Bend Radius. Multiply this bend allowance (0.00268 in this case) by the number of degrees of the desired bend angle: 0.00268 x 50 = 0.1340 = total bend allowance to be added to the length of the straight sides of the part to determine the total length of the material needed.

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Table A-18.

Bend Set Back Chart

A-21

T.O. 1-1A-9

Table A-19.

Comparative Table of Standard Gages

1. United States Steel Wire Gage (STL.W.G.) Also known as: National Wire, Standard Steel Wire, Steel Wire, American Steel and Wire Company, Roebling, Washburn and Moen Gages. Used for bare wire of galvanized, black annealed, bright basic tinned or copper coated, iron or steel, spring steel wire. Not used for telephone and telegraph wire. 2. British Imperial Standard Wire Gage (I.S.W.G.) or (N.B.S.) Also known as British Imperial Wire or English Legal Standard Gages. Used for bare copper telephone wires in the U.S. and for all wires and aluminum sheets in England. 3. Browne & Sharpe Gage (B.&S.G.) Also known as American or American Wire Gages. Used for bare wire of brass, phosphor bronze, German silver, aluminum, zinc and copper (not for copper telephone or telegraph wire). Also resistance wire of German silver and other alloys, and for insulated wire of aluminum and copper. Also for rods of brass, copper, phosphor bronze and aluminum; sheets of copper, brass, phosphor bronze, aluminum and German silver; brazed brass and brazed copper tubing. 4. Birmingham Wire Gage (B.W.G.) Also known as Birmingham, Stubs or Studs Iron Wire Gages. Used for iron and steel telephone and telegraph wire and strip steel, steel bands, hoop steel, crucible spring steel, round-edged f lat wire, and with limited usage for copper sheets. Also for seamless brass, seamless copper, seamless steel, stainless steel and aluminum tubes, and for boiler tubes. 5. Standard Birmingham Sheet and Hoop Gage (B.G.) Used in England for iron and steel sheets and hoops. 6. United States Standard (Revised) (U.S.S.G.) Also known as U.S. Standard Sheet Metal or U.S. Standard for Steel and Iron Sheets and Plates Gages. This is a gage based on the weight per square foot of sheets rather than on thickness. It is used for commercial iron and steel sheets and plates including planished, galvanized, tinned and terne plates, black sheet iron, blue annealed sof t steel, steel plate, hot-rolled sheet steel, cold-rolled sheet steel, hot-rolled monel metal, cold-rolled monel metal. Other gages in use: Trenton Iron Company Gage. Zinc gage for sheet zinc only. Birmingham Metal Gage-in England for brass sheets. American Steel and Wire Companys music wire gage. Twist Drill and Steel Wire Gage for twist drill and steel drill rods. THICKNESS IN DECIMALS OF AN INCH United States Standard (Revised) U.S.S.G. Gage Number United States Steel Wire (STL.W.G) .4900 .4615 .4305 .3938 .3625 .3310 .3065 .2830 .2625 .2437 .2253 .2070 .1920 .1770 .1620 .1483 .1350 .1205 .1055 .0915 .0800 .0720 .0625 .0540 .0475 British Imperial Standard Wire (I.S.W.G.) .500 .464 .432 .400 .372 .348 .324 .300 .276 .252 .232 .212 .192 .176 .160 .144 .128 .116 .104 .092 .080 .072 .064 .056 .048 Standard Birmingham Sheet and Hoop (B.G.) .6666 .6250 .5883 .5416 .5000 .4452 .3964 .3532 .3147 .2804 .2500 .2225 .1981 .1764 .1570 .1398 .1250 .1113 .0991 .0882 .0785 .0699 .0625 .0556 .0495

Browne & Sharpe (B.& S.G.) ------.580000 .516500 .460000 .409642 .364796 .324861 .289297 .257627 .229423 .204307 .181940 .162023 .144285 .128490 .114423 .101897 .090742 .080808 .071962 .064084 .057068 .050821 .045257 .040303

Birmingham Wire (B.W.G.) ----------.500 .454 .425 .380 .340 .300 .284 .259 .238 .220 .203 .180 .165 .148 .134 .120 .109 .095 .083 .072 .065 .058 .049

Thickness Approx. ---------------------------------------------.2391 .2242 .2092 .1943 .1793 .1644 .1494 .1345 .1196 .1046 .0897 .0749 .0673 .0598 .0538 .0478

Weight Oz/Sq Ft. ---------------------------------------------160 150 140 130 120 110 100 90 80 70 60 50 45 40 36 32

0000000 000000 00000 0000 000 00 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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T.O. 1-1A-9

Table A-19.

Comparative Table of Standard Gages - Continued

THICKNESS IN DECIMALS OF AN INCH United States Standard (Revised) U.S.S.G. Gage Number United States Steel Wire (STL.W.G) .0410 .0348 .03175 .0286 .0258 .0230 .0204 .0181 .0173 .0162 .0150 .0140 .0132 .0128 .0118 .0104 .0095 .0090 .0085 .0080 .0075 .0070 British Imperial Standard Wire (I.S.W.G.) .040 .036 .032 .028 .024 .022 .020 .018 .0164 .0148 .0136 .0124 .0116 .0108 .0100 .0092 .0084 .0076 .0068 .0060 .0052 .0048 Standard Birmingham Sheet and Hoop (B.G.) .0440 .0392 .0349 .03125 .02782 .02476 .02204 .01961 .01745 .015625 .0139 .0123 .0110 .0098 .0087 .0077 .0069 .0061 .0054 .0048 .0043 .0038

Browne & Sharpe (B.& S.G.) .035890 .031961 .028462 .025346 .022572 .020101 .017900 .015941 .014195 .012641 .011257 .010025 .008928 .007950 .007080 .006305 .005615 .005000 .004453 .003965 .003531 .003144

Birmingham Wire (B.W.G.) .042 .035 .032 .028 .025 .022 .020 .018 .016 .014 .013 .012 .010 .009 .008 .007 .005 .004 ---------------------

Thickness Approx. .0418 .0359 .0329 .0299 .0269 .0239 .0209 .0179 .0164 .0149 .0135 .0120 .0105 .0097 .0090 .0082 .0075 .0067 .0064 .0060 -----------

Weight Oz/Sq Ft. 28 24 22 20 18 16 14 12 11 10 9 8 7 6.5 6 5.5 5 4.5 4.25 4 -----------

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Table A-20.

Melting Points Approximate

ELEMENTS C ALUMINUM ANTIMONY BARIUM BERYLIUM BISMUTH CADMIUM CALCIUM CARBON CHROMIUM COBALT COPPER GOLD IRON LEAD LITHIUM MAGNESIUM MANGANESE MERCURY MOLYBDENUM 660 631 850 1350 271 321 810 3500 1765 1480 1083 1063 1535 327 186 651 1260 -39 2620

DEGREES F 1220 1167 1562 2462 520 610 1490 6332 3209 2696 1981 1945 2795 621 367 1204 2300 -38 4748

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T.O. 1-1A-9

Table A-20.

Melting Points Approximate - Continued

ELEMENTS C NICKEL PHOSPHOROUS (YELLOW) PLATINUM SILICON SILVER TIN TUNGSTEN VANADIUM ZINC 1446 44 1773 1420 961 232 3400 1710 420

DEGREES F 2635 111 3223 2588 1761 449 6152 3110 787

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T.O. 1-1A-9

GLOSSARY

A ACID BRITTLENESS--Brittleness of steel resulting from use of acid solutions to remove scale, clean and electroplate. Brittleness is caused by the absorption of hydrogen into the metal from the acid solutions (also called hydrogen embrittlement). AGING--(a) Generally any change in properties with time which occurs at relatively low temperature (room or elevated) af ter a f inal heat treatment of a cold marking operation. Aging is a process in which the trend is toward restoration of real equilibrium and away from an unstable condition induced by a prior operation. (b) Specif ically the formation of a new phase by cooling a solid solution to super saturated state and allowing the super saturated solution to partially return to equilibrium by the formation of a less concentrated solid solution and a new phase. AIR HARDENING--An alloy which does not require quenching from a high temperature to harden. Hardening of the material occurs simply by cooling in air from above critical temperature. The term refers only to the ability of the material to harden in air and does not imply any def inite analysis or composition. AIR COOLING/QUENCHING--Cooling from an elevated temperature in air, still or forced. ALLOY--A mixture with metallic properties composed of two or more elements of which at least one is a metal. However, a metal is not designated an alloy based on elements incidental to its manufacture. For example; iron, carbon, manganese, silicon, phosphorus, sulphur, oxygen, nitrogen and hydrogen are incidental to the manufacture of plain carbon steel. It does not become an alloy steel until the elements are increased beyond regular composition or until other elements (metal) are added in significant amounts for a specif ic purpose. ALLOY ELEMENTS--Chemical elements comprising an alloy, usually limited to the metallic elements added to modify the basic metal properties. AMORPHOUS--Non-crystalline. ANNEALING--Generally it is a controlled heating procedure which leads to maximum sof tness, ductility and formability. The annealing procedure is utilized for the following: (a) Remove stresses. (b) Induce softness. (c) Af ter ductility, toughness, electrical, magnetic, or physical properties. (d) Ref ine crystalline structure. (e) Remove gases. (f) Produce a def inite micro-structure. ANNEALING FULL--A controlled heating procedure which leads to maximum sof tness, ductility and formability. ANNEALING, ISOTHERMAL--Heating of a ferritic steel to a austenitic structure (fully or partial) followed by cooling to and holding at a temperature that causes transformation of the austenite to a relatively soft ferrite and carbide structure. ANODIC OXIDE COATING--A thin f ilm of aluminum oxide formed on the surface of aluminum and aluminum alloy parts by electro-chemical means. AS CAST--Condition of a casting as it leaves the mold with no heat treatment. AUSTENITE--A solid solution of iron carbide in gamma iron. It forms when the metal solidif ies and remains a solution until it cools to about 732oC (1350oF). Theoretically the solution would remain if the iron or steel were cooled instantaneously from a bright red heat to atmospheric temperature, but in practice, this degree of rapidity is impracticable, and only a portion of the austenite is preserved by rapid cooling. Addition of certain alloying elements such as nickel and manganese perserves austenite below - 17oC (0oF).

Glossary 1

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GLOSSARY - Continued

B BARK--The decarburized skin or layer just beneath the scale found af ter heating steel in an oxidizing atmosphere. BASE METAL--The metal to which other elements are added to form an alloy possessing specif ic properties. BESSEMER PROCESS--A process for making steel by blowing air through molten pig iron contained in a suitable vessel. The process is one of rapid oxidation primarily of silicon and carbon. BILLET--An ingot or bloom that has been reduced through rolling or hammering to an approximate square ranging from 1 1/2 inches square to 6 inches square, or to an approximate rectangular cross-section of equivalent area. Billets are classif ied as semi-f inished products for re-rolling or forging. BINARY ALLOY--An alloy containing two elements, apart from minor impurities. BLACK ANNEALING--A process of box annealing of sheets prior to tinning whereby a black color is imparted to the surface of the product. BLUE ANNEALING--A process of annealing sheets af ter rolling. The sheets, if fairly heavy, are allowed to cool slowly af ter the hot rolling; if of lighter gage, as is usually the case, they are passed singly through an open furnace for heating to the proper annealing temperature. The sheets have a bluishblack appearance. BLUE BRITTLENESS--Brittleness occurring in steel when in the temperature range of 149o to 371oC (300o to 700oF), or when cold af ter being worked within this temperature range. BOX ANNEALING--Sof tening steel by heating it, usually at a sub-critical temperature, in a suitable closed metal box or pot to protect it from oxidation, employing a slow heating and cooling cycle; also called closed annealing or pot annealing. BRIGHT ANNEALING--A process of annealing, usually with reducing gases, such that surface oxidation is reduced to a minimum, thereby yielding a relatively bright surface. BRITTLENESS--Brittleness is the property of a material which permits little bending or deformation without fracture. Brittleness and hardness are closely associated. BURNING--The heating of a metal to temperatures sufficiently close to the melting point to cause permanent injury. Such injury may be caused by the melting of the more fusible constituents, by the penetration of gases such as oxygen into the metal with consequent reactions, or perhaps by the segregation of elements already present in the metal. BUTT-WELD--The welding of two abutting edges. C CARBON FREE--Metals and alloys which are practically free from carbon. CARBURIZING (CEMENTATION)--Adding carbon to the surface of iron-base alloys by heating the metal below its melting point in contact with carbonaceous solids, liquids, or gases. CASE--The surface layer of an iron-base alloy which has been made substantially harder than the interior by the process of case hardening. CASE HARDENING--A heat treatment of a combination of heat treatments in which the surface layer of an iron-base alloy is made substantially harder than the interior by altering its composition by carburizing, cyaniding, or nitriding.

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GLOSSARY - Continued

C (Cont) CHAPMANIZING--A process for hardening steel by bubbling ammonia through a cyaniding salt bath and holding the f inished part in the gas stream. This method produces a case almost as hard as nitriding at a time factor of slightly longer than required for cyaniding. CHARPY IMPACT--An impact test made by measuring in a Charpy machine the energy required to fracture a standard notched specimen in bending. The values so obtained are merely comparative between different materials tested by the same method. COLD DRAWING--The permanent deformation of metal below its recrystallization temperature, by drawing the bay through one or more dies. COLD ROLLING--The permanent deformation of metal below its recrystallization temperature by rolling. This process is frequently applied in f inishing rounds, sheets, strip, and tin plate. COLD TREATING--Cooling to sub-zero temperature for various purposes, but primarily to promote transformation of austenite. COLD WORKING--Plastic deformation of a metal at a temperature low enough to insure strain hardening. CORE--The interior portion of an iron-base alloy which is substantially sof ter than the surface layer as the result of case hardening. Also, that portion of a forging removed by trepanning; the inner part of a rolled section of rimmed steel as distinct from the rimmed portion or rim; a body of sand or other material placed in a mold to produce a cavity in a casting. CONVERSION COATING (CHEMICAL)--A f ilm intentionally produced on a metal by subjection to a selected chemical solution for the purpose of providing improved corrosion resistance or to improve the adhesion of subsequently applied organic coating. CYANIDING--Surface hardening by carbon and nitrogen absorption of an iron-base alloy article or portion of it by heating at a suitable temperature in contact with a cyanide salt, followed by quenching. COOLING--Any decrease in temperature; however, specif ic term usually applies to reducing metal temperature in a gaseous environment rather than quenching in a liquid. D DECALESCENCE--When a piece of steel is heated, the temperature rises uniformly until it reaches a point between 718oC and 732oC (1,325oF and 1,350oF). At this point the rise in temperature suddenly halts due to the fact that the metal absorbs the heat necessary for the change of state. Af ter this halt the temperature will continue its normal rate of increase. It is the halting in the temperature range that is termed decalescence. At the point of decalesence, the carbon and iron are forming a solid solution and the steel is passing from its annealed condition into its hardened condition. DECARBURIZATION--The removal of carbon (usually refers to the surface of solid steel) by the (normally oxidizing) action of media which reacts with carbon. The decarburized area is sometimes referred to as the bark.

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GLOSSARY - Continued

D (Cont) DEFECTS IN METALS--Damage occurring to metal during manufacture/fabrication process. Some typical defects are as follows: (a) Blister - a defect in metal produced by gas bubbles either on the surface or formed beneath the surface. Very f ine blisters are called pinhead or pepper blisters. (b) Blow hole - a hole produced during the solidif ication of metal by evolved gas which in falling to escape, is held in pockets. (c) Bursts -ruptures made in forging or rolling. (d) Fin (Flash) - a thin f in of metal formed at the side of a forging or weld where a small portion of the metal is forced out between the edges of the forging or welding case. (e) Flake -Internal f issures (cracks or clef ts) in large steel forgings or large (MASS) rolled shapes. In a factured surface or test piece, they appear as sizable areas of silvery brightness and coarser grain size than their surroundings. Sometimes known as chrome checks and hairline cracks. (f) Ghost - (Ferrite ghost) a faint band of ferrite. (g) Lap - a surface defect appearing as a seam caused from folding over hot metal, f ins, or sharp corners and then rolling or forging, but not welding, them into the surface. (h) Pipe - a cavity formed in metal (especially ingots) during solidification of the last portion of liquid metal causes the cavity or pipe. (i) Scab - a rough projection on a casting caused by the mold breaking or being washed by the molten metal; or occuring where the skin from a blowhole has partly burned away and is not welded. (j) Seam - a crack on the surface of metal which has been closed but not welded; usually produced by blowholes which have become oxidized. If very f ine, a seam may be called a hair crack or hair seam. (k) Segregation a mixture of compounds and elements, which, when cooled from the molten state, solidify at different temperatures. (l) Ductility the ability of a metal to withstand plastic deformation without rupture. Ductility is usually determined by tension test using a standard test (2 gauge length) specimen. The test specimen is loaded in tension to rupture. The specimen is then assembled and measured for length and diameter at the fracture. The increase in length is expressed as per cent elongation and the decrease in diameter as per cent reduction of area. The above terms measure ductility and since they are comparative, considerable experience is required for proper evaluation of material for the purpose intended. DUCTILITY--The property that permits permanent deformation before fracture by stress in tension. E ELASTIC LIMIT--The elastic limit of a material is the greatest load per unit area which will not produce a measurable permanent deformation af ter complete release of load. ELONGATION--The amount of permanent extension at any stage in any process which continuously elongates a body. EMBRITTLEMENT--Loss of ductility of a metal, which may result in premature failure. (see acid brittleness). ENDURANCE LIMIT--The highest unit stress at which a material can be subjected to a very large number of repetitions of loading and still show no evidence of failure. Above this limit failure occurs by the generation and growth of cracks until fracture results in the remaining section. ENDURANCE RATIO--The ratio of the endurance limit for cycles of reversed f lexural stress to the tensile strength. EQUALIZING--Intermediate heat treatment (special) which assists in developing desired properties, primary use is for equalizing/relieving stresses resulting from cold working. EUTECTIC ALLOY--An alloy which has a lower melting point than neighboring compositions. More then one eutectic composition may occur in a given alloy system. EXFOLIATION--The cracking or f laking off of the outer layer of an object. EXPOSURE--Heating to or subjecting to an elevating temperature or environment for a certain period of time.

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GLOSSARY - Continued

E (Cont) ETCHING--Attack of metals structure by reagents. In metallography, the process of revealing structual details by the preferential attack of reagents on a metal surface. (a) Micro - etching is for the examination of the sample under a microscope and for this purpose the sample must be very carefully polished (by an experienced person) prior to etching. (b) Macro-etching is for the examination of the sample under a low power magnifying glass or by unaided eye. High polishing for this purpose is not absolutely essential; however, a good polish is necessary. (c) Deep-etching is a form of macro-etching in which the sample with regular cut surface may be immersed in hot hydrocloric acid (50% acqueous solution) and then examined for major defects such as inclusions, segregations, cracks; etc. F FATIGUE--The phenomenon of the progressive fracture of a metal by means of a crack which spreads under repeated cycles of stress. FATIGUE LIMIT--Usually used as synonymous with endurance limit. FERRITE--A solution in which alpha iron is the solvent, and which is characterized by a body centered cubic crystal structure. FILLET--A concave junction of two surfaces usually perpendicular. FLAME HARDENING--A process of hardening a ferrous alloy by heating it above the transformation range by means of a high-temperature f lame and then cooling as required. FORGING STRAINS--Elastic strains resulting from forging or from cooling from the temperature. FORMING--To shape or fashion with hand/tools or by a shape or mold. FRACTURE TESTING--A test used to determine type of structure, carbon content and the presence of internal defects. The test specimen is broken by any method that will produce a clean sharp fracture. The fracture is then examined by eye or with the aid of a low former magnifying glass. A trained/ experienced observer will determine grain size; approximate depth of carburized or decarburized surface area; the presence of inclusions of dirty steel; and defects such as seams, cracks, pipes bursts and f lakes. FULLY HARDENED--Applies generally to the maximum hardness obtainable. (In particular, applies to materials that are hardened by a strain and/or age hardening process). FUSIBLE ALLOYS--A group of nonferrous alloys which melt at relatively low temperatures. They usually consist of bismuth, lead, tin, etc., in various proportions, and iron only as an impurity. G GALVANIC SERIES--A list of metals and alloys arranged in order of their relative potentials in a given environment. The galvanic series indicates the tendency of the serval metals and alloys to set up galvanic corrosion. The relative position within a group sometimes changes with external conditions, but it is only rarely that changes occur from group to group. GRAINS--Individual crystals in metal. When metal is in molten state, the atoms have no uniform grouping. However, upon solidif ication they arrange themselves in a geometric pattern. GRAIN GROWTH--An increase in the grain size of metal.

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GLOSSARY - Continued

H HARDENABILITY--The ability of an alloy to harden fully throughout the entire section thickness either by cold working or heat treatment. The maximum thickness at which this may be accomplished can be used as a measure of hardenability. HARDENING--Hardening accomplished by heating the metal to a specif ied temperature, then rapidly cooling by quenching in oil, water, or brine. This treatment produces a f ine grain structure, extreme hardness, maximum tensile strength, and minimum ductility. HARDNESS--Hardness refers to the ability of a material to resist abrasion, penetration, indentation, or cutting action. The wearing qualities of a material are in part dependent upon its hardness. Hardness and strength are properties which are closely related for wrought alloys. HARDNESS TESTING--Test used to determine the ability of a metal to resist penetration. The test results are usually directly related to tensile and yield strength of the metal involved. An exception would be case hardness. See Section VIII for typical testing methods. HEAT TINTING--Heating a specimen with a suitable surface in air for the purpose of developing the structure by oxidizing or otherwise affecting the different constituents. HEAT TREATMENT--An operation, or combination of operations, involving the heating and cooling of a metal or alloy in the solid state for the purpose of obtaining certain desirable conditions or properties. Heating and cooling for the sole purpose of mechanical working are excluded from the meaning of this definition. HOMOGENIZING--Annealing or soaking at very high temperatures in order to reduce alloy segregation by diffusion. HOT SHORTNESS--Brittleness in metal when hot. In iron when sulphur is in excess of the manganese necessary to combine with it to form manganese sulphide the excess sulphur combines with the iron to form iron sulphide. This constituent has a lower melting point than the iron and the result can be that steel may crack during hot working. HYDROGEN EMBRITTLEMENT--See Acid Brittleness. I IMPACT TEST--A test in which one or more blows are suddenly applied to a specimen. The results are usually expressed in terms of energy absorbed or number of blows (of a given intensity) required to break the specimen. See Charpy Impact and Izod Impact. INCLUSION--Particles of impurities, usually oxides, sulphides, silicates, and such which are mechanically held during solidif ication or which are formed by subsequent reaction of the solid metal. INDUCTION HARDENING--A process of hardening a ferrous alloy by heating above the transformation range by means of electrical induction and then cooling as required. M MACHINABILITY--The cutting characteristic of metal and resulting surface f inish using standard cutting tools and coolant/lubricants. There are various factors that effect the machinability of a metal such as hardness, grain size, alloy constituents, structure, inclusions; shape, type, condition of tool and coolant. The standard machinability ratings are usually based on comparison to SAE 1112/Aisi B 1112 Bessemer screw stock which is rated at 100% machinability.

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GLOSSARY - Continued

M (Cont) MAGNA FLUX TESTING--A method of inspection used to detect/locate defects such as cavities, cracks or seams in steel parts at or very close to the surface. The test is accomplished by magnetizing the part with equipment specially designed for the purpose and applying magnetic powder, wet or dry, Flaws are then indicated by the powder clinging to them (see Section VIII for additional data). MALLEABILITY--Malleability is the property of a material which enables it to be hammered, rolled, or to be pressed into various shapes without fracture. Malleability refers to compression deformation as contrasted with ductility where the deformation is tensile. MARTEMPERING--This is a method of hardening steel by quenching from the austenitizing temperature into a medium at a temperature in the upper part of or slightly above the martensite range and holding it in the medium until temperature is substantially uniform throughout the alloy is then allowed to cool in air through the martensite range. MARTENSITE--It is the decomposition product which results from very rapid cooling of austenite. The lower the carbon content of the steel, the faster it must be cooled to obtain martensite. MECHANICAL HARDNESS--See Hardness. MECHANICAL PROPERTIES--Those properties that reveal the reaction, elastic and inelastic, of a material to an applied force, or that involve the relationship between stress and strain; for example, tensile strength, yield strength, and fatigue limit. MECHANICAL TESTING--Testing methods by which mechanical properties are determined. MECHANICAL WORKING--Subjecting metal to pressure exerted by rolls, presses, or hammers, to change its form, or to affect the structure and therefore the mechanical and physical properties. MODULUS OF ELASTICITY--The ratio, within the limit of elasticity, of the stress in the corresponding strain. The stress in pounds per square inch is divided by the elongation in fractions of an inch for each inch of the original gage length of the specimen. N NITRIDING--Adding nitrogen to iron-base alloys by heating the metal in contact with ammonia gas or other suitable nitrogenous material. Nitriding is conducted at a temperature usually in the range 502o-538oC (935o-1000oF) and produces surface hardening of the metal without quenching. NORMALIZING--Heating iron-base alloys to approximately 55oC (100oF) above the critical temperature range, followed by cooling to below that range in still air at ordinary temperatures. This process is used to remove stresses caused by machining, forging, bending, and welding. O OVERHEATING--Heating to such high temperatures that the grains have become coarse, thus impairing the properties of the metal. P PATENTING--Heating iron-base alloys above the critical temperature range followed by cooling below that range in air, or in molten lead, or a molten mixture of nitrate or nitrites maintained at a temperature usually between 427o-566oC (800-1050oF),depending on the carbon content of the steel and the properties required of the f inished product. This treatment is applied to wire and to medium or high carbon steel as a treatment to precede further wire drawing.

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GLOSSARY - Continued

P (Cont) PHYSICAL PROPERTIES--Those properties exclusive of those described under mechanical properties; for example, density, electrical conductivity, coefficient of thermal expansion. This term has of ten been used to describe mechanical properties, but this usage is not recommended. PHYSICAL TESTING--Testing methods by which physical properties are determined. This term is also inadvisedly used to mean the determination of the mechanical properties. PICKLING--Removing scale from steel by immersion in a diluted acid bath. PLASTIC DEFORMATION--The permanent change in size or shape of a material under stress. POTENTIOMETER--Potentiometer 1s an instrument used to measure thermocouple voltage by balancing a known battery voltage against it. PROCESS ANNEALING--Heating iron-base alloys to a temperature below or close to the lower limit of the critical temperature range, followed by coolings desired. This treatment is commonly applied to sheet and wire and the temperatures generally used are from 549o to 649oC (1020o to 1200oF). PROOF STRESS--The proof stress of a material is that load per unit area which a material is capable of withstanding without resulting in a permanent deformation of more than a specif ied amount per unit of gage length af ter complete release of load. PROPORTIONAL LIMIT--The proportional limit of a material is the load per unit area beyond which the increases in strain cease to be directly proportional to the increases in atress. PYROMETER--An instrument for measuring temperature. Q QUENCHING--Rapid cooling by immersion in liquids or gases. QUENCHING MEDIA--Quenching media are liquids or gases in which metals are cooled by immersion. Some of the more common are brine (10 percent sodium chloride solution), water 18oC (65oF), f ish oil, paraffin base petroleum oil, machine oil, air, engine oil, and commercial quenching oil. R RECALESCENCE--When steel is slowly cooled from a point above the critical temperature, the cooling proceeds at a uniform rate until the piece reaches a point between 677o and 704oC (1,250o and 1,300oF). At this time, the cooling is noticeably arrested and the metal actually rises in temperature as the change of state again takes place. This change is the opposite of decalescence and is termed recalescence. REDUCTION OF AREA--The difference between the original cross-sectional area and that of the smallest area at the point of rupture. It is usually stated as a percentage of the original area; also called contraction of area. REFINING TEMPERATURE OR HEAT--A temperature employed in case hardening to ref ine the case and core. The f irst quench is from a high temperature to ref ine the core and the second quench is from a lower temperature to further ref ine and harden the case. S SCALE--A coating of metallic oxide that forms on heated metal. SENSITIZING--Developing a condition in stainless steels, which is susceptible to intergranular corrosion. The condition is usually formed by heating the steel above 800oF and cooling slowly, e.g., welding.

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GLOSSARY - Continued

S (Cont) SHEETS COLD ROLLED--The f lat products resulting from cold rolling of sheets previously produced by hot rolling. SHEETS HOT ROLLED--The f lat-rolled products resulting from reducing sheet bars on a sheet mill, or slabs, blooms, and billets on a continuous strip-sheet mill. SOAKING--Holding steel at an elevated temperature for the attainment of uniform temperature throughout the piece. SOLIDIFICATION RANGE--The temperature range through which metal freezes or solidif ies. SPALLING--The cracking and f laking of small particles of metal from the surface. SPHEROIDAL OR SPHEROIDIZED CEMETITE--The globular condition of iron carbide resulting from a spheroidizing treatment. The initial structure may be either pearlitic or martensitic. SPHEROIDIZING--Any process of heating and cooling steel that produces a rounded or globular form of carbide. The spheroidizing methods generally used are: (a) Prolonged heating at a temperature just below the lower critical temperature, usually followed by relatively slow cooling. (b) In the case of small objects of high carbon steels, the spheroidizing result is achieved more rapidly by prolonged heating to temperatures alternately within and slightly below the critical temperature range. (c) Tool steel is generally spheroidized by heating to a temperature of 749o-804oC (1380o-1480oF) for carbon steels and higher for many alloy tool steels, holding at heat from 1 to 4 hours, and cooling slowly in the furnace. STRAIN--The elongation per unit length. STRESS--The internal load per unit area. STRESS-RELIEF--This is annealing process which removes or reduces residual stresses retained af ter forming, heat treating, welding or machining. The anneal is accomplished at rather low temperatures for the primary purposes of reducing residual stresses, without material affecting other properties. T TEMPERING (ALSO TERMED DRAWING)--Reheating hardened steel to some temperature below the lower critical temperature, followed by any desired rate of cooling. Although the terms tempering and drawing are practically synonymous as used in commercial practice, the term tempering is preferred. TENSILE STRENGTH--The tensile strength is the maximum load per unit area which a material is capable of withstanding before failure. It is computed from the maximum load carried during a tension test and the original cross-sectional area of the specimen. TENSION--That force tending to increase the dimension of a body in the direction of the force. THERMOCOUPLE--Thermocouple consists of a pair of wires of dissimilar metals connected at both ends. When the two junctions are subjected to different temperatures an electric potential is set up between them. This voltage is almost in direct proportion to the temperature difference, and hence, a voltage measuring instrument inserted in the circuit will measure temperature. The voltage measuring instrument is usually calibrated in oC or oF. TOLERANCES--Slight deviations in dimensions or weight or both, allowable in the various products. V VISCOSITY--Viscosity is the resistance offered by a f luid to relative motion of its parts.

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GLOSSARY - Continued

W WIRE--The product obtained by drawing rods through a series of dies. WORK HARDNESS--Hardness developed in metal resulting from mechanical working, particularly cold working. Y YIELD POINT--The load per unit of original cross section at which a marked increase in deformation occurs without increase in load. YIELD STRENGTH--Stress arbitrarily def ined as the stress at which the material has a specif ied permanent set (the value of 0.2% is widely accepted). YOUNGS MODULUS--See Modulus of Elasticity.

Glossary 10