Let’s discover why this alloy is a top choice. Understand how it can produce reliable parts, knowing its castability and its usage, along with specific properties.

Composition and Properties of A380 Aluminum Alloy

1.   Chemical Composition

Primary Elements:

Siliciu (Si):

The primary element of alloy A380 is silicon. Its proportion is around 7.5–9.5%. These particles cut the melting point, creating a eutectic phase with aluminum.

Silicon is brittle and hard. That’s why it improves fluidity and minimizes shrinkage. However, an excessive amount (>9.5%) is not always suitable. This will result in the buildup of coarse particles, affecting ductility

Cupru (Cu):

2.5–3.5% of copper content is mixed in aluminum metal in case to produce high strength. It forms Al₂Cu precipitates during aging.

Adding more than 3.5% copper element induces trouble during solidification. It causes hot cracking.

Fier (Fe):

The amount of iron in the A380 is around 0.5–1.5%. This metal prevents molten ingots from sticking to the die. This is because there are AlFeSi compounds. That is hard enough to handle. Overuse of iron, above 1.5 %, brittle β-AlFeSi structure. It lowers the impact of toughness.

Mangan (Mn):

Aluminum-based alloy A380 consists of 0.1-0.5% manganese. It alternates the hazardous phase of β-AlFeSi into minimal-damaging α-AlFeMnSi. They also refine grains during solidification.

Magneziu (Mg):

The amount of magnesium (0.1–0.5%) combines with the silicon content to produce Mg₂Si precipitates. It increases hardness. However, castability is reduced with mg over >0.5%

Zinc (Zn):

0.1–0.5% of zinc alloy minimizes impact on A380 metal. Despite this, it causes a decrease in resistance to corrosion. This usually happens with the presence of impurities.

Trace Elements:

• Up to 0.5% of nickel produces better high-temperature stability. This is because of its Al₃Ni phase formation.
• The presence of each Tin (Sn) and Lead (Pb) lower than 0.1% improves machinability. It, however, affects weldability.
• Incorporating <0.1% of Chromium (Cr) refines grain.

Standards:

In ASTM B85 form, the specification of A380 alloy shows certain limits. For instance, Fe ≤1.5%, Cu ≤3.5%. It mandates that the composition must pass chemical testing through spectrometry.

2.   Physical Properties

• Density: 2.7 g/cm³
• Melting Range: 565°C to 630°C
• Thermal Conductivity: 100 W/m·K at 25°C
• Electrical Conductivity: 35% IACS
• Thermal Expansion: 21.8 µm/m·°C (20–100°C)
• Corrosion Resistance: Moderate

3.   Mechanical Properties

A.  Strength and Ductility:

As-Cast (No Heat Treatment):

• Ultimate Tensile Strength (UTS): 325 MPa.
• Yield Strength (YS): 160 MPa at 0.2% offset.
• Elongation: 3% (limited by its high silicon content as well as the brittle α-AlFeMnSi and β-AlFeSi phases).
• Hardness: 80 HB (Brinell).

T5 Temper:

• Aging at 150–200°C for 2–8 hours
• UTS: 330 MPa
• YS: 170 MPa.
• Elongation: 2%
• Hardness: 85 HB

T6 Temper:

• Solutionized at 500°C for 4–12 hours + Aged
• UTS: 350 MPa
• YS: 185 MPa.
• Elongation: 2.5%
• Hardness: 90 HB

B.  Microstructure:

The A380 alloy of aluminum creates a grain size of 50–200 µm as the primary matrix.

Intermetallic phases:

• The plate-like particles of α-AlFeMnSi with 5–20 µm longevity upgrade wear resistance.
• The kind of needle-shaped phases (β-AlFeSi) up to 10–30 µm show crack induction sites.
• Mn elements improve grain size, reducing it to <100 µm. They create better toughness.

C.  Specialized Properties:

A380 alloy has good fatigue strength ranging from 150 MPa at 10⁷ cycles (R = -1). This quality is beneficial for manufacturing engine brackets.

Furthermore, the Shear Strength of this ingot is around 200 MPa. That’s very important to create threading or fasten various assemblies.

Besides all of the above, the alloy is limited to its impact toughness (Charpy test), which is 5 J at 25°C. This limit also minimizes its usage across dynamic loads.

D.  Temperature Effects:

Higher temperatures become the reason for the precipitation of coarse particles. Because of this, UTS drops to 260 MPa (-20%).

At the point of low temperature below -50°C, it causes a surge in hardness level around 88 HB (+10%). This is because the dislocations’ movement gets slower.

Applications of A380 Aluminum Alloy

1.   Automotive Industry Usage

Strength-to-weight ratio in alloy A380 makes it an optimal choice. That’s why the automotive industry uses it for its vast variety of applications.

Key Components and Properties:

The automotive parts, such as brackets and housings, contain an ultimate tensile strength of around 325 MPa. They also set barriers against excessive heat up to 200°C.

This means the part does not require more energy or fuel consumption as compared to older iron blocks.

Thermal and Mechanical Advantages:

Manufacturers leverage the thermal conductivity of A380 alloy (100 W/m·K) into cylinder heads.

They possess efficient heat dissipation. Wherein the silicon material flows smoothly during casting to take on any complex shape.

Durability and Limitations:

The gearbox housings after a T6 tempering process would be harder. It achieves 90 HB hardness.

The parts, however, do not match ductility needs, which restricts their use in high-impact applications. For this, you use its substitute alloys like A383 to fabricate critical parts.

Aerospace Applications of A380 Aluminum Alloy

Non-Structural Component Usage:

Strength and castability features of the A380 ingot make it preferable. Aerospace industries use it for the fabrication of spoiler housings, flap brackets, and aileron mounts.

Temperature and Strength Performance:

This alloy can endure moderate temperatures (-50°C to 150°C). They have a yield strength of 185 MPa after T6 temper. In the case of flight control equipment, this treatment makes them more suitable.

Precision Casting Advantages

The A380 material offers suitable castability, taking on the most intricate profile. Because of this, you can use it for things like rudder hinges with dimensional exactitude.

Limitations and Enhancements:

Despite the alloy offering many exceptional qualities, it lacks the qualities of aerospace-grade (7075). For instance, high-strength wrought alloy.

The enhancement you can make to it is durability in humid conditions. This can be done via the T6 heat process or anti-corrosion coatings.

Other Industry Applications of A380 Aluminum Alloy

Construction Sector Uses:

In the construction sector, A380 alloy is cast to manufacture architectural molds and window frames.

The industry leverages its most optimal traits. That’s with corrosion resistance and tight tolerances for accuracy.

Marine Applications:

The durability of the A380 creates long-lasting and strong parts for engine mounts and deck fittings.

Treatment, like anodizing, further adds to better resistance against saltwater.

Electrical Industry Benefits:

This material is beneficial for producing heat sinks and motor housing. It gives them a good IACS and thermal conductivity. That’s why this option is a cost-performance offer.

Industry-Specific Advantages:

Key properties that the A380 contains include, most usually, dimensional stability across construction and corrosion resistance for marine.

Meanwhile, the thermal management suits are for electrical systems. This means alloy A380 falls in the category of a versatile metal.

Casting Characteristics of A380 Aluminum Alloy

Casting Process

Because the alloy A380 has much better fluidity, it is cast with process parameters. These parameters include melting points of 660–680°C and injection pressures of 30–150 MPa.

Die casting:

Aluminum die casting is the best technique to use. It produces output results within a few minutes and gives a tight tolerance. This process, however, risks mold sticking to iron particles.

Sand Casting:

In sand casting, there is no need to use high pressure or high temperatures. This is because it forms a profile shape with molten alloy using a lower amount (1–5 pressure to 600–650°C).

You can use this process to cast longer parts like engine blocks. It, however, is very slow and produces rough surfaces.

Permanent Mold Casting:

Permanent mold casting gives balanced benefits of cost along with precision results.

It works at 630–670°C.

Right cooling rates are necessary in respect of controlling solidification. This will reduce the risk of hot tears.

Casting Defects

Casting defects that occur during manufacturing can be porosity, shrinkage, or inclusions.

• Porosity: air or gases mixed in the casting cause porosity. Find out with X-ray inspection. To control this, use vacuum degassing.
• Shrinkage: Uneven cooling of casting produces shrinkage in parts. The thermal simulation software aids in analyzing hotspots. Tackle these errors with optimized feeder designs.
• Inclusion: It happens because of the presence of impurities. Filter the metal before use to minimize particle size. Also, opt for preheat mold techniques.

Tratament termic

Solution heat treatment:

In this kind of treatment, manufacturers heat the metal at 500°C for 4–12 hours. So that it dissolves Al₂Cu precipitates. This is done via a cooling rate >100°C/s (quenching water).

Artificial aging

Artificial aging, like the T6 temper technique, works at 150–200°C for 2–8 hours. It produces excessive strength in ingots. For this, they form Mg₂Si and Al₂Cu phases. It also raises hardness.

However, the overaging above 250°C makes for coarse precipitation. It, as a result, affects the strength, reducing it by up to 15 percent.

Also, T6 temper improves fatigue resistance, making a refined microstructure. Despite this, it lowers the elongation rate up to 2.5%.

Corrosion Resistance of A380 Aluminum Alloy

Corrosion Mechanisms:

In A380s, there are chances of pitting corrosion from where the chloride-rich areas, like coasts present. Similar to this issue, crevice corrosion occurs in stagnant spots (under bolts).

Galvanic corrosion happens when electrochemical potential differences occur. The iron and copper content is also the reason for worsening corrosion.

Protection from Corrosion:

There are many options to protect parts from corrosion. Among them, anodizing is one that adds a 10–25 µm oxide layer.

The chromating process aids in getting rid of moisture or resisting salt. Meanwhile, the paint coatings (epoxy) increase strength by blocking exposure.

The other options are powder coatings and sealants. They work to improve marine or automotive parts performance and increase durability.

Machining and Fabrication of A380 Aluminum Alloy

Machining:

With a rating of 65 to 70%, aluminum alloy a380 is very easy to machine. There is content of allying elements, which can be hard, like silicon particles. For this, you can use carbide or PCD tools to cut it.

For instance, a rake angle of 15° and sharp edges aid in the cutting process. As the image shows, Cut at 300–500 m/mi, feed 0.5 mm/rev, and depth ≤3.25 mm.

Also, proper cooling rate techniques can avoid overheating of tools and increase their lastability.

Fabrication:

It is quite hard to weld A380 material. Because it cracks. But you can use Friction stir welding. It does a great job at 500–1500 RPM, 1–3 mm/s.

Also, preheating and aluminum silicon filler help as well for brazing. To fasten or rivet, you must work manually to pierce or use tough rivets like 1–5 mm.

Concluzie:

Aluminum alloy A380 is the most important metal. It contains less weight yet tough content. Their excellent castability allows you to manufacture multiple applications with impressive heat resistance. It is a combination of cost-effectiveness and balanced performers.

However, you might struggle with its low ductility. The treatment T6 temper and coatings can improve its durability.  This is why it is important for most of the major industries, like automotive and industrial.