Aluminum fasteners are significantly lighter than their steel counterparts, weighing about one-third as much. Despite this, they offer impressive strength characteristics, making them highly efficient in terms of strength-to-weight ratio. This makes aluminum fasteners a preferred choice in many industries where weight reduction is crucial. Additionally, aluminum is non-magnetic and has excellent thermal and electrical conductivity—about two-thirds that of copper. Its good formability allows for both cold working and hot forging, making it versatile for manufacturing.
When comparing the mechanical properties of aluminum alloy fasteners to those made from other metals, there are key differences to consider. For instance, when calculating load capacity, the cross-sectional area at the root of the thread should be used instead of the tensile stress area. The true tensile and yield strengths provided in ASTM F468 are based on test specimens, and these values must be adjusted for full-sized fasteners. The resulting load capacity is then calculated by multiplying the stress value by the threaded area, which typically results in a value close to the product of the actual strength and the smaller root area.
Another important point is that the hardness difference between aluminum alloys is minimal, so hardness testing isn't a reliable indicator of performance. Instead, shear strength tests are commonly used for quality control.
Among the most commonly used aluminum alloys for fasteners are 2024-T4, 6061-T6, 7075-T73, and 6062-T9. Each offers unique benefits: 2024-T4 provides a good balance of strength, corrosion resistance, and cost, making it ideal for general use. 7075-T73, while stronger and more resistant to stress corrosion due to its special heat treatment, is more expensive. 6061-T6 is known for its corrosion resistance and versatility, often used in both internal and external threads. 6062-T9 is primarily used for nuts and offers higher strength compared to 6061-T6.
For specific applications, other aluminum alloys are also utilized. For example, 1100-F, 5052-F, and 5056-F are commonly used for solid, half-pipe, and blind rivets. Heat-treatable alloys like 2017-T4, 2117-T4, 2024-T4, and 6061-T6 are suitable for high-strength fasteners that can be driven without pre-drilling. Plain washers are often made from 2024-T4, while spiral spring washers and tapping screws may use 7075-T6. Anodizing is an effective way to enhance the corrosion resistance of aluminum, especially in harsh environments. It also improves wear resistance and offers a range of colors for aesthetic or identification purposes.
Pure aluminum has a tensile strength of around 13,000 psi, but with the addition of alloying elements, this can be significantly increased. Alloys from the 2XXX, 6XXX, and 7XXX series are particularly effective for heat treatment, making them the go-to choices for load-bearing fasteners. These materials ensure durability, reliability, and performance across a wide range of applications.
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