ASM Handbook, Volume 2B, Properties and Selection of Aluminum Alloys Copyright # 2019 ASM InternationalW

Kevin Anderson, John Weritz, and J. Gilbert Kaufman, editors All rights reserved
DOI 10.31399/asm.hb.v02b.a0006559 www.asminternational.org

295.0
Al-Cu-Si Heat-Treatable Sand Casting Alloy

Alloy 295.0 is an Al-Cu-Si alloy (Table 1) suitable for sand casting It is used for heat-treated castings where good shock resistance and cor-
requiring high strength with ductility and toughness. It has fair castabil- rosion resistance are required. Equivalent specifications are:
ity, good machinability, and has been used for a number of aerospace
• Former designation: 195
and automotive applications. It is not suitable for permanent mold or
• UNS number: A02950
die castings.
• ISO: AlCu-4Si
Typical applications have been flywheel housings, rear-axle housings,
• AMS: 4230, 4231
bus wheels, aircraft wheels, fittings, crankcases and other applications
• ASTM: B108, B26, B275, B618 and B917
where a combination of high tensile properties and good machinability
• Former ASTM: C4A
is required but pressure tightness is not needed. Although used exten-
• SAE: 38 (J452)
sively prior to the mid- 1930s, alloy 295.0 has been largely replaced
• Government: QQ-A-601, class 4
by 355.0 and 356.0 because of their superior casting characteristics
• Canada: CSA-C4
and service performance (Ref 1).
Typical properties are listed in Tables 2 and 3. It responds to age
hardening and has an excellent combination of ductility and strength. Casting

Table 1 Alloy 295.0 composition limits This alloy shows good fluidity and resistance to shrinkage formation.
It has only fair resistance to hot cracking and is moderately pressure
Element(a) 295.0 (UNS 02950)
tight. It has fair castability with respect to mold-filling properties, rela-
Si 0.7–1.5 tive freedom from cracking and hot shortness, ease of feeding and ten-
Fe 1.0 max
Cu 4.0–5.0
dency toward low shrinkage. Pattern shrinkage allowance is 0.13 mm/cm
Mn 0.35 max (0.16 in./ft). Melting temperature is 675–815  C (1250–1500  F) and cast-
Mg 0.03 max ing temperature is 675–790  C (1250–1450  F).
Ti 0.25 max
Zn 0.35 max
Other (each), max 0.05
Other (total), max 0.15 Heat treatment
Al bal
(a) High iron or silicon decreases tensile properties, especially ductility. Manganese or magnesium decreases Stress relief of alloy 295.0 (T5 Temper) is by heating to 230  C
(450  F), holding for 4 to 5 h at temperature followed by air cooling.
ductility. Tin reduces strength, hardness, and resistance to corrosion

The solution treatment for subsequent aging involves heating to

515–520  C (955–965  F), holding at temperature for 6 to 12 h, quench-
Table 2 Alloy 295.0 typical physical properties ing in hot water at 65–100  C (150–212  F). Quenching in hot water
minimizes quenching stresses and distortion. Subsequent aging treat-
Property Value
ments comprise these variations:
Poisson’s ratio at 20  C (68  F) 0.33
Elastic modulus at 20  C (68  F) 70 GPa (10.0  106 psi) • T4 Temper: As solution treated, no artificial aging.
25.9 GPa (3.75  106 psi)
Modulus of rigidity, shear
Density at 20  C (68  F) 2.823 g/cm3 (0.102 lb/in.3)
• T6 Temper: Age at 154  C (310  F) for 3–6 h, partial aging
Liquidus temperature 645  C (1190  F)
• T62 Temper: Age at 154  C (310  F) 12–24 h, full aging
Solidus temperature 520  C (970  F) • T7 Temper: Age at 260  C (500  F) for 4–6 h, overaging for
Specific heat at 100  C (212  F) 963 J/kg
K (0.230 Btu/lb
 F stabilization
Latent heat of fusion 389 kJ/kg (167 Btu/lb)
Thermal conductivity at 25  C (77  F) T4 and T62 tempers: 138 W/m
K
(79.8 Btu/ft
h
 F) Table 3 Alloy 295.0 typical mechanical properties with sand
Electrical conductivity, volumetric at T4 temper, 35% IACS
20  C (68  F): T62 temper, 37% IACS
casting
Electrical resistivity at 20  C (68  F) T4 and T6 tempers: 49.3 nO m Tension
Electrolytic solution potential Versus 0.1 N calomel electrode in an aqueous
Ultimate Yield Elongation Shear Compressive Endurance
solution containing 53 g NaCl plus 3 g H2O2 strength, strength, in 50 mm strength, yield, MPa Brinell limit, MPa
per liter: T4 temper, 0.70 V; T6 temper, Temper MPA (ksi) MPa (ksi) (2 in.), % MPa (ksi) (ksi) hardness (ksi)
0.71 V; T62 temper, 0.73 V
Average coefficient of linear thermal 23 mm/m  C from 20–100  C T4 221 (32) 110 (16) 8.5 179 (26) 117 (17) 60 48 (7.0)
expansion from 20–100  C 24 mm/m  C from 20–100  C T6 248 (36) 165 (24) 5 207 (30) 172 (25) 75 52 (7.5)
(68–212  F) 25 mm/m  C from 20–100  C T62 283 (41) 221 (32) 2 228 (33) 234 (34) 90 55 (8.0)

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by Manjunath Aithal
 Cast Aluminum Alloy Datasheets / 527

Table 4 lists typical properties with variation in heat treatment. Solu- Helical plain milling cutters are made with helix angles of about 50
tion treatment followed by a partial precipitation treatment results in a and they perform satisfactorily when the teeth are provided with consid-
material increase in yield strength, tensile strength, hardness, and a erable top rake. Milling speeds in roughing are 500–700 sfpm, with
reduction of ductility to a point still consistent with engineering require- high-speed-steel cutters for a feed of 100–250 mm (4–10 in.) travel of
ments. Solution treatment followed by complete aging produces maxi- work and 6.5 mm (0.25 in.) maximum depth of cut.
mum hardness, yield strength and tensile strength combination. This Standard high-speed steel drills on a drill press should have a 118–140
treatment is desired where the maximum yield strength is necessary, point angle, 24–40 spiral angle and 15–17 lip clearance. Cutting speeds
and the castings are not subjected to excessive impact conditions. may be as high as 1500 sfpm.
Mechanical finishes from polishing are very good, and electroplating
imparts an excellent finish to this alloy. Anodizing shows up well and
Machining and Finishing gives a good protective finish.

The machinability of 295.0 is very good. Aluminum 295.0 can be

machined readily as-cast and in all its heat-treated conditions. Best results
Weldability
are obtained with sharp, polished tools with sufficient rake and clearance.
Moderate to fast speeds and feeds are recommended (Table 5). Alloy 295.0 can be welded by the torch process or the arc process.
Milling cutters should be ground to be inclined to work at an angle of Very good results can be obtained using arc or resistance welding meth-
60–70 to prevent chatter and to increase shearing action of the tool. The ods. Gas welding is generally satisfactory. Brazing is not used. Welding
leading corner is beveled as much as 45 for rough milling and as little rods of the same composition are used in arc welding, although the 95–5
as 3 for finishing on a smooth surface. The cutting edge should be Al-Si welding rod may be used. Always use a flux in torch welding.
cleared to 1–2 . A clearance of 0.08–0.12 mm (0.003–0.005 in.) at Coated rods are used in metallic arc-welding. For best results, the
3.2 mm (0.125 in.) at the back of the cutting edge may be increased inert-gas arc welding process is recommended.
beyond this point at an angle of 5–7 .
Milling cutters should have relatively few teeth so that ample space is
provided for chip formation and so that each tooth actually cuts. Where Corrosion Resistance
possible, the teeth should be designed to afford positive top and side
rake. Primary clearance angles of 5–10 are suggested and secondary
relief should be provided. Heavy-duty, coarse-tooth plain-type milling Alloy 295.0 exhibits only fair resistance to common corrosive envir-
cutters with spiral teeth are well suited. These cutters are usually made onments. Sodium chloride atmospheres in standard laboratory corrosion
with spiral angles ranging from 20–30 and the teeth should be undercut tests produce only a slight attack on 295.0 in the solution-treated and in
to provide a top rake of 10–20 . the solution-treated and-aged conditions. There is, however, a medium
amount of attack by such atmospheres in the as-cast and in the stress-
relieved conditions.

Table 4 Alloy 295.0 typical mechanical properties of sand castings Table 6 Alloy 295.0 tensile property requirements specified in
in various heat-treated conditions ASTM B26 for sand castings
Solution treated at 515  C (960  F) Tensile Yield strength, Elongation in 50 mm Typical Brinell
Stress Aged 3 h at Aged 18 h at strength, min, 0.2% offset, min, (2 in.) or 4D, min, hardness(a)
Properties As-cast relieved As treated 155  C (310  F) 155  C (310  F) Temper MPA (ksi) MPA (ksi) MPA (ksi) (500 kgf, 10mm)

Tensile strength, 160–180 160–180 230–255 260–295 310–345 T4, solution 200 (29) 90 (13) 6.0 60
MPa (ksi) (23–26) (23–26) (33–37) (38–43) (45–50) heat treated
Yield strength, 0.2% 70–85 85–105 105–120 170–200 275–310 T6, solution 220 (32) 140 (20) 3.0 75
ext. (a), MPa, ksi (10–12) (12–15) (15–17) (25–29) (40–45) treated and
Elongation in 50 mm 3–5 3–5 6–8 3–5 1–2 aged
(2 in.), % T62, solution 250 (36) 195 (28) (b) 95
Brinell hardness 60–70 60–70 65–75 80–95 100–120 treated and
Charpy impact, 1 1 4 2–3 1 aged
notched, V-notch, T7, solution 200 (29) 110 (16) 3.0 70
ft-lb treated and
Charpy impact, no 8 6 18 12 6 over aged
notch, smooth, ft-lb (a) For information only, not required for acceptance. (b) Not required
(a) Permanent extension. All tensile and impact specimens were tested unmachined with casting skin intact;
notch was cast in notched impact specimens

Table 7 Typical tensile properties for separately cast test bars of

alloy 295.0 at elevated temperatures
Table 5 Cutting tool geometries and machining parameters Temperature Tensile strength Yield strength
 
Tool type Tool geometry Machining parameters C F MPa ksi MPa ksi Elongation in 50 mm (2 in), %

High-speed 30–45 cutting angle, 35–50 top rake, Cutting speeds up to 1000 sfpm may T4 temper
steel 10–15 side rake, 7–10 Front be used with feeds of 0.18–0.5 mm/ 24 75 220 32 110 16 8.5
lathe clearance and 7–10 side clearance rev (0.007–0.020 in/rev.) and depth 150 300 195 28 105 15 5.0
tools of cut up to 5 mm (0.200 in.) for 205 400 105 15 60 9 15.0
roughing. 260 500 60 9 40 6 25.0
Carbide- 55–70 cutting angle, 5–25 top rake, Cutting speeds up to 1600 sfpm may 315 600 30 4 20 3 75.0
tipped 5–10 side rake, 6–10 front be used with feeds up to 0.25 mm/
cutting clearance and 6–9 side clearance rev (0.010 in./rev) and depth of cut T6 temper
tools up to 5 mm for roughing, while 24 75 250 36 165 24 5.0
cutting speeds up to 2500 sfpm may 150 300 195 28 140 20 5.0
be used with feeds up to 0.25 mm/ 205 400 105 15 60 9 15.0
rev and depth of cut up to 0.5 mm 260 500 60 9 40 6 25.0
(0.020 in.) for finishing 315 600 30 4 20 3 75.0

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by Manjunath Aithal
 528 / Properties and Selection of Cast Aluminum Alloys

Application Characteristics

Table 6 lists minimum tensile properties per ASTM B26, and Table 7
lists typical tensile properties at an elevated temperature. Alloy 295.0
exhibits excellent mechanical stability (tendency to retain its initial
mechanical properties upon subsequent room-temperature aging) in the
stress-relieved and in the over-aged (T7) solution treated-and-aged con-
ditions (Fig. 1). In the as-cast, solution-treated conditions, or partially
aged (T6) condition, there is a change in properties with aging at room
temperature.

REFERENCES
1. Aluminum Casting Technology, 3rd ed., American Foundry Society,
2017, p 150
2. J.G. Kaufman and E.L. Rooy, Aluminum Alloy Castings: Properties,
Processes, and Applications, ASM International, 2004, p 133–173

Fig. 1 Room-temperature aging characteristics for aluminum alloy 295.0-F, -T4, -T6,
and -T7, sand cast Source: Ref 2

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