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Aluminum alloys extruded profiles used for structural material of railway vehicle carbodies

2018-05-21 15:18
The railway cars are typically designed for a 30 year life. Thus, the rail industry is very cautious when it select the alloys. Trade offs between cost and performance dictate the materials
used in construction of passenger vehicles. Although aluminum alloys are more expensive than steel they are selected for there low density.

At present the Al-Mg-Si 6XXX alloys (e.g. 6061,6106,6082,6005,6005A,6008,6060,6063,6A01) and Al-Mg 5XXX alloys (e.g. 5083,5052,5754)and Al-Zn-Mg-Cu 7XXX series (e.g. 7005,7020,7B05)
are used to fabricate structural material of railway vehicle carbodies.

aluminum extruded profiles

Chalco Aluminum has Aluminum alloys extruded profiles used for structural material of railway vehicle carbodies,has different alloys 6061,6106,6082,6005,6005A,6008,6060,6063,6A01, 5083,5052,5754, 7005,7020,7B05,etc with different supplied temper H112,T1,T4,T5,T6,etc.

1)Alloy,Temper and Profile category of Aluminum alloys extruded profiles used for structural material of railway vehicle carbodies

Alloy Temper Profile category
5052,5754 H112        Ⅰ
5083 H112
6005 ,6005A,6008 T4,T6
6060 T4,T5,T6
6063 T1,T4,T5,T6
6101,6061,6082 T6
6A01 T4,T5
7003 T5
7005,7020 T6
7B05 T4,T5,T6

2)The chemical component of Aluminum alloys extruded profiles used for structural material of railway vehicle carbodies

6063 aluminum profile

Alloy Chemical component(%)
Si Fe Cu Mn Mg Cr Zn   Ti Zr Other Al
 Each Total  
5052 ≤0.25 ≤0.40 ≤0.10 ≤0.10 2.2-
2.8
0.15-0.35 ≤0.10 - - - ≤0.05 ≤0.15 Remain
5754 ≤0.40 ≤0.40 ≤0.10 ≤0.50 2.6-
3.6
≤0.30 ≤0.20 Mn+Cr:0.10-0.60 ≤0.15 - ≤0.05 ≤0.15 Remain
5083 ≤0.40 ≤0.40 ≤0.10 0.40-1.0 4.0-4.9 0.05-0.25 ≤0.25 - ≤0.15 - ≤0.05 ≤0.15 Remain
6008 0.5-0.9 ≤0.35 ≤0.30 ≤0.30 0.40-0.7 ≤0.30 ≤0.20 V:
0.05-0.20
≤0.10 - ≤0.05 ≤0.15 Remain
6005 0.6-0.9 ≤0.35 ≤0.10 ≤0.10 0.40-0.6 ≤0.10 ≤0.10 - - ≤0.10 ≤0.05 ≤0.15 Remain
6005A 0.5-0.9 ≤0.35 ≤0.30 ≤0.50 0.40-0.7 ≤0.30 ≤0.20 Mn+Cr:0.12-0.50 ≤0.10 ≤0.05 ≤0.15 Remain
6061 0.40-0.8 ≤0.7 0.15-0.40 ≤0.15 0.8-1.2 0.04-0.35 ≤0.25 - ≤0.15 ≤0.05 ≤0.15 Remain
6082 0.7-
1.3
≤0.50 ≤0.10 0.40-1.0 0.6-1.2 ≤0.25 ≤0.20 - ≤0.10 - ≤0.05 ≤0.15 Remain
6063 0.20-0.6 ≤0.35 ≤0.10 ≤0.10 0.45-0.9 ≤0.10 ≤0.10   ≤0.10 ≤0.05 ≤0.15 Remain
6060 0.30-0.6 0.10-0.30 ≤0.10 ≤0.10 0.35-0.6  ≤0.05 ≤0.15 - ≤0.10 - ≤0.05 ≤0.15 Remain
6101 0.30-0.7 ≤0.50 ≤0.10 ≤0.03 0.35-0.8 ≤0.03 ≤0.10 B:0.06 - - ≤0.03 ≤0.10 Remain
7003 ≤0.30 ≤0.35 ≤0.20 ≤0.30 0.5-1.0 ≤0.20 5.0-6.5 - ≤0.20 0.05-0.25 ≤0.05 ≤0.15 Remain
7005 ≤0.35 ≤0.40 ≤0.10 0.20-0.7 1.0-1.8 0.06-0.20 4.0-5.0 - 0.01-0.06 0.08-0.20 ≤0.05 ≤0.15 Remain
7020 ≤0.35 ≤0.40 ≤0.20 0.05-0.50 1.0-1.4 0.10-0.35 4.0-5.0 Zr+Ti
0.08-0.25
- 0.08-0.20 ≤0.05 ≤0.15 Remain

3-1)Allowable curved surface gap (unit:mm)

Curved surface chord length  Allowable curved surface gap on below chord length
 Any 25mm chord length  All the chord length( W)
   ≤25        ---       ≤0.13
   >25        ≤0.13       ≤0.6% X W

3-2)Curve contour deviation(unit:mm)

Circumscribed circle diameter Curve contour deviation C
≤30 ≤0.30
>30-60 ≤0.50
>60-90 ≤ 0.70
>90-120 ≤1.0
>120-150 ≤1.2
>150-200 ≤1.5
>200-250 ≤2.0
>250-300 ≤2.5
>300-400 ≤3.0
>400-500 ≤3.5
>500-1000 ≤4.0

3-3)Allowable Cutting slant angle

Max width of Aluminium profile  mm Cutting slant angle
≤ 150.00 ≤ 3°
 > 150.00-400.00 ≤ 2°
>400.00 ≤ 1°

4)Mechanical Property of Aluminum alloys extruded profiles used for structural material of railway vehicle carbodies

extruded aluminum profiles

Alloy Temper Aluminum profile mode Wall thickness (mm) Cross sectional area
cm²
Mechanical Property BH(Brinell Hardness)
HBW
Tensile Strength
(MPa)
Yield Strength
(MPa)
Elongation (%)
A A50mm
Not less than
5052 H112 - - - 170 70 15 13 47
5754 H112 - ≤25.00 - 180 80 14 12 47
5083 H112 - - - 270 140 12 10 70
6005
6005A
T4 solid ≤25.00 - 180 90 15 13 50
hollow ≤10.00 - 180 90 15 13 50
T6 solid ≤5.00 - 270 225 - 6 90
>5.00-10.00 - 260 215 - 6 85
>10.00-50.00 - 250 200 8 6 85
hollow ≤5.00 - 255 215 - 6 85
>5.00-15.00 - 250 200 8 6 85
>15.00-25.00 - 250 200 8 - -
6008 T4 solid ≤10.00 - 180 90 15 13 50
hollow ≤10.00 - 180 90 15 13 50
T6 solid ≤5.00 - 270 225 8 6 90
>5.00-10.00 - 260 215 8 6 85
hollow ≤5.00 - 255 215 8 6 85
>5.00-10.00 - 250 200 8 6 85
6060 T4 - ≤25.00 - 120 60 16 14 50
T5 - ≤5.00 - 160 120 - 6 60
>5.00-25.00 - 140 100 8 6 60
T6 - ≤3.00 - 190 150 - 6 70
>3.00-25.00 - 170 140 8 6 70
6061 T6 - ≤5.00 - 260 240 - 7 95
>5.00-25.00 - 260 240 10 8 95
6063 T1 - ≤12.00 - 120 60 - 12 -
>12.00-25.00 - 110 55 - 12 -
T4 - ≤25.00 - 130 65 14 12 50
T5 - ≤3.00 - 175 130 - 6 65
>3.00-25.00 - 160 110 7 5 65
T6 - ≤10.00 - 215 170 - 6 75
>10.00-25.00 - 195 160 8 6 75
6082 T6 - ≤5.00 - 290 250 - 6 95
>5.00-50.00 - 310 260 10 8 95
6106 T6 - ≤10.00 - 250 200 8 6 85
6A01 T4 solid ≤25.00 - 160 70 15 13 -
hollow ≤10.00 - 160 70 15 13 -
T5 - ≤6.00 - 245 205 - 8 -
>6.00-12.00 - 225 175 - 8 -
7003 T5 - ≤25.00 - 310 260 10 8 -
7005 T6 - ≤40.00 - 350 290 10 8 110
7020 T6 - ≤40.00 - 350 290 10 8 110
7B05 T4 - - ≤200cm² 315 195 - 11 -
T5 - - ≤200cm² 325 245 - 10 -
T6 - - ≤200cm² 335 275 - 10 -

5)Tensile mechanical properties of welded joints at room temperature

Alloy Temper Wall Thickness
(mm)
Tensile mechanical properties Result at room temperature
Tensile Strength
(MPa)
Yield Strength
(MPa)
Not less than
5083 H112 ≤ 15.00 270 125
> 15.00 270 125
5754 H112 ≤ 15.00 180 80
6005 T6 ≤ 15.00 160 90
6005A T6 ≤ 15.00 165 115
6008 T6 ≤ 15.00 165 115
6061 T6 ≤ 15.00 175 115
> 15.00 165 115
6063 T6 ≤ 15.00 110 65
> 15.00 85 55
6082 T6 ≤ 15.00 185 125
> 15.00 165 115
6106 T6 ≤ 15.00 160 95

6)The bending radius of the profile

The profile Type Wall thickness(mm) The bending radius(mm)
Hollow Profile ≤ 10 4 times of wall thickness
> 10 5 times of wall thickness
Solid profile ≤ 5 3 times of wall thickness
> 5-10 4 times of wall thickness
> 10 5 times of wall thickness

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