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

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.
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	Ⅱ
6005 ,6005A,6008	T4,T6	Ⅰ
6060	T4,T5,T6	Ⅰ
6063	T1,T4,T5,T6	Ⅰ
6101,6061,6082	T6	Ⅰ
6A01	T4,T5	Ⅰ
7003	T5	Ⅱ
7005,7020	T6	Ⅱ
7B05	T4,T5,T6	Ⅱ

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

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

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