Standards For Aluminium Sand and Permanent Die Casting

Standards for Aluminum
Standards for Aluminum 18
Sand and Permanent Mold Castings

15th Edition 2008
Sand and Permanent
Mold Castings
Standards For Aluminum Sand
and Permanent Mold Castings PREFACE
THE ALUMINUM ASSOCIATION CASTING STANDARDS PROGRAM
Aluminum permanent mold and sand castings are widely used in all types of applications due to aluminum’s exceptional
characteristics and the great design flexibility inherent in these two casting processes.
Historically, foundries each used their own individual standards covering the various aspects of permanent mold and sand
castings. As new techniques and molding materials became available, they also contributed to further variations. The
variations in that information, along with the lack of data in many areas, indicated the need for reliable and realistic criteria
to which castings could be consistently produced. These criteria would provide all persons involved in the procurement of
castings with an instrument by which they could expect foundries to base proposals and produce castings to a specific
quality level.
Therefore, The Aluminum Association, as a service to the customers of the industry, prepared this guide for designers,
engineers, buyers and production personnel as to the most economical use of the permanent mold and sand casting
processes. This guide has two chapters each of which contains a series of product standards: E Series, Engineering
Standards and M Series, Metallurgical Standards and Data.
Dimensions, tolerances and other quantities expressed in both U.S. customary and Metric units in these standards are not
necessarily identical due to rounding practices used by the committee.
These Product Standards are not intended to be limiting in any way but rather they are expected to provide a measure of
optimum conditions for the most economical use of the processes included and to provide consistency in terminology and
definition, thereby resulting in a better understanding between supplier and user. The use of these standards by any member
or nonmember of The Aluminum Association is voluntary and issuance or existence of these standards does not in any respect
prevent or restrict any member or nonmember from manufacturing or supplying products not in conformance with these
standards.
As all published material is subject to change as new experience is gained, it is suggested that the data contained herein be
verified with The Aluminum Association if there is any doubt as to their current validity.
FIFTEENTH EDITION
JULY 2008
This issue supersedes all prior issues.
© Copyright 2008, The Aluminum Association, Inc.

Unauthorized reproduction by photocopy or any other method is illegal.
1-1
and Permanent Mold Castings INDEX
CHAPTER 1, ENGINEERING SERIES (E) Page
E-1 LINEAR TOLERANCES—One Side of Parting Line 1-4

E-2 LINEAR TOLERANCES—Across Parting Line 1-5
E-3 LINEAR TOLERANCES—Cored Areas; Sand and Moving Parts 1-6
E-4 DRAFT REQUIREMENTS AND INTERPRETATION 1-7
E-5 FLATNESS—STRAIGHTNESS 1-9
E-6 HOLES AND POCKETS—Sand Cast 1-10
E-7 HOLES AND POCKETS—Permanent Mold 1-11
E-8 PROFILE TOLERANCE 1-12
E-9 EJECTOR PIN MARKS 1-15
E-10 FLASH REMOVAL—Snagging, Grinding, Removal of P/L,
Chill Marks, Gates and Risers 1-16
E-11 ANGULARITY - PERPENDICULARITY - PARALLELISM 1-17
E-12 CONCENTRICITY 1-21
E-13 MACHINE FINISH ALLOWANCE 1-24
E-14 POSITIONAL TOLERANCE 1-25
E-15 WALLS, FILLETS & RIBS 1-27
E-16 LETTERING 1-28
E-17
E-18 CAST SURFACE SMOOTHNESS 1-30
E-19 METAL THICKNESS 1-31
E-20 DATUMS - TARGET POINTS - LINES 1-32
E-21 PRODUCT REQUIREMENT FORM 1-36
CHAPTER 2, METALLURGICAL SERIES (M)

M-1 ALLOY CROSS REFERENCE CHARTS 2-2
M-2 CHEMICAL COMPOSITION LIMITS 2-3
M-3 MECHANICAL PROPERTY LIMITS 2-4
M-4 CHARACTERISTICS OF ALUMINUM ALLOYS 2-6
M-5 ALUMINUM CASTING QUALITY STANDARD 2-8
M-6 RADIOGRAPHY 2-11
M-7 PENETRANT AND OTHER INSPECTION TECHNIQUES 2-13
M-8 IMPREGNATION OF CASTINGS 2-14
M-9 WELDING OF CASTINGS 2-15
M-10 TYPICAL PHYSICAL PROPERTIES 2-16
M-11 RECOMMENDED HEAT TREATMENTS 2-17
APPENDIX 1 - ALLOY REGISTRATION 2-21
APPENDIX 2 - TEMPER REGISTRATION 2-22
This index lists all Standards currently planned. Standards not now included
will be issued as approved. Symbols used on drawings are shown at left and
conform to ANSI Y14.5 M—1982 (R1989)
1-2
ENGINEERING SERIES (E)
and Permanent Mold Castings INTRODUCTION
Permanent mold and sand castings can be produced with a variety of surface finishes, dimensional
precision, finish allowances and drafts. The flexibility of these forms of castings give the engineer and
manufacturer wide latitude in design to meet specific requirements. The Engineering Series is established
for the individual requirements involved in producing a usable, unmachined casting consistent with normal
production practices, reproducibility, reasonable mold or pattern life and maintenance costs, normal
inspection, packing and shipping procedures. Special requirements for finish, tolerances, etc., beyond the
standard may be specified where required although additional costs may be involved. Consultation with
the foundry will usually result in such requirements being properly considered in the quotation and mutually
understood. Conversely, more liberal values should be indicated where acceptable since they tend to keep
costs to a minimum.
These Engineering Standards are not designed to reduce quality level, lessen competition, restrict customer
requirements or increase costs. On the contrary, for the types of castings to which they may be applied, the
program will improve understanding of quality levels, widen the area of available sources of supply, increase
the customer’s ability to distinguish special requirements, and reduce costs by eliminating the specification
of unnecessary rigid limits where they are not required.
1-3
E1*
and Permanent Mold Castings LINEAR TOLERANCES — One Side of
Parting Line
NOTE: The values shown herein represent normal production practice at the most economic level.
Greater accuracy involving extra close work or care in production should be specified only when and
where necessary since additional costs may be involved. Conversely, more liberal values should be
indicated, when acceptable, as these tend to keep costs to a minimum. Any variations in these values
shall not be binding on the foundry unless accepted in writing.
TOLERANCE, in., mm
Sand Casting* Permanent Mold
Fully machined
mold cavities
in. mm in. mm in. mm in. mm
Basic Tolerance up thru 6 152 ± .030 ± 0.76 Basic Tolerance up thru 1 25 ± .015 ± 0.38
Additional Tolerance for Additional Tolerance for

each additional inch over 6 152 ± .002 ± 0.051 each additional 1 25 ± .002 ± 0.051
*Calculated for castings produced from mounted wood or metal matchplate pattern equipment.
NOTE: The tolerances shown above must be modified when dimensions are affected by a parting line,
cores and/or moving mold parts. See E2 and E3.
DRAFT: A dimension pertaining to a surface requiring draft is measured at one point on that surface only.
Draft will increase or decrease such dimensions as indicated in E4.
STARTING DIMENSIONS: The points or planes from which inspection and/or machining layouts are started,
should be indicated on the drawing by symbol or other means. Such designation tends to control the
accumulation of tolerances, in addition to the prime purpose of establishing a common location from which
to work. The points on which the casting rests for inspection should be located close to its extremities to
minimize variations in alignment. See E20 for details.
1-4 *Formerly AA-CS-E1-92 in previous editions

E2*
and Permanent Mold Castings LINEAR TOLERANCES—
Across Parting Line
Parting line tolerances must be added to the linear tolerances, indicated in E1, on all dimensions which
cross the parting line of the casting. The tolerances in E1 reflect only the variations caused by expansion
and contraction of the mold itself, the metal during solidification, patternmaking tolerances and vibration of
the pattern during its removal from the mold. Dimensions crossing a parting line are affected by all of these,
plus the hydrostatic pressure of the fluid metal, which acts as a hydraulic fluid in a cylinder, attempting to
force the mold halves apart and, in sand, the tendency of the top half of the mold to ‘sag’ from its own
weight. The amount of additional variation across the parting line therefore, is related to the ‘projected area’
of the casting at the parting line and the values shown below must be added to the tolerances listed in E1
on dimensions crossing the parting line. For multiple cavity molds the projected area will be the area of the
mold occupied by the cavities including the area between the cavities.
E2 dimensions parallel to the parting plane, as well as those which are perpendicular, are affected if the
surfaces are on opposite sides of the parting line.
(E2) ADDITIONAL TOLERANCE, in., mm
Projected Area Sand Casting Permanent

Mold
in.2 cm2 in.2 cm2 in. mm in. mm

Up thru 10 65 ± .020 ± 0.50 ± .010 ± 0.25
Over 10 65 thru 50 320 ± .035 ± 0.90 ± .015 ± 0.38
Over 50 320 thru 100 650 ± .045 ± 1.10 ± .020 ± 0.50
Over 100 650 thru 250 1600 ± .060 ± 1.50 ± .025 ± 0.60
Over 250 1600 thru 500 3200 ± .090 ± 2.30 ± .030 ± 0.80
For over 500 in.2 (3200 cm2) of projected area, consult foundry.
Additional tolerances, in the case of cores or moving mold parts, are shown in Standard E3.
*Formerly AA-CS-E2-92 in previous editions 1-5

E3*
and Permanent Mold Castings LINEAR TOLERANCES—Cored Areas;
Sand and Moving Parts
The use of sand and/or metal cores broaden the design flexibility of sand and permanent mold castings
by allowing a hole or undercut to be produced in a surface of a casting perpendicular to the parting plane.
Since these cores are separate from the sand or metal mold there must be a clearance allowance for
placement or movement. Such allowances create an added variation in dimensions of a surface produced
by the core to a surface produced by the mold. The amount of this additional tolerance is governed by the
projected area of the core.
ADDITIONAL TOLERANCE, in., mm
Sand Mold PM to PM to
Projected Area
Sand Core Sand Core Metal Core
in.2 cm2 in.2 cm2 in. mm in. mm in. mm

Up thru 10 65 ± .020 ± 0.50 ± .015 ± 0.38 ± .010 ± 0.25
Over 10 65 thru 50 320 ± .035 ± 0.90 ± .025 ± 0.60 ± .015 ± 0.38
Over 50 320 thru 100 650 ± .045 ± 1.10 ± .030 ± 0.80 + .015 ± 0.38
Over 100 650 thru 250 1600 ± .060 ± 1.50 ± .040 ± 1.00 + .022 ± 0.60
Over 250 1600 thru 1000 6500 ± .090 ± 2.30 ± .060 ± 1.50 + .032 ± 0.80
For over 1000 in.2 (6500 cm2) of projected area, consult foundry.
NOTE: The above tolerances are to be added to those determined for a dimension as provided in
Standards E1 and E2. Dimensions wholly within the area of a single core need not have this tolerance
added; linear tolerance, only, would apply.

E4*
and Permanent Mold Castings DRAFT REQUIREMENTS
Page 1 of 2
shall not be binding on the foundry unless accepted in writing. The molding process, the overall casting
size and configuration need also be considered when specifying draft requirements.
All walls on castings that are perpendicular to the parting plane require draft or taper. This draft is not
constant. It will vary with the length of draw (L). See sketches below and graph on Page 2 which applies to
all surfaces except cored holes and pockets.
Fig. 1 Fig. 2
Normally the drawing does not show draft (Figure 1). Standard foundry practice is to ‘add’ draft to the
part. To avoid misunderstanding, this is synonymous with saying it will add metal to the casting, thereby
increasing its size and weight.
Draft “d” will be ‘added’ to “A”, increasing its size to “A1”. Note that ‘added’ draft affects dimension “B” by
decreasing its size to “B1”. This is shown in Figure 2.
Fig. 3
Fig. 4
Draft may be ‘removed’ if desired but must be specified on drawing, as shown in Figure 3.
In holes, draft will be ‘added’ to “a” decreasing its size to “a1”; see Figure 4. When the designer desires a
hole dimension to become larger for reasons such as clearance, he should so indicate.
Fig. 5 Fig. 6
The ‘direction’ in which draft is applied is governed by the location of the parting line and will be at the
foundry’s option unless otherwise specified; see Figure 5.
When a parting line interrupts a surface to which draft is applied, the amount of draft to be added will be
determined by the longer portion of surface to be drawn. Drafts will be applied to the remainder of the
surface to provide a match at the parting line; see Figure 6.

E4*
and Permanent Mold Castings DRAFT REQUIREMENTS
Page 2 of 2
NOTE: Figures shown in degrees are recommended angular draft for a given length of draw.

E5*
and Permanent Mold Castings FLATNESS- STRAIGHTNESS-
FLATNESS: Flatness is that condition which exists when all points on a surface lie in the same plane. The
surfaces of castings can be measured for flatness by supporting the surface in question on three widely
separated points to establish the basic plane. The flatness variation is the deviation from that plane as
measured by mutually accepted methods.
FLATNESS TOLERANCE: A flatness tolerance is that total deviation permitted from a plane and consists of
the distance between two parallel planes within which the entire surface so toleranced must lie.
Greatest Dimension Permanent Mold Tolerance Sand Tolerance
in. mm in. mm in. mm

0 thru 6 150 within 0.020 within 0.50 within 0.030 within 0.80
each additional 1 thru 24 25 thru 600 0.003 per inch 0.08 per 25 mm 0.003 per inch 0.08 per 25 mm
For castings over 24 inches (600 mm), consult foundry.
Checking for flatness will be performed only on those surfaces specified.
On castings of such configuration and/or alloy where it becomes impossible or impractical to straighten,
exceptions to the above tolerances are required. In such cases the foundry should be consulted.
Tolerances closer than the above can at times be obtained. Special gauges and fixtures requiring extra
costs may be needed.
STRAIGHTNESS: Straightness is that condition which, when matched with a true straight edge of a true flat
surface, will permit full line contact along the full length. Tolerance should be discussed with foundry.

and Permanent Mold Castings E6*
HOLES AND POCKETS—SAND CAST
Holes and pockets in sand castings may be produced either by incorporation as integral features of the
pattern equipment (provided size limitations, draft requirements and direction of draw are satisfactory), or
by insertion of separately made sand cores. These sand cores will give a flexibility of design to the pattern
equipment (see figure above), but generally at a higher production cost.
The limiting factors in casting holes and pockets are depth, degree of draft and the narrowest dimension
across the hole.
The table below lists limiting sizes, depths and drafts for holes as produced with or without separate sand
cores. Note that as in the above figure, “a” refers to the shortest dimension across the base of the hole or
pocket.
‘a’ Base—Hole diameter or

Minimum dimension of recess in., mm
in. mm in. mm in. mm in. mm in. mm
0.25 6 0.50 12 1.0 25 2.0 50 4.0 100
‘L’ Maximum Depth, in., mm
Sand Mold Solid Solid 0.50 12 0.75 19 1.50 38 2.0 50
Sand Core Solid Solid 0.50 12 2.0 50 4.0 100 8.0 200
‘d’ Draft Required Per Side, Deg.
Sand Mold — — 10 10 10 10 7 7 5 5
Sand Core — — Same as Standard E4 for Sand Castings

HOLES AND POCKETS—PERMANENT MOLD
Holes and pockets in permanent mold castings are preferably produced by steel cores which are so
incorporated in the mold design that they can be withdrawn manually or mechanically during the casting
cycle. Such cores require draft for withdrawal.
Sand cores may be used where normal draft cannot be tolerated, or where internal chambers are required
which do not permit withdrawal of steel cores. Thus modified, the process is known as “Semi-permanent”
mold.
In special circumstances steel cores may be collapsed and removed in sections to accomplish a similar
result. Loose pieces can be used to form undercuts or provide non-drafted surfaces. In such cases
consultation with the foundry is advisable.
The table below gives desired values for core depths and drafts in relation to diameters.
Base—Hole diameter or
Minimum dimension of recess in., mm
0.25 6.0 0.50 12.0 1.00 25.0 2.00 50.0 4.00 100.0
Maximum Depth, in., mm
Permanent Core 0.25 6 1.0 25 2.0 50 4.0 100 8.0 200
Sand Core Solid Solid 0.50 12 2.0 50 4.0 100 8.0 200
Draft Required Per Side, Deg.
Permanent Core 10 10 7 7 5 5 3 3 3 3
Sand Core — — Same as Standard E4 for Sand Castings

and Permanent Mold Castings
E8*
PROFILE TOLERANCES Page 1 of 3
indicated when acceptable, as these tend to keep costs to a minimum. Any variations in these values
A profile is the outline of an object in a given plane. Profiles are formed by projecting a three-dimensional
figure onto a plane or by taking cross sections through the figure. The elements of a profile are straight lines,
arcs, and other curved lines.
The profile tolerance specifies the width of a uniform zone (one half on each side of the basic profile) within
which the elements of the surface must lie.
Where applicable, a general profile tolerance requirement may be specified in a note on the drawing. The
general profile tolerance should specify the datum system (usually defined by datum target points—See
AA-CS-E20-92, Page 32) from which the basic profile of the toleranced surfaces are located. (Figure 1)
In determining the amount of tolerance to be specified in a general profile tolerance requirement,

consideration must be given to a number of factors. The general profile tolerance should be broad enough to
reflect the variations caused by expansion and contraction of the mold itself, the metal during solidification,
patternmaking tolerances and vibration of the pattern during its removal.
TABLE 1 shows recommended tolerance values which should be attainable between features that are
contained within the same mold half. The general profile tolerance should also allow for variance in
dimensions which cross the parting line. These dimensions are affected by all of the above factors plus
the hydrostatic pressure of the fluid metal which acts similar to hydraulic fluid in a cylinder trying to force
the mold halves apart. The amount of additional variation across the parting line, therefore, is related to the
“projected area” of the casting at the parting line. For multiple cavity molds the projected area is the area of
the mold occupied by the cavities including the area between the cavities.
TABLE 2 shows recommended tolerance values which should be added to those found in TABLE 1 for
dimensions crossing the parting line.
TABLE 3 shows recommended tolerance values which should be added to those found in TABLE 1 for
dimensions which include areas formed by sand or metal cores.
Specific features which require a more stringent tolerance than the general profile tolerance should be
toleranced separately in the appropriate views on the drawing. (Figure 2)
Figure 1 Figure 2

E8*
PROFILE TOLERANCES Page 2 of 3
TABLE 1: Basic Tolerance

Sand Casting* Permanent Mold
*Calculated for castings produced from Fully Cast to
mounted wood or metal matchplate machined size molds
pattern equipment mold
cavities
Basic Tolerance up thru 6 in. .06 Basic Tolerance up thru 1 in. .03 .06
Basic Tolerance up thru 150 mm 1.5 Basic Tolerance up thru 25 mm .8 1.5

Additional Tolerance for each Additional Tolerance for each
additional inch over 6 in. .004 additional in. .003 .005
Additional Tolerance for each Additional Tolerance for each
additional 25 mm over 150 mm .10 additional 25 mm .080 .12
Linear Tolerances for cm2 expressed in mm
TABLE 2: Additional Tolerance for Dimensions Across Parting Line

Projected Area Sand Casting Permanent Mold
Up thru 10 in. .04 .02
Up thru 65 cm 1.0 .5
Over 10 thru 50 in. .06 .03
65 thru 320 cm 1.5 .8
Over 50 thru 100 in. .08 .04
320 thru 650 cm 2.0 1.0
Over 100 thru 250 in. .10 .05
650 thru 1600 cm 2.5 1.2
Over 250 thru 1000 in. .15 .07
1600 thru 6500 cm 3.8 1.8
TABLE 3: Additional Tolerance for Cored Features

Sand Core Metal Core To Sand Core To
Projected Area
Sand Mold Perm Mold Perm Mold
Up thru 10 in. .04 .02 .03
Up thru 65 cm 1.0 .5 .8
Over 10 thru 50 in. .05 .03 .04
65 thru 320 cm 1.2 .8 1.0
Over 50 thru 100 in. .07 .03 .06
320 thru 650 cm 1.8 .8 1.5
Over 100 thru 250 in. .09 .05 .08
650 thru 1600 cm 2.2 1.2 2.0
Over 250 thru 1000 in. .13 .07 .12
1600 thru 6500 cm 3.3 1.8 3.0

E8*
and Permanent Mold Castings PROFILE TOLERANCES—Cored Areas;
Sand and Moving Parts Page 3 of 3
The use of sand and/or metal cores broaden the design flexibility of sand and permanent mold castings
by allowing a hole or undercut to be produced in a surface of a casting perpendicular to the parting plane.
Since these cores are separate from the sand or metal mold there must be a clearance allowance for
placement or movement. Such allowances create an added variation in dimensions of a surface produced
by the core to a surface produced by the mold. The amount of the additional tolerance is governed by the
projected area of the core.

EJECTOR PIN MARKS
EJECTOR PIN MARKS: Ejector pin marks on permanent mold castings are formed by the movable pins
which eject the castings from the mold. The number, location, and size of the ejector pins required will vary
with the size and complexity of the casting.
LOCATION OF EJECTOR PINS: Locations shall be at the option of the foundry unless otherwise specified.
Areas of possible interference should be specified on the drawing.
EJECTOR PIN MARK TOLERANCES: The ejector pin marks will vary from the adjoining surface by the
amount shown in the table below. Marks may be specified as raised or depressed. If so specified, the
permissible variations of the marks will be the total of the given tolerance band.
Ejector Pin Mark Tolerances, in., mm

Projected Area Tolerance
in.2 cm2 in. mm

Up thru 50 320 ± 0.020 ± 0.50
Over 50 thru 100 320 thru 650 ± 0.030 ± 0.80
Over 100 thru 200 650 thru 1300 ± 0.045 ± 1.10
Over 200 1300 CONSULT FOUNDRY
EJECTOR PIN FLASH: Ejector pin marks may be surrounded by a ring of metal that may extend up to
0.060/inch (1.5 mm) in height. This metal is not be removed unless specified by the customer.

E10*
and Permanent Mold Castings SNAGGING, GRINDING, REMOVAL OF
P/L, CHILL MARKS, GATES AND RISERS
A parting line is that line on a casting caused by the junction or separation between mold
sections in either sand or permanent mold. A similar line is produced at the juncture
between mold sections and sand cores or moving metal parts.
In addition to the parting line generally some mismatch or shift between two mold halves
or mold sections is inherent with the casting process. Flash, fins and shifts will be removed
and adjoining surfaces blended to the limits specified below or otherwise specified by the
customer. Chill marks and vent marks normally will not be removed unless they exceed the
values set forth below, or unless specified by the customer.
Gates and risers will be removed to within limits indicated. Additional grinding or snagging
will be performed only when specified.
Minimizing the requirements for snagging and grinding will result in a more economical
part. In general, less trimming will be performed on those surfaces that subsequently will
be machined.
In the absence of specific requirements regarding snagging and grinding, it will be

considered normal to blend excess material into the casting contour within the plus values
shown below.
Nonmachined Machined
Casting Weight
Surface Surface
lb. kg in. mm in. mm
Up thru 10 5 0.031 0.80 0.063 1.60
Over 10 thru 25 5 thru 12 0.047 1.20 0.063 1.60
Over 25 thru 50 12 thru 25 0.063 1.60 0.094 2.40
Over 50 thru 100 25 thru 45 0.125 3.20 0.188 4.80
Where the casting configuration is complex, consult foundry.

E11*
and Permanent Mold Castings ANGULARITY— PERPENDICULARITY—
PARALLELISM— Page 1 of 4
The angularity (including perpendicularity & parallelism) tolerance is the total deviation between two planes
within which the entire surface, so toleranced, must lie. The planes of deviation (tolerance zone) forms the
basic angle to the datum plane which is expressed by the symbol
The tolerances indicated (Page 2 & Page 3) are for those surfaces or planes that are normally considered
to be free of any draft requirements.
Engineering Standard E-5, Flatness and Straightness, tolerances must be considered in establishing planes,
and must be added to the above.
ANGULARITY: Angularity refers to the angular departure from the designed relationship between the
elements of a casting. The angular accuracy is affected by numerous factors including the size of the casting,
the strength and rigidity of the mold and mold parts under conditions of high temperature, positioning of
mold members, distortion during handling, and heat treating the casting. The angularity of cored holes may
vary as a result of distortion and wear of metal cores and wear of core boxes.
This standard may be applied to plane surfaces of, or cored holes in, permanent mold or sand castings.
Where applicable, consideration of E4, Draft Requirements, and E5, Flatness and Straightness, is required
in their effect on angularity tolerances.

E11*
PLANE SURFACES: Tolerances required vary with the length of the casting surface and the relative location
of the surface in the mold cavity.
All tolerances in inches are Total Indicator Reading (T.I.R.) in inches. All tolerances in metric are Full Indicator
Movement (F.I.M.) in millimeters.
PM Sand
Surfaces in fixed relationship
in same mold section
or member.
Surface length up thru 3 75 0.020 0.50 0.045 1.10
Additional tolerance per 1 25

length in excess of 3 75 0.002 0.05 0.003 0.08
Surface formed across a
parting line.

PERMANENT MOLD: One

surface formed by a mold
section, and the other surface
by a moving mold member in
the same mold section
SAND: One surface formed by

a mold section, and the other
surface by a core set in the
same mold section.

PERMANENT MOLD: One

surface formed by a mold
section, and the other surface
by a moving mold member
located across the parting
line, or surfaces formed by
two moving mold members in
the same mold section.
SAND: One surface formed by

a mold section, and the other
surface by a core located
across the parting line, or
surfaces formed by two cores
in the same mold section.

For Angularity Tolerances for Cored Holes, see page 19.

E11*
CORED HOLES: The alignment tolerances are applicable only when proportions of the cored holes conform
to the diameter-to-depth ratios and draft requirements of Engineering Standards E6 and E7.
The values shown refer to deviation from the normal axis of the cored hole.
In some instances additional angularity tolerance will be necessary if the measuring methods used involve
Engineering Standard E5, Flatness.
ANGULARITY TOLERANCES—(DEVIATION FROM NORMAL AXIS, in., mm)—CORED HOLES
Permanent Mold Sand

Tolerance for hole
depth up thru 3 75 0.020 0.50 0.030 0.80
Tolerance for hole

depth greater than 3 75 0.020 plus 0.005 0.50 plus 0.12 per 0.030 plus 0.007 0.8 mm plus 0.18 mm
per in. of depth 25 mm of depth per in. of depth per 25 mm of depth
over 3 in. over 75 mm over 3 in. over 75 mm

E11*
HOW TO APPLY THIS STANDARD: In the examples shown below, permanent mold tolerances have been
used. For sand castings tolerance is applied in the same manner.
1. Surfaces in fixed relationship:
Surface B and the datum plane are formed by the same mold section. If surface B is 5 in. (125 mm)
long, it will be parallel to the datum plane within 0.024 inch (0.6 mm) (e.g., 0.020 inch for the first 3 in.
+ 2 × 0.002 [0.50 mm for the first 75 mm + 2 × .050]).
2. Surfaces formed by mold surfaces across parting line:
Surface B and the datum plane are formed in opposite mold sections. If surface B is 7 in. (175 mm)
long, it will be parallel to the datum plane within 0.035 inch (0.9 mm) (e.g., 0.025 inch for the first 3 in. +
4 × 0.0025 [0.6 mm for the first 75 mm + 4 × .065]).
3. One surface formed by a mold section, and the other by a moving mold member in the same mold
section:
Surface B is formed by a moving mold member in the same mold section as the datum plane. If surface B
is 5 in. (125 mm) long, it will be perpendicular to the datum plane within 0.030 inch (0.7 mm) (e.g., 0.025
for the first 3 in. + 2 × 0.0025 [0.6 mm for the first 75 mm + 2 × .065]).
4. One surface formed by a mold section, and the other by a moving mold member located across the
parting line; or surfaces formed by two moving mold members.
Surface B is formed by a moving mold member and the datum plane is formed by the opposite mold
section. If surface B is 5 in. (125 mm) long, it will be perpendicular to the datum plane within 0.036"
(1.0 mm) (e.g., 0.030 for the first 3 in. + 2 × 0.003 [0.6 mm for the first 75 mm + 2 × .080]).
Surfaces B and C are formed by two moving mold members. If surface B is used as the datum plane
and surface C is 5 in. (125 mm) long, surface C will be parallel to the datum plane within 0.036 inch
(1.0 mm) (e.g., 0.030 inch for the first 3 in. + 2 × 0.003 [0.8 mm for the first 75 mm + 2 × .080]).

and Permanent Mold Castings CONCENTRICITY—
E12*
Page 1 of 3
Concentricity is the relative position of two or more cylindrical surfaces in respect to a common axis.
Concentricity tolerance is one half the difference in the diameters of a cylindrical tolerance zone about
which axis the feature so toleranced must lie and is expressed See figure below.
Concentricity requirements in inches are usually expressed as “Total Indicator Readings” (T.I.R.).
Concentricity requirements in metric are always expressed as “Full Indicator Movement” (F.I.M.).

and Permanent Mold Castings CONCENTRICITY—
E12*
Page 2 of 3
Concentricity of cylindrical surfaces is affected by the design of the casting. Factors involved include the
size, wall thickness, shape and complexity of the casting.
APPLICABILITY OF STANDARD: This standard applies to castings having maximum rigidity and uniformity
of shape and wall thickness. Under these conditions castings may be slightly out-of-round but this ovality is
included in the concentricity tolerances.
NOTE: Castings containing inserts are not covered by this standard. Concentricity tolerances will only
apply when specified on drawing.
TOLERANCE FOR CONCENTRICITY OF CAST SURFACES: Concentricity of cast surfaces is affected by

the type of mold or pattern construction. These include surfaces in fixed relationship (formed by one mold
member), by opposite mold sections, by auxiliary mold members such as slides and cores, or combinations
of these.
All tolerances in inches are Total Indicator Reading (T.I.R.). All tolerances in metric are Full Indicator
Movement (F.I.M.).
BASIC TOLERANCES, in., mm

Diameter of Largest Tolerance, T.I.R., F.I.M.
Surface (A) PM Sand
5 or less 125 or less .025 0.60 .050 1.20
.003 0.08 .005 0.12
Over 5 add Over 125 add
per addt’l in. or 25 mm
ADDITIONAL TOLERANCE—
ADD TO BASIC TOLERANCE
*Projected Area (C) Additional Over
of Casting Basic Tolerance
PM Sand
sq. in. sq. cm in. mm in. mm
Less than 50 Less than 320 .025 0.60 .045 1.10
50 thru 100 320 thru 650 .030 0.80 .050 1.20
Over 100 trhu 200 Over 650 thru 1300 .035 0.90 .065 1.70
Over 200 thru 300 Over 1300 thru 1900 .045 1.10 .080 2.00
ADDITIONAL TOLERANCE—ADD TO BASIC

TOLERANCE—EACH MOLD MEMBER
*Projected Area (C, D) Additional Over
of Moving Member Basic Tolerance
PM Sand
sq. in. sq. cm in. mm in. mm
Less than 10 Less than 60 .015 0.38 .030 0.80
10 thru 20 60 thru 130 .020 0.50 .040 1.00

E12*
CONCENTRICITY— Page 3 of 3
CONCENTRICITY TOLERANCES: How to apply this standard. Example below is for permanent mold
casting.
1. Basic Tolerances—Surfaces in fixed mold relationship:
Cylindrical surfaces A and B are formed by the same mold section. If diameter A is 7 in. (175 mm)
and diameter B is 4 in. (100 mm), diameter A will be concentric with diameter B within .031 in. T.I.R.
(8 mm F.I.M.) (e.g., .025 in. + (2 × .003) = .031 in. [.6 mm for the first 125 mm + (2 × .080)]).
2. Surfaces formed by opposite mold sections:
Diameters A and B are formed by opposite mold halves. If the projected area C of the casting is 10 ×
15 in. or 150 sq. in. (1000 cm2), cylindrical surface A is 8 in. (200 mm) in diameter and cylindrical surface
B is 6 in. (150 mm) in diameter, diameter A will be concentric with diameter B within .069 in. T.I.R.
(1.7 mm F.I.M.).
Projected area allowance .035 in. + basic tolerance [.025 in. + (3 × .003)] = .069 in.
Projected area allowance .9 mm + basic tolerance [.6 mm + (3 × .080)] = 1.70 mm
3. Surfaces formed by two moving mold members:
Diameters A and B are formed by moving mold members. If diameter A is 5 in. (125 mm) and diameter B
is 2 in. (50 mm), projected area of member C is 25 sq. in. (160 cm2) and projected area of mold member D
is 12 sq. in. (75 cm2), diameter A will be concentric with diameter B within .075 in. T.I.R. (1.9 mm F.I.M.).
Basic tolerance for 5 in. (125 mm) diameter – .025............................ .025 in. 0.60 mm
Projected area allowance for member C (25 sq2 or 160 cm2)............. .030 in. 0.80 mm
Projected area allowance for member D (12 sq2 or 75 cm2)............... .020 in. 0.50 mm
Total..................................................................................................... .075 in. 1.90 mm

MACHINE FINISH ALLOWANCE
Drawings furnished for the manufacture of castings usually picture the finished part after machining or the
casting prior to machining.
CASTING DRAWINGS: Drawings showing the casting prior to machining should have the finish allowance
indicated in table included in the dimensions shown and no finish symbols added. It is recommended that
an undimensioned phantom line be used to represent surfaces after machining, thus enabling the foundry
to recognize them for processing reference.
FINISHED PART DRAWINGS: The symbols which follow represent those most commonly used on finished
part drawings to indicate those surfaces requiring allowance for subsequent machine operations. Generally,
only surfaces so marked will have such allowance added.
CAUTION: Confusion arises when the tolerances on the decimal dimensions specified for a surface cannot
be held without machining, yet no finish symbol is shown on the surface. It is recommended that the
designer’s intent be clearly indicated to avoid costly misunderstandings.
Following is a table showing the amount of metal normally added for machining. The amount of material
to be added is related to the overall size of the casting rather than varying with individual dimensions. The
designer should select that line on the table below showing the range within which the casting’s greatest
dimension falls. The finish allowance shown next to this range is then used on all surfaces requiring
machining.
MACHINE FINISH ALLOWANCE, in. mm
Greatest Dimension Cores in PM’s
Sand Sand Shell Permanent Mold

Up thru 6 150 .060 1.50 .060 1.50 .060 1.50 .045 1.10
Over 6 thru 12 150 thru 300 .090 2.30 .090 2.30 .060 1.50 .060 1.50
Over 12 thru 18 300 thru 450 .120 3.00 .120 3.00 .090 2.30 .075 1.90
Over 18 thru 24 450 thru 600 .150 3.80 .180 4.50 .120 3.00 .090 2.30
The values given in above table are based on a maximum “build-up” or a “safety factor” for average casting
variations of flatness, squareness, concentricity, etc., as well as linear tolerance. The values are minimum
recommended and foundry draft when required must be added to above values.

E14*
POSITIONAL TOLERANCE Page 1 of 2
A positional tolerance defines a zone within which the center, axis, or center plane of a feature of size
is permitted to vary from true (theoretically exact) position. Basic dimensions establish the true position
from specified datum features and between interrelated features. A positional tolerance is indicated by the
position symbol, a tolerance, and appropriate datum references placed in a feature control frame. (5.2) See
Figure 1.
Figure 1
Regardless of Feature Size S , where applied to the positional tolerance of circular features, requires the
axis of each feature to be located within the specified positional tolerance regardless of the size of the
feature. (5.3.4)
Where positional tolerancing at Least Material Condition L is specified, the stated positional tolerance
applies when the feature contains the least amount of material permitted by its toleranced size dimension.
Specification of L further requires perfect form at L . Where the feature departs from its L size, an
increase in positional tolerance is allowed, which is equal to the amount of such departure. (5.3.5)
It is only when the feature (hole) is at Maximum Material Condition M that the specified positional tolerance
applies. Where the actual size of the feature is larger, additional positional tolerance results. This increase
of positional tolerance is equal to the difference between the specified maximum material limit of size and
the actual size of the feature. (5.3.2.1)
*Above as defined in ANSI Y14.5M-1982 (R1989).

E14*
POSITIONAL TOLERANCE Page 2 of 2
TABLE 4: Positional Tolerance
Sand Permanent Mold
Positional Tolerances Required Fully Cast

Machined to Size
Basic tolerance up to 6" greatest dim. 150 mm greatest dim.
(1" PM) (25 PM) .085 2.20 .040 1.00 .085 2.20
Additional tolerance required over basic in./in. (mm/25 mm) .008 0.20 .005 0.12 .008 0.20
Additional for a separate core .060 1.50 .030 0.80 .050 1.20
Additional over a parting line .060 1.50 .045 1.10 .060 1.50

WALLS, FILLETS & RIBS
NOTE: The following is not to be considered an Engineering Standard but rather a guide to good casting
design.
A production problem of fundamental importance to foundries is establishing a sequence of progressive

solidification that will compensate for the change in unit volume as the cast shape solidifies. The designer
should, wherever possible, use sections that are tapered to increase in thickness toward points accessible
to feed metal. If it is necessary to join light and heavy sections, a gradual increase in thickness is most
desirable. If tapered sections are not practical or the increased expense of building the pattern or mold is
not warranted, a uniform section should be maintained. Intersecting surfaces forming junctions of metal
thickness should be joined with fillets in order to obtain improved foundry characteristics and a more
uniform distribution of stress in service.

E16*
and Permanent Mold Castings LETTERING (SAND CASTING)
Page 1 of 2
NOTE: The values shown herein represent normal production practices. Fine detail may involve
additional costs.
Lettering, trademarks, and identification symbols may be reproduced on the surfaces of sand castings. This
lettering can be added to the pattern by means of metal or plastic ribbons, spiked or glued letters, engraved
inserts, by casting or stamping the information integrally to the pattern or by the use of inserted plugs that
can be replaced if a change is required.
RAISED LETTERS: This is the preferred method of casting lettering on a surface.
RAISED LETTERS IN A RECESS: A satisfactory alternative if raised letters on the cast surface are
objectionable.
DEPRESSED LETTERS: Depressed letters are more difficult to cast legibly and are not recommended for
wood patterns.
Sharp face letters will be used unless otherwise specified as this type makes a good impression in the sand
and reproduces well on the casting. When lettering is to be highlighted, specify a flat face letter. Lettering
should be placed on a flat surface, parallel to the parting line, with adequate space allowed (see below) and
should not run into fillets or radii. Readability is reduced when placed on a curved surface or in a core.
The above illustration indicates the spacing required for 1/2 in. (12 mm) and 1/4 in. (6 mm) letters. The table
below indicates the minimum width required for standard letters, in inches and millimeters.
in. mm in. mm in. mm in. mm in. mm in. mm
*Size 0.125 3 0.188 5 0.25 6 0.31 6 0.38 10 0.50 12
Min. Width 10 Letters 1.44 36 1.94 50 2.38 60 2.88 75 3.38 85 4.25 110
Height 0.031 0.8 0.047 1.2 0.047 1.2 0.047 1.2 0.063 1.6 0.078 2.0
All dimensions in inches and millimeters.

*Minimum sizes: Raised—1/8 in. (3 mm) minimum with 1/4 in. (6 mm) preferred.
Depressed—3/16 in. (5 mm) minimum with 5/16 in. (8 mm) preferred.

E16*
and Permanent Mold Castings LETTERING (PERMANENT MOLD)
Page 2 of 2
NOTE: The values shown herein represent normal production practices. Fine detail may involve
additional costs.
Lettering, trademarks, and identification symbols may be reproduced on the surfaces of permanent mold
castings by stamping or engraving the mold. Letters can be incorporated integrally on the surface of the
mold or as an inserted plug that can be replaced if a change is required.
RAISED LETTERS: This is the preferred method of casting lettering on a surface. It is the least expensive
to incorporate into the mold and requires minimum maintenance.
RAISED LETTERS IN A RECESS: A satisfactory alternative if raised letters on the cast surface are
objectionable. This requires additional work on the mold.
DEPRESSED LETTERS: Depressed letters should be avoided. They increase mold costs as they must be
raised on the mold surface. In addition, maintenance costs are increased since this type of lettering is more
subject to wear and damage.
Flat face letters will be used unless otherwise specified. Lettering should be located on a flat surface,
parallel to the parting line, with adequate space allowed and should not run into fillets or radii.
SIZE—Raised—0.156 in. (4 mm) minimum; Depressed—0.25 in. (6 mm) minimum

LINE—.015 in. (0.40 mm) minimum
HEIGHT—0.15 in. (4 mm) minimum but shall not exceed the line
FLANK ANGLE—20 deg. minimum
All dimensions in inches and millimeters.

CAST SURFACE SMOOTHNESS
Cast surface smoothness depends on the molding process used. Ranges of smoothness normally obtained
by the three processes—sand, permanent mold, and shell—are shown in the figure below. Values shown
apply to major portion of the casting surfaces. Areas of gating, risering, fillets, and parting lines are not
included.
The surface smoothness required shall be expressed by a numerical surface “roughness-height-rating”

(RHR) in microinches and in microns adjacent to and at left of long leg:
for example
300 7 .5

The value of the number is maximum as specified and indicates the maximum permissible sustained height
rating. Any lesser rating is acceptable. A microinch is one millionth (0.000001) of an inch. A micron is one
millionth (0.000001) of a meter.
It is the designer’s responsibility to differentiate clearly between those surfaces on which he wants to specify
“machine finish” and those surfaces on which he wants to specify “as cast smoothness.” If the basic symbol
XX

is used on the field of drawing, stock will be allowed for machining. When the designer’s intention is to
control the function as cast smoothness of specific areas, it should be indicated in the list of drawing notes.
Example:
Cast surface comparator blocks for visual and touch inspection are available. One type, shown in the
figure below, may be obtained from the American Foundry Society, Inc. It is necessary, of course, that
inspections be made against the actual comparator block. Microinch and micron values are recommended
for designating surface smoothness ratings.

METAL THICKNESS
Many conditions and specifications affect the ability of foundries to cast to a desired metal wall thickness i.e.
(1) fluidity of alloy

(2) metallurgical quality
(3) design
(4) surface finish
(5) pattern or mold equipment
The figures in the graph below show desired minimum metal thickness that should be specified for aluminum
castings of minimum complexity. When metal flow is restricted, or other factors become more important, an
increase in values shown may be required.
Reference to E-4 (Draft), E-15 (Fillets) and E-18 (Surface Finish) is necessary for consideration of this
Reference to E-4 (Draft), E-15 (Fillets) and E-18 (Surface Finish) is necessary for consideration of this
specification.

E20*
and Permanent Mold Castings DATUM IDENTIFICATION
DATUM TARGET Page 1 of 4
A “DATUM” is a feature or a group, of features of a part, selected for use as a base from which other features
or points are located within specified limits.
To achieve consistency in the manner in which measurements are made in all stages of production;
i.e.; pattern making, casting layout, tooling layout, etc., a system known as target points or datum lines,
or datum planes has been devised. For the purpose of this standard, “target point” and “tooling point”
are synonymous. This system relates all significant dimensions to a common reference (datum plane). It
is strongly recommended that those points or planes from which inspection and/or machining layouts are
started, be indicated on the drawing by symbol or other means. Where datum planes or target points are
not indicated they shall be selected by the foundry, which will choose surfaces formed by the most stable
portion of the mold. Such designations tend to control the accumulation of tolerances in addition to their
prime purpose of establishing a common location from which to work. It is preferred that they be surfaces
not affected by mold parting. Also, the surfaces at which gates and risers are to be placed are unsuitable
as target points as a result of trimming and rough grinding operations. Target points should be avoided
if possible on cored or tapered surfaces. They should be located close to the extremities of the casting
whenever possible to eliminate variations in alignment due to projecting small surface irregularities.
The designer of a casting, the tooling engineer and the foundry should work together in establishing target
points or datum planes because they directly influence casting cost not only from tooling standpoint but
also from the foundry standpoint.
Fig. 1 Schematic illustration showing the perpendicular relations among the three planes in a system

E20*
Fig. 2. Schematic illustration of the establishment of datum planes by means of a datum target system.
Dimensions for locating the datum points are omitted here
Fig. 3. A practical illustration of Fig. 2

E20*
DATUM PLANE C
The amount of draft must be taken into consideration when

locating the “Datum Targets” on applicable surfaces
Datum targets define points, lines, or areas on a part used in establishing datum planes. To apply the three-
plane concept to certain parts, specific points, lines, or areas on features are designated to establish datum
planes. Datum targets may vary from the conventional three point, two point, one point target orientation to
assure a fixed position of the part. Datum targets, while intended for use on parts having irregular surfaces,
may be applied to any part where the design requirements dictate use of specific datum points, lines, or
areas on surfaces rather than use of entire surfaces as datums.
Fig. 4. Satisfactory method for showing datum targets and locations on drawing

E20*
V-TYPE LOCATORS: Certain designs require the use of V-type locators. These are fixture accessories used
to locate radial sections relative to the theoretical center of the V-block. Figure 5 illustrates a casting whose
center line location is important; because of the function for which it was intended, it is mandatory that a
symmetry be maintained, within tolerances, about the center line. To satisfy this condition, a V-type locator
is used as part of the fixturing and provided datum targets 1 and 2. The locator served to center the round
boss “M” so that the drilled hole “G” was concentric with the surrounding wall as required. Proper location
of datum target 3 positioned the casting so that the machining surface “P” would be in relation to the center
line of the hole “G”.
Fig. 5. Illustration of the use of V-type locators

E21*
and Permanent Mold Castings PRODUCT REQUIREMENT FORM
Page 1 of 2
This Product Requirement Form has been prepared by the Aluminum Association for the convenience of
purchasers of aluminum sand and permanent mold castings and is designed for use in conjunction with
the Aluminum Association Standards for Aluminum Sand and Permanent Mold Castings. This Form is
intended to achieve a higher level of understanding between supplier and purchaser and is not intended
to limit or restrict casting requirements. The use of this Form by any prospective purchaser, any member
of the Aluminum Association or any other supplier is voluntary and the Form is not intended to prevent any
purchaser from issuing specifications which differ from those set forth in the Form or to prevent any supplier
from manufacturing or selling products made to specifications which differ from the Form.
The check list, on page 2, provides supplemental data on specific product requirements that affect the
basis on which a casting quotation is prepared. It will be to the advantage of both the purchaser and the
foundry if this check list accompanies prints submitted for quotation. The Aluminum Association or member
foundries can supply check lists for this purpose. The information may also be indicated on prints by coding
with the applicable requirement numbers such as A1, B2, C1, etc.

E21*
and Permanent Mold Castings PRODUCT REQUIREMENT FORM
Page 2 of 2
Customer’s name _________________________________________________________________ Date _________________
Casting Process: Sand _______________ Permanent Mold _______________ Semi-Permanent Mold ______________
Prints Attached h yes, h no. Part Number __________________________________ Rev. __________________
Is part in present production? h yes, h no. Sample available? If not __________________________________

Estimated weight
Anticipated total order ____________________________ Quantity per release _____________________________________
Anticipated annual requirement ________________ daily ________________ or weekly _________________ requirements
Quotation due date __________________________________
Aluminum Alloy ___________ Surface treatment A ______ 1. None required.

______ 2. Blasted.
______ 3. Other requirements.
Temper __________________
Cast surface B ______ 1. No significant requirements.
smoothness ______ 2. Per AA Standard AA-CS-E18.
Per AA Standard AA-CS-M2 ______ 3. Other requirements.
and AA Standard AA-CS-M3
Gates, risers, chill C ______ 1. No specific requirement.
marks, P/L ______ 2. Per AA Standard AA-CS-E10.
Other specifications or ______ 3. Other requirements.
requirements _____________
Flash removal, cored D ______ 1. Not removed.
holes ______ 2. Per AA Standard AA-CS-E10.
_________________________ ______ 3. Other.
Ejector pin marks and E ______ 1. No specific requirements.
_________________________ flash pin removal P.M. ______ 2. Per AA Standard AA-CS-E9.
only ______ 3. Other requirements.
_________________________ Pressure tightness F ______ 1. No requirement.
______ 2. Pressure tight to agreed upon psi, time,
testing medium; repair permitted.
_________________________ ______ 3. Other requirements.
Flatness and G ______ 1. No requirement.
_________________________ straightness ______ 2. Per AA Standard AA-CS-E5.
Dimensional H ______ 1. No specific requirement.
tolerances ______ 2. Per applicable AA Standards.
Remarks: ________________
Casting quality I ______ 1. No specific requirement.
______ 2. Per AA Standard AA-CS-M5.
_________________________ Quality Level _____. Frequency Level _____
_________________________ Packaging J ______ 1. Bulk packaged.
______ 2. Layer packaged-with separators.
_________________________ ______ 3. Other requirements.
Welding K ______ 1. Foundry controlled welding permitted per
AA Standard AA-CS-M9.
______ 2. Special permission required to weld.
Machining L ______ 1. Not by foundry.
______ 2. Machine in accordance with blueprint
specifications
______ 3. Other requirements
Other requirements M ______ 1. ______________________________________
______ 2. ______________________________________
______ 3. ______________________________________

METALLURGICAL SERIES (M)
and Permanent Mold Castings INTRODUCTION
Permanent mold and sand castings can be produced to a variety of metallurgical standards. This series is
established to provide a guide for the metallurgical requirements involved in producing a casting of material
and quality available within normal production procedures.
These standards are in no way intended to supplant any standards that are in existence but rather to
establish a common understanding between the foundry and the user.
These metallurgical standards are designed to provide criteria of quality to the buyer and the foundry which
will be consistent with the application of the casting. When further information is required, consultation
with the foundry should establish a mutual understanding of customer requirements. However, the final
designation of the material and the standards will be the responsibility of the purchaser.
The data in the following pages are representative of that from separately cast test bars. Special consideration
should be given to using test bars cut from castings as a determinant of casting strength or casting quality.
The casting process, casting design, heat treatment and location of test specimens can produce internal
properties exceeding those indicated in AA-CS-M3-2000 when required, but can also result in properties
lower than indicated.
Alloy designations and associated chemical composition limits conforming to the requirements of ANSI
H35.1/H35.1(M) are registered with the Aluminum Association and published in the Registration Record of
Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingot.
Similarly, tempers for aluminum alloy products are registered with the Association and published in the
Registration Record of Tempers For Aluminum and Aluminum Alloy Products, which contains registered
property data that complements property data contained in these metallurgical standards. Templates
for the proposed registration of new alloys and tempers are included in Appendix 1 and 2 at the end of
this metallurgical section.
2-1
and Permanent Mold Castings M1*
ALLOY CROSS REFERENCE CHART
CROSS REFERENCE CHART

OF COMMONLY USED SPECIFICATIONS
Former
Federal ASTM Former
ANSI Former (QQ-A-596) (B26) SAE Military
AA Designation UNS (QQ-A-601) (B108) (J453c) (MIL-A-21180)
201.0 — A02010 — CQ51A 382 —

204.0 — A02040 — — — —
206.0 — A02060 — — — —
B206.0 — A22060 — — — —
208.0 108 A02080 108 CS43A — —
213.0 C113 A02130 113 CS74A 33 —
222.0 122 A02220 122 CG100A 34 —
242.0 142 A02420 142 CN42A 39 —
295.0 195 A02950 195 C4A 38 —
296.0 B295.0 A02960 B195 — 380 —
308.0 A108 A03080 A108 — — —
319.0 319, Allcast A03190 319 SC64D 326 —
328.0 Red X-8 A03280 Red X-8 SC82A 327 —
332.0 F332.0 A03320 F132 SC103A 332 —
333.0 333 A03330 333 SC94A 331 —
336.0 A332.0 A03360 A132 SN122A 321 —
354.0 354 A03540 — — — C354
355.0 355 A03530 355 SC51A 322 —
C355.0 C355 A33550 C355 SC51B 335 C355
356.0 356 A03560 356 SG70A 323 —
A356.0 A356 A13560 A356 SG70B 336 A356
B356.0 — A23560 — — — —
357.0 357 A03570 357 — — —
A357.0 A357 A13570 — — — A357
359.0 359 A03590 — — — 359
443.0 43 A04430 — S5B 35 —
B443.0 43 A24430 43 S5A — —
A444.0 — A14440 — — — —
512.0 B514.0 A05120 B214 GS42A — —
513.0 A514.0 A05130 A214 GZ42A — —
514.0 214 A05140 214 G4A 320 —
520.0 220 A05200 220 G10A 324 —
535.0 Almag 35 A05350 Almag 35 GM70B — —
705.0 603, Ternalloy 5 A07050 Ternalloy 5 ZG32A 311 —
707.0 607, Ternalloy 7 A07070 Ternalloy 7 ZG42A 312 —
710.0 A712.0 A07100 A612 ZG61B 313 —
711.0 C721.0 A07110 — ZC60A 314 —
712.0 D712.0 A07120 40E ZG61A 310 —
713.0 613, Tenzaloy A07130 Tenzaloy ZC81A 315 —
771.0 Precedent 71A A07710 Precedent 71A — — —
850.0 750 A08500 750 — — —
851.0 A850.0 A08510 A750 — — —
852.0 B850.0 A08520 B750 — — —
2-2 *Formerly AA-CS-M1-85 in previous editions

CHEMICAL COMPOSITION LIMITS
CHEMICAL COMPOSITION LIMITS FOR COMMONLY USED SAND

AND PERMANENT MOLD CASTING ALLOYS a b
Others
Alloy Product c Silicon Iron Copper Manganese Magnesium Chromium Nickel Zinc Titanium Each Total k
201.0 S 0.10 0.15 4.0–5.2 0.20–0.50 0.15–0.55 — — — 0.15–0.35 0.05 h 0.10

204.0 S&P 0.20 0.35 4.2–5.0 0.10 0.15–0.35 — 0.05 0.10 0.15–0.30 0.05 i 0.15
206.0 S&P 0.10 0.15 4.2–5.0 0.20–0.50 0.15–0.35 — 0.05 0.10 0.15–0.30 0.05 0.15
A206.0 S&P 0.05 0.10 4.2–5.0 0.20–0.50 0.15–0.35 — 0.05 0.10 0.15–0.30 0.05 0.15
208.0 S&P 2.5–3.5 1.2 3.5–4.5 0.50 0.10 — 0.35 1.0 0.25 — 0.50
222.0 S&P 2.0 1.5 9.2–10.7 0.50 0.15–0.35 — 0.50 0.8 0.25 — 0.35
242.0 S&P 0.7 1.0 3.5–4.5 0.35 1.2–1.8 0.25 1.7–2.3 0.35 0.25 0.05 0.15
295.0 S 0.7–1.5 1.0 4.0–5.0 0.35 0.03 — — 0.35 0.25 0.05 0.15
296.0 P 2.0–3.0 1.2 4.0–5.0 0.35 0.05 — 0.35 0.50 0.25 — 0.35
308.0 P 5.0–6.0 1.0 4.0–5.0 0.50 0.10 — — 1.0 0.25 — 0.50
319.0 S&P 5.5–6.5 1.0 3.0–4.0 0.50 0.10 — 0.35 1.0 0.25 — 0.50
328.0 S 7.5–8.5 1.0 1.0–2.0 0.20–0.6 0.20–0.6 0.35 0.25 1.5 0.25 — 0.50
332.0 P 8.5–10.5 1.2 2.0–4.0 0.50 0.50–1.5 — 0.50 1.0 0.25 — 0.50
333.0 P 8.0–10.0 1.0 3.0–4.0 0.50 0.05–0.50 — 0.50 1.0 0.25 — 0.50
336.0 P 11.0–13.0 1.2 0.50–1.5 0.35 0.7–1.3 — 2.0–3.0 0.35 0.25 0.05 —
354.0 S&P 8.6–9.4 0.20 1.6–2.0 0.10 0.40–0.6 — — 0.10 0.20 0.05 0.15
355.0 S&P 4.5–5.5 0.6 d 1.0–1.5 0.50 d 0.40–0.6 0.25 — 0.35 0.25 0.05 0.15
C355.0 S&P 4.5–5.5 0.20 1.0–1.5 0.10 0.40–0.6 — — 0.10 0.20 0.05 0.15
356.0 S&P 6.5–7.5 0.6 d 0.25 0.35 d 0.20–0.45 — — 0.35 0.25 0.05 0.15
A356.0 S&P 6.5–7.5 0.20 0.20 0.10 0.25–0.45 — — 0.10 0.20 0.05 0.15
B356.0 S&P 6.5–7.5 0.09 0.05 0.05 0.25–0.45 — — 0.05 0.04–0.20 0.05 0.15
357.0 S&P 6.5–7.5 0.15 0.05 0.03 0.45–0.6 — — 0.05 0.20 0.05 0.15
A357.0 S&P 6.5–7.5 0.20 0.20 0.10 0.40–0.7 — — 0.10 0.04–0.20 0.05 e 0.15
359.0 S&P 8.5–9.5 0.20 0.20 0.10 0.50–0.7 — — 0.10 0.20 0.05 0.15
443.0 S&P 4.5–6.0 0.8 0.6 0.50 0.05 0.25 — 0.50 0.25 — 0.35
B443.0 S&P 4.5–6.0 0.8 0.15 0.35 0.05 — — 0.35 0.25 0.05 0.15
A444.0 P 6.5–7.5 0.20 0.10 0.10 0.05 — — 0.10 0.20 0.05 0.15
512.0 S 1.4–2.2 0.6 0.35 0.8 3.5–4.5 0.25 — 0.35 0.25 0.05 0.15
513.0 P 0.30 0.40 0.10 0.30 3.5–4.5 — — 1.4–2.2 0.20 0.05 0.15
514.0 S 0.35 0.50 0.15 0.35 3.5–4.5 — — 0.15 0.25 0.05 0.15
520.0 S 0.25 0.30 0.25 0.15 9.5–10.6 — — 0.15 0.25 0.05 0.15
535.0 S&P 0.15 0.15 0.05 0.10–0.25 6.2–7.5 — — — 0.10–0.25 0.05 f 0.15
705.0 S&P 0.20 0.8 0.20 0.40–0.6 1.4–1.8 0.20–0.40 — 2.7–3.3 0.25 0.05 0.15
707.0 S&P 0.20 0.8 0.20 0.40–0.6 1.8–2.4 0.20–0.40 — 4.0–4.5 0.25 0.05 0.15
710.0 S 0.15 0.50 0.35–0.65 0.05 0.6–0.8 — — 6.0–7.0 0.25 0.05 0.15
711.0 P 0.30 0.7–1.4 0.35–0.65 0.05 0.25–0.45 — — 6.0–7.0 0.20 0.05 0.15
712.0 S 0.30 0.50 0.25 0.10 0.50–0.65 0.40–0.6 — 5.0–6.5 0.15–0.25 0.05 0.20
713.0 S&P 0.25 1.1 0.40–1.0 0.6 0.20–0.50 0.35 0.15 7.0–8.0 0.25 0.10 0.25
771.0 S 0.15 0.15 0.10 0.10 0.8–1.0 0.06–0.20 — 6.5–7.5 0.10–0.20 0.05 0.15
850.0 S&P 0.7 0.7 0.7–1.3 0.10 0.10 — 0.7–1.3 — 0.20 — g 0.30
851.0 S&P 2.0–3.0 0.7 0.7–1.3 0.10 0.10 — 0.30–0.7 — 0.20 — g 0.30
852.0 S&P 0.40 0.7 1.7–2.3 0.10 0.6–0.9 — 0.9–1.5 — 0.20 — g 0.30
a The alloys listed are those which have been included in Federal Specifications QQ-A-596d, ALUMINUM ALLOYS PERMANENT AND SEMI-
PERMANENT MOLD CASTINGS, QQ-A-601E, ALUMINUM ALLOY SAND CASTINGS, and Military Specification MIL-A-21180c, ALUMINUM ALLOY
CASTINGS, HIGH STRENGTH. Other alloys are registered with The Aluminum Association and are available. Information on these should be
requested from individual foundries or ingot suppliers.
b Except for “Aluminum” and “Others,” analysis normally is made for elements for which specific limits are shown. For purposes of determining
conformance to these limits, an observed value or calculated value obtained from analysis is rounded off to the nearest unit in the last right hand place
of figures used in expressing the specified limit, in accordance with the following:
When the figure next beyond the last figure or place to be retained is less than 5, the figure in the last place retained should be kept unchanged.
When the figure next beyond the last figure or place to be retained is greater than 5, the figure in the last place retained should be increased by 1.
When the figure next beyond the last figure or place to be retained is 5 and
(1) there are no figures or only zeros, beyond this 5, if the figure in the last place to be retained is odd, it should be increased by 1; if even, it should
be kept unchanged.
(2) if the 5 next beyond the figure in the last place to be retained is followed by any figures other than zero, the figure in the last place retained should
be increased by 1; whether odd or even.
c S = Sand Cast P = Permanent Mold Cast
d If iron exceeds 0.45 percent, manganese content shall not be less than one-half the iron content.
e Also contains 0.04–0.07 percent beryllium.
f Also contains 0.003–0.007 percent beryllium, boron 0.005 percent maximum.
g Also contains 5.5–7.0 percent tin.
h Also contains 0.40–1.0 percent silver.
i Also contains 0.05 max. percent tin.
k The sum of those “Others” metallic elements 0.010 percent or more each, expressed to the second decimal before determining the sum.
*Formerly AA-CS-M2-84 in previous editions 2-3

M3*
and Permanent Mold Castings MECHANICAL LIMITS
Page 1 of 2
MECHANICAL PROPERTY LIMITS FOR COMMONLY USED

ALUMINUM SAND CASTING ALLOYS 1
MINIMUM PROPERTIES Typical Brinell
Tensile Strength % Elongation Hardness 4
Alloy Temper 2
Ultimate Yield (0.2% Offset) in 2 inches or 4 500 – kgf load
ksi ( Mpa ) ksi ( Mpa ) times diameter 10 – mm ball
201.0 T7 60.0 ( 415 ) 50.0 ( 345 ) 3.0 110–140
204.0 T4 45.0 ( 310 ) 28.0 ( 195 ) 6.0 —
206.0 — — — — — — —
A206.0 — — — — — — —
208.0 F 19.0 ( 130 ) 12.0 ( 85 ) 1.5 40–70
222.0 0 23.0 ( 160 ) — — — 65–95
222.0 T61 30.0 ( 205 ) — — — 100–130
242.0 0 23.0 ( 160 ) — — — 55–85
242.0 T571 29.0 ( 200 ) — — — 70–100
242.0 T61 32.0 ( 220 ) 20.0 ( 140 ) — 90–120
242.0 T77 24.0 ( 165 ) 13.0 ( 90 ) 1.0 60–90
295.0 T4 29.0 ( 200 ) 13.0 ( 90 ) 6.0 45–75
295.0 T6 32.0 ( 220 ) 20.0 ( 140 ) 3.0 60–90
295.0 T62 36.0 ( 250 ) 28.0 ( 195 ) — 80–110
295.0 T7 29.0 ( 200 ) 16.0 ( 110 ) 3.0 55–85
319.0 F 23.0 ( 160 ) 13.0 ( 90 ) 1.5 55–85
319.0 T5 25.0 ( 170 ) — — — 65–95
319.0 T6 31.0 ( 215 ) 20.0 ( 140 ) 1.5 65–95
328.0 F 25.0 ( 170 ) 14.0 ( 95 ) 1.0 45–75
328.0 T6 34.0 ( 235 ) 21.0 ( 145 ) 1.0 65–95
355.0 T51 25.0 ( 170 ) 18.0 ( 125 ) — 50–80
355.0 T6 32.0 ( 220 ) 20.0 ( 140 ) 2.0 70–105
355.0 T7 35.0 ( 240 ) — — — 70–100
355.0 T71 30.0 ( 205 ) 22.0 ( 150 ) — 60–95
C355.0 T6 35.0 ( 250 ) 25.0 ( 170 ) 2.5 75–105
356.0 F 19.0 ( 130 ) — — 2.0 40–70
356.0 T51 23.0 ( 160 ) 16.0 ( 110 ) — 45–75
356.0 T6 30.0 ( 205 ) 20.0 ( 140 ) 3.0 55–90
356.0 T7 31.0 ( 215 ) 29.0 ( 200 ) — 60–90
356.0 T71 25.0 ( 170 ) 18.0 ( 125 ) 3.0 45–75
A356.0 T6 34.0 ( 235 ) 24.0 ( 165 ) 3.5 70–105
B356.0 — — — — — — —
357.0 — — — — — — —
A357.0 — — — — — — —
359.0 — — — — — — —
443.0 F 17.0 ( 115 ) 7.0 ( 50 ) 3.0 25–55
B433.0 F 17.0 ( 115 ) 6.0 ( 40 ) 3.0 25–55
512.0 F 17.0 ( 115 ) 10.0 ( 70 ) — 35–65
514.0 F 22.0 ( 150 ) 9.0 ( 60 ) 6.0 35–65
520.0 T4 5 42.0 ( 290 ) 22.0 ( 150 ) 12.0 60–90
535.0 F or T5 35.0 ( 240 ) 18.0 ( 125 ) 9.0 60–90
705.0 F or T5 30.0 ( 205 ) 17.0 ( 115 ) 5.0 50–80
707.0 T5 33.0 ( 230 ) 22.0 ( 150 ) 2.0 70–100
707.0 T7 37.0 ( 255 ) 30.0 ( 205 ) 1.0 65–95
710.0 F or T5 32.0 ( 220 ) 20.0 ( 140 ) 2.0 60–90
712.0 F or T5 34.0 ( 235 ) 25.0 ( 170 ) 4.0 60–90
713.0 F or T5 32.0 ( 220 ) 22.0 ( 150 ) 3.0 60–90
771.0 T5 42.0 ( 290 ) 38.0 ( 260 ) 1.5 85–115
771.0 T51 32.0 ( 220 ) 27.0 ( 165 ) 3.0 70–100
771.0 T52 36.0 ( 250 ) 30.0 ( 205 ) 1.5 70–100
771.0 T53 36.0 ( 250 ) 27.0 ( 185 ) 1.5 —
771.0 T6 42.0 ( 290 ) 35.0 ( 240 ) 5.0 75–105
771.0 T71 48.0 ( 330 ) 45.0 ( 310 ) 2.0 105–135
850.0 T5 16.0 ( 110 ) — — 5.0 30–60
851.0 T5 17.0 ( 115 ) — — 3.0 30–60
852.0 T5 24.0 ( 165 ) 18.0 ( 125 ) — 45–75
1 Values represent properties obtained from separately cast lest bars and are derived from ASTM 8-26, Standard Specification for Aluminum-
Alloy Sand Castings; Federal Specification QQ-A-601e, Aluminum Alloy Sand Castings; and Military Specification MIL-A-21180c, Aluminum
Alloy Castings, High Strength. Unless otherwise specified, the tensile strength, yield strength and elongation values of specimens cut from
castings shall be not less than 75 percent of the tensile and yield strength values and not less than 25 percent of the elongation values given
above. The customer should keep in mind that (1) some foundries may offer additional tempers for the above alloys, and (2) foundries are
constantly improving casting techniques and, as a result, some may offer minimum properties in excess of the above.
2 F indicates “as cast” condition; refer to AA-CS-M11 for recommended times and temperatures of heat treatment for other tempers to
achieve properties specified.
3 Footnote no longer in use.
4 Hardness values are given for information only; not required for acceptance.
5 The T4 temper of Alloy 520.0 is unstable; significant room temperature aging occurs within life expectancy of most castings. Elongation
may decrease by as much as 80 percent.

M3*
and Permanent Mold Castings MECHANICAL PROPERTY LIMITS
Page 2 of 2
MECHANICAL PROPERTY LIMITS FOR COMMONLY USED

ALUMINUM PERMANENT MOLD CASTING ALLOYS 1
MINIMUM PROPERTIES Typical Brinell

Tensile Strength % Elongation Hardness 3
Alloy Temper 2
Ultimate Yield (0.2% Offset) in 2 inches or 4 500 – kgf load
ksi ( Mpa ) ksi ( Mpa ) times diameter 10 – mm ball
204.0 T4 48.0 ( 330 ) 29.0 ( 200 ) 8.0 —
208.0 T4 33.0 ( 230 ) 15.0 ( 105 ) 4.5 60–90
208.0 T6 35.0 ( 240 ) 22.0 ( 150 ) 2.0 75–105
208.0 T7 33.0 ( 230 ) 16.0 ( 110 ) 3.0 65–95
222.0 T551 30.0 ( 205 ) — — — 100–130
222.0 T65 40.0 ( 275 ) — — — 125–155
242.0 T571 34.0 ( 230 ) — — — 90–120
242.0 T61 40.0 ( 275 ) — — — 95–125
298.0 T6 35.0 ( 240 ) — — 2.0 75–105
308.0 F 24.0 ( 165 ) — — 2.0 55–85
319.0 F 28.0 ( 195 ) 14.0 ( 95 ) 1.5 70–100
319.0 T6 34.0 ( 235 ) — — 2.0 75–105
332.0 T5 31.0 ( 215 ) — — — 90–120
333.0 F 28.0 ( 195 ) — — — 65–100
333.0 T5 30.0 ( 205 ) — — — 70–106
333.0 T6 35.0 ( 240 ) — — — 65–115
333.0 T7 31.0 ( 215 ) — — — 75–105
336.0 T551 31.0 ( 215 ) — — — 90–120
336.0 T65 40.0 ( 275 ) — — — 110–140
354.0 T61 48.0 ( 330 ) 37.0 ( 255 ) 3.0 —
354.0 T62 52.0 ( 360 ) 42.0 ( 290 ) 2.0 —
355.0 T51 27.0 ( 185 ) — — — 60–90
355.0 T6 37.0 ( 255 ) — — 1.5 75–105
355.0 T62 42.0 ( 290 ) — — — 90–120
355.0 T7 36.0 ( 250 ) — — — 70–100
355.0 T71 34.0 ( 235 ) 27.0 ( 185 ) — 85–95
C355.0 T61 40.0 ( 275 ) 30.0 ( 205 ) 3.0 75–105
356.0 F 21.0 ( 145 ) — — 3.0 40–70
356.0 T51 25.0 ( 170 ) — — — 55–85
356.0 T6 33.0 ( 230 ) 22.0 ( 150 ) 3.0 65–95
356.0 T7 25.0 ( 170 ) — — 3.0 60–90
356.0 T71 25.0 ( 170 ) — — 3.0 60–90
A356.0 T61 37.0 ( 255 ) 26.0 ( 180 ) 5.0 70–100
B356.0 T6 37.0 ( 255 ) 27.0 ( 185 ) 7.0 —
357.0 T6 45.0 ( 310 ) — — 3.0 75–105
A357.0 T61 45.0 ( 310 ) 36.0 ( 250 ) 3.0 85–115
359.0 T61 45.0 ( 310 ) 34.0 ( 235 ) 4.0 75–105
359.0 T62 47.0 ( 325 ) 38.0 ( 260 ) 3.0 85–115
443.0 F 21.0 ( 145 ) 7.0 ( 50 ) 2.0 30–60
B443.0 F 21.0 ( 145 ) 6.0 ( 40 ) 2.5 30–60
A444.0 T4 20.0 ( 140 ) — — 20.0 —
513.0 F 22.0 ( 150 ) 12.0 ( 85 ) 2.5 45–75
535.0 F 35.0 ( 240 ) 18.0 ( 125 ) 8.0 60–90
705.0 T5 37.0 ( 255 ) 17.0 ( 120 ) 10.0 55–85
707.0 T7 45.0 ( 310 ) 35.0 ( 240 ) 3.0 80–110
711.0 T1 28.0 ( 195 ) 18.0 ( 125 ) 7.0 55–86
713.0 T5 32.0 ( 220 ) 22.0 ( 150 ) 4.0 60–90
850.0 T5 18.0 ( 125 ) — — 8.0 30–60
851.0 T5 17.0 ( 115 ) — — 3.0 30–60
851.0 T6 16.0 ( 125 ) — — 8.0 —
852.0 T5 27.0 ( 185 ) — — 3.0 55–85
1 Values represent properties obtained from separately cast test bars and are derived from ASTM B-108, Standard Specification for Aluminum-Alloy
Permanent Mold Castings; Federal Specification QQ-A-596d, Aluminum Alloy Permanent and Semi-Permanent Mold Castings; and Military Specification
MIL-A-21180c, Aluminum Alloy Castings, High Strength. Unless otherwise specified, the average tensile strength, average yield strength and average
elongation values of specimens cut from castings shall be not less than 75 percent of the tensile strength and yield values and not less than 25 percent
of the elongation values given above. The customer should keep in mind that (1) some foundries may offer additional tempers for the above alloys, and
(2) foundries are constantly improving casting techniques and, as a result, some may offer minimum properties in excess of the above.
2 F indicates “as cast” condition; refer to AA-CS-M11 for recommended times and temperatures of heat treatment for other tempers to
achieve properties specified.
3 Hardness values are given for information only; not required for acceptance.

M4*
and Permanent Mold Castings CHARACTERISTICS OF ALUMINUM ALLOYS
Page 1 of 2
Selection of an alloy for a particular application requires consideration not only of mechanical properties, but
also of numerous other characteristics, such as behavior in the casting process or subsequent treatments
in the course of manufacture, and response to the environmental conditions of service.
The following table includes several significant characteristics which deserve consideration in the selection
of an alloy. The characteristics are comparatively rated from 1 to 5 in decreasing order of performance.
Strength
Resis- at
tance Normally Elevated Corrosion Anodizing
to Hot Pressure Heat Tempera- Resis- Machin- Appear- Weld-
Alloy Product Fluidity Cracking Tightness Treated tures tance ability Polishing ance ability
201.0 S 3 4 3 Yes 1 4 1 1 2 4
204.0 S&P 3 4 3 Yes 1 4 1 2 3 4
206.0 S 3 4 3 Yes 1 4 1 1 2 4
A206.0 S 3 4 3 Yes 1 4 1 1 2 4
208.0 S 2 2 2 Optional 3 4 3 3 3 2
222.0 S&P 3 3 3 Yes 1 4 1 2 3 3
242.0 S&P 3 4 4 Yes 1 4 2 2 3 4
295.0 S 3 4 4 Yes 3 4 2 2 2 3
296.0 P 3 4 3 Yes 2 4 3 2 3 3
308.0 P 2 2 2 No 3 3 3 3 4 2
319.0 S&P 2 2 2 Optional 3 3 3 4 4 2
328.0 S 1 1 2 Optional 2 3 3 3 4 1
332.0 P 1 2 2 Yes 1 3 4 4 4 2
333.0 P 1 2 2 Optional 2 3 3 3 4 3
336.0 P 1 2 2 Yes 1 3 4 4 4 3
354.0 P 1 1 1 Yes 2 3 4 4 4 3
355.0 S&P 1 1 1 Yes 2 3 3 3 4 1
C355.0 S&P 1 1 1 Yes 2 3 3 3 4 1
356.0 S&P 1 1 1 Yes 3 2 3 4 4 1
A356.0 S&P 1 1 1 Yes 3 2 3 4 4 1
B356.0 S&P 1 1 1 Yes 3 2 3 4 4 1
357.0 S&P 1 1 1 Yes 3 2 3 4 4 1
A357.0 S&P 1 1 1 Yes 2 2 3 4 4 1
359.0 S&P 1 2 2 Yes 2 2 4 4 4 1
443.0 S&P 1 1 1 No 4 3 5 4 4 1
B443.0 S&P 1 1 1 No 4 2 5 4 4 1
A444.0 P 1 1 1 Optional 4 2 5 4 4 1
512.0 S 3 3 4 No 3 1 2 2 2 3
513.0 P 4 4 4 No 3 1 1 1 1 3
514.0 S 4 4 5 No 3 1 1 1 1 3
520.0 S 4 4 5 Yes 5 1 1 1 1 4
535.0 S 5 4 5 Optional 3 1 1 1 1 4
705.0 S&P 4 4 4 No 4 2 1 2 2 4
707.0 S&P 4 4 4 No 4 2 1 2 2 4
710.0 S 4 5 4 No 4 4 1 2 2 4
711.0 P 4 5 4 Yes 5 2 1 1 1 4
712.0 S 3 5 4 No 4 3 1 2 2 4
713.0 S&P 3 4 4 No 4 3 1 1 1 4
771.0 S 3 4 4 Yes 4 3 1 1 1 4
850.0 S&P 4 5 5 Yes 5 4 1 3 * 5
851.0 S&P 4 5 5 Yes 5 4 1 3 * 5
852.0 S&P 4 5 5 Yes 5 4 1 3 * 5
*Information not available.

M4*
and Permanent Mold Castings CHARACTERISTICS OF ALUMINUM ALLOYS
Page 2 of 2
Fluidity is the ability of a liquid metal to flow (into a mould). It is equivalent to “mold filling” capacity.
Resistance to Hot Cracking is the property of an alloy to withstand stresses from contraction while cooling
through the final (“hot short”) stage of solidification.
Pressure Tightness is the absence of leakage at a specified pressure.
Response to Heat Treatment is a characteristic dependent upon composition. Some of the alloys listed as
“not normally heat treated” may show some improvement of properties when heat treated. Moreover, alloys
listed as normally heat treated are frequently used without heat treatment if their as-cast properties are
adequate for a specific application.
Corrosion Resistance is the resistance of alloys to loss of volume strength and surface appearance
upon exposure to various environments. The comparative ratings given here are based in general upon
performance in various industrial or sea coast atmospheres. Exposures to specific corroding agents should
be investigated in further detail.
Strength at Elevated Temperatures is a rating based upon tests made at temperatures up to 500ºF after
prolonged exposure at such temperatures.
Machinability is based upon ease of cutting, chip characteristics, quality of finish and tool life. For the
heat treated alloys, the ratings are based upon the T6 temper. Naturally aging alloys are rated after room
temperature aging to their stable condition.
Polishing characteristic is a composite rating based on the ease and speed of polishing, and finish quality,
after various standard polishing techniques.
Anodizing Appearance is based upon visual examination after a standard anodizing treatment.
Weldability rating is based upon the ease of joining parts by gas and arc welding, and the quality of the final
welded joint. Brazing, a related process, is applicable to some of the 7XX.X series alloys which have the
unique property of withstanding the brazing temperature, and regaining their original strength after room
temperature aging.

M5*
and Permanent Mold Castings ALUMINUM CASTING QUALITY STANDARD
Page 1 of 3
The purpose of this standard is to establish quality standards for aluminum castings, so that purchasers may
specify and expect a product consistent with their needs. TO BE IN EFFECT, THIS STANDARD, AA-CS-M5-
92, INCLUDING THE QUALITY AND FREQUENCY LEVELS, MUST BE CALLED OUT ON THE DRAWING.
When using this standard, two factors should be determined by the person responsible for designating the
proper level. These are:
1. QUALITY LEVEL: The inherent quality of the casting having the capability of doing the job for which the
part was designed.
2. FREQUENCY LEVEL: The amount of inspection necessary to determine compliance, or that number of
parts to be inspected that will satisfy the requirement of quality level.
Both of these factors may affect cost and should not be higher than necessary for the application of the
part.
Workmanship, tolerances, drafts and other features of castings produced to this standard will be within the
limits set forth in the Engineering Series. Special requirements such as sealing surfaces, high stress areas,
anodic or chemical finishes and pressure testing, shall be designated on print. Welding, peening, plugging
and impregnation are acceptable methods of processing unless specifically prohibited. The foundry will use
those controls necessary to produce the casting to the quality level indicated.
Example Drawing Callout (blanks to be filled in to levels described in Tables I and II)
All castings produced to this standard will be visually inspected. No cracks will be permitted. Cold shuts,
laps and surface discontinuities of linear nature will be investigated. In most applications, no greater degree
of inspection is necessary, but when the function of the casting indicates that it will require some additional
degree of examination, frequency levels calling for radiographic and penetrant inspection may be used.
Certification of chemical composition and mechanical properties, if required, to be agreed on between the
supplier and purchaser.

M5*
Page 2 of 3
Quality levels as indicated in Table I and referenced in ASTM E 155 show the type of discontinuity and maximum size
or degree allowed in each case.
An illustration of a typical reference radiograph as contained in ASTM E 155 is shown in Standard AA-CS-M6.
TABLE I—MAXIMUM PERMISSIBLE RADIOGRAPHIC SEVERITY LEVELS FOR DISCONTINUITIES

IN ALUMINUM CASTINGS3,4
Grade A Grade B Grade C Grade D
Inch Inch Inch Inch
Discontinuity ¼ ¾ ¼ ¾ ¼ ¾ ¼ ¾
Gas holes None 1 1 2 2 5 5
Gas porosity (round) None 1 1 3 3 7 7
Gas porosity (elongated) None 1 2 3 4 5 5
Shrinkage cavity None 1 NA 2
2 NA 2
3 NA2
Shrinkage (sponge) None 1 1 2 2 4 3
Foreign material (less dense material) None 1 1 2 2 4 4
Foreign material (more dense material) None 1 1 2 1 4 3
Cracks 1
None None None None
Cold shuts1 None None None None
Surface irregularity1 Not to exceed drawing tolerance
Core shift1 Not to exceed drawing tolerance
1
No reference radiographic plates available.
2
Not available, use the ¼ inch reference radiographic plate thickness with a severity level 2 units greater than the one shown for the
¼ inch column.
3
ASTM E 155 Volume I reference radiographic plates.
4
For feature thicknesses greater than two inches, the ¾ inch reference radiographic plates may be used.
TABLE II—FREQUENCY LEVELS

Frequency Level** Radiographic Penetrant
1 100% 100%
2 See Table III See Table III
3 Foundry Control
4 Visual Inspection Only
**Differing frequency levels for radiographic and penetrant inspection may be negotiated.
TABLE III—SAMPLING PLAN

Acceptable Rejection
Lot Size† Sample Size
Number Number
2–50 2 0 1
51–500 8 1 2
501–Over 13 2 3
†Unless otherwise specified, a lot shall consist of all castings of a specific design of one alloy
produced at one facility by the same production technique and submitted for inspection at one time.

M5*
Page 3 of 3
EXAMPLE: A drawing callout is for a Quality Level of “C” and a Frequency Level of “2”. The lot size to be
inspected is 300 castings. In Table II, Frequency Level 2 refers you to Table III. Table III indicates that a lot of
51–500 castings requires a sample lot of eight castings. If interpretation of the radiographs shows that not
more than one of the eight castings failed to meet the Quality Levels set forth in Table I, the lot would pass
without further X-ray inspection. If two or more of the castings failed to meet these standards, the foundry
would either scrap the lot or X-ray and evaluate each of the castings.
NOTE: Where requirements dictate, higher quality levels may be specified when mutually agreed upon
between supplier and purchaser.

M6*
and Permanent Mold Castings RADIOGRAPHY
Page 1 of 2
Radiography is a non-destructive technique which may be used to reveal discontinuities inside casting
walls. This method of inspection provides a permanent record for cross reference to established standards,
and promotes confidence as to the integrity of aluminum castings. Radiography serves best when customer
and supplier agree on procedures and references.
Radiography is used:
1) For foundry control (to develop gating systems)
2) For systematic inspection during production as specified by the customer or the foundry quality control
procedure.
3) For inspection of welding, plugging, detection of fins, steel shot, pockets of core sand, etc.
To produce radiographs, the desired technique is to penetrate the casting thickness with the lowest voltage
in a reasonable exposure time, and provide an image of maximum detail and resolution. Films used vary in
speed, contrast and graininess. Better quality images are produced with high-contrast, fine-grained films.
The interpretations of discontinuities as exhibited by radiographic films can be based on ASTM E 155
reference radiographs for inspection of aluminum castings. Common indications encountered are gas holes,
gas porosity (round or elongated), shrinkage (cavity or sponge or porosity), and foreign material (less dense
or more dense). Each indication is rated in a series of 8 levels, which are then used for inspection criteria.

M6*
and Permanent Mold Castings RADIOGRAPHY
Page 2 of 2
DEFINITION OF COMMON RADIOGRAPHIC TERMS
Back Scatter The deflection of particles or of radiation by scattering processes through

angles greater than 90 degrees with respect to the original direction of motion.
Cassett A lightproof container used for holding the radiographic films in position during
the radiographic exposure.
Contrast The difference in film blackening from one area to another.
Definition The sharpness of outline of the image.
Densitometer An instrument for measuring density of exposed film to standardize techniques.
Density The degree of blackening of a film.
Discontinuity An undesirable variation of structure of composition hidden within the interior
of the part being inspected.
Dosimeter A precision instrument for cumulatively measuring the amount of X-ray and
gamma radiation received by the wearer.
Film Size Usually vary from 14″ × 17″ to 5″ × 7″—also special strip cuts.
Focal Film Distance The distance in inches between the focal spot of the X-ray tube or the radiation
source and the film.
Focal Spot Area of anode where electrons impinge on the target (usually rectangular in
shape). The apparent focal spot is usually square when viewed in the central
beam because of the angle of the anode.
Focal Spot Size in mm 1–10 mm in the voltage range of 100–200KV.
Grain Image on X-ray film formed by countless minute silver grains. The “clumping”
together of these small particles produces the visual impression which is
called graininess.
Intensifying Screen A layer of material placed in contact with the film to increase the effect of the
radiation, thus shortening the exposure time.
Kilovolt (kv) Unit of electromotive force or potential equal to 1000 volts (commonly used
to rate radiographic equipment).
Lead Room Radiation-producing equipment is located in a lead-lined or concrete enclosure
to provide protection against radiation.
Milliampere Unit of electric current equal to one thousandth of an ampere.
Mottling A special form of scattering on radiographic film due to X-ray diffraction of
incident X-rays by the subject material.
Penetrameter A strip of metal of essentially the same composition as that of the metal being
tested, representing a percentage of object thickness and provided with a
combination of steps, holes or slots. When placed in the path of rays, its image
provides a check on the sensitivity of the radiographic technique employed.
Radiography Recording of an X-ray image pattern on a film.
Screen Filter A layer of absorptive material which is placed in the beam of radiation for the
purpose of absorbing rays of certain wave lengths and thus controlling the
quality of the radiographs.
Sensitivity The percent ratio of the thickness of the smallest detectable defect to the
thickness of the specimen.
Viewer An illuminator used for the examination of finished radiographs.

M7*
and Permanent Mold Castings PENETRANT AND OTHER NON-DESTRUCTIVE
INSPECTION TECHNIQUES
There are several non-destructive testing techniques adaptable to use with aluminum alloy castings.
Perhaps the most widely used, other than radiography, is the fluorescent penetrant method. Although no
interpretive standards have been established, this method of inspection is relatively reliable for finding
surface discontinuities, and, when properly applied, permits some evaluation of both the source and severity
of such discontinuities. With the additional application of radiography, it is possible to further determine the
depth and extent of a discontinuity. Fluorescent penetrant techniques can vary. To avoid misunderstandings
in interpretation, it is imperative that (1) methods and interpretation be agreed upon between supplier
and purchaser, (2) carefully controlled materials and procedures are used, (3) definitive interpretation be
applied, and (4) limitations of the method be recognized. Generally, penetrant inspection is performed per
the applicable ASTM standards.
For your general information, basic procedure includes the following:
1. Clean the casting.
2. Apply fluorescent penetrant and allow time for penetration.
3. Remove penetrant from the surface of the casting.
4. Apply developer to absorb penetrant bleeding out of surface discontinuities, allowing time for development.
5. Inspect the casting using ultra-violet light.
Extended delays in inspection after development time will give enlarged and false surface readings. Tooling
of the surface, within limits of drawing tolerance, to remove indications of discontinuities is permissible.
Dye penetrant inspection follows the same basic technique except for the use of a colored penetrant permitting
examination in normal light.
Non-linear discontinuities should be evaluated by radiographic techniques to determine the extent and
acceptability of the discontinuity.
Some efforts have been made to apply ultrasonic techniques to inspection of castings. Other specialized
tests such as electrical conductivity, magnetic flux hysteresis and the like are sometimes specified to fulfill
specific requirements.

IMPREGNATION OF CASTINGS
Impregnation is an accepted method of sealing aluminum alloy castings. It can be used to avoid the loss of
serviceable castings, to achieve pressure tightness, or to promote high quality paint coatings.
Equipment needed for impregnation may vary with the type of impregnant used and the size and volume of
castings being treated. Impregnation is usually accomplished through the vacuum-pressure method which
provides effective filling of channels by pressure after they are evacuated of air or testing liquids. Typical
equipment used for impregnation includes an autoclave tank, cleaning and rinsing tanks, a vacuum pump
and in most cases a curing oven or heated oil or water tank.
There are numerous impregnating materials in use and precise information regarding the relative merits of
each can be obtained from the suppliers of these materials. It is generally agreed that an ideal impregnating
material should possess the following characteristics.
1. Thermosetting (infusible on reheating)
2. Capable of plasticizing to avoid formation of brittle solids
3. Good penetrating properties
4. Low viscosity before setting
5. Minimum contraction on setting
6. Insoluble in water, coolants, solvents, gasoline and oil after setting
7. Chemically inert to aluminum alloys
Commonly used impregnants include synthetic resins such as polyester styrene, acrylics, methacrylics, and
epoxy. Other satisfactory impregnating materials are also available.
Anodizing, painting, or other coating procedures may be affected by impregnation. Films of impregnant
remaining on the surface of castings will interfere with the formation of uniform, continuous coatings. If proper
cleaning is performed, interference by the impregnant should not occur. In some instances, impregnation is
used to fill small surface voids in castings prior to painting to achieve high quality paint coatings.
The curing at elevated temperatures of impregnated castings may change dimensions and mechanical properties.
Therefore, it is important that the user and impregnator agree on the sealants and procedures.
For best sealing results, impregnation should be performed after final machining and the casting retested to
check for pressure tightness. In many cases the casting supplier is responsible for an initial impregnation but if
machining exposes further porosity, the casting buyer assumes responsibility for any additional impregnations.
If impregnation is done after user machines, user is responsible for any leaks.

WELDING OF ALUMINUM CASTINGS
In many instances it is necessary to weld aluminum sand or permanent mold castings, and, when the welding is
carried out under controlled conditions, castings and assemblies of high integrity can be expected. Examples
of most frequent use of welding are: the fabrication of welded assemblies, the closing of openings which are
not pertinent to the design of the casting except to provide core prints and access for core removal, and the
repair of certain defects in casting.
Welding is usually accomplished using an inert gas shielded are either with tungsten electrode (TIG) or by
using the welding rod as the electrode (MIG). The most commonly used gases are argon and helium. The
oxy-acetylene torch method may also be used. However, it is difficult to consistently achieve high quality
welds with this method.
Carefully controlled conditions are a requisite for good quality in welding. Surfaces to be welded must be
clean and dry. To repair a defective area and make a sound weld, the defect must be completely removed.
If the area to be welded is large, it may be necessary to preheat the casting before welding. Temperatures
and time used to preheat castings must be carefully controlled. Castings are usually welded before
heat treatment; when castings are to be welded after heat treatment, care should be taken to keep the
temperature of the casting as low as possible to minimize any changes in mechanical properties. Welding
rod alloy must be compatible with the alloy or alloys of the parts being joined or prepared. If the casting is to
be anodized, and uniform appearance is an important consideration, welding should be avoided because,
even though the same alloy rod is used, the structure of the metal in the welded area is different enough so
that the welded area will be discolored.
Improper welding techniques can result in poor bond, excessive oxide, gas holes, tungsten inclusions,
or cracks. Foundries will usually dress welded areas to conform to the casting contour and dimensional
requirements. All welded areas should be visually inspected after the welds are dressed. Foundries normally
control operating procedures by periodic radiographic inspection for excessive oxide, gas holes, and
tungsten inclusions and by periodic penetrant inspection of welds to sampling plans or even to 100%
coverage. Radiographic and penetrant standards should be the same for welds and welded areas as for
the rest of the casting or assembly.
Good quality welds within a casting will normally provide mechanical properties comparable to those of the
parent metal. Users of castings should confidently accept welding as a technique for fabrication, closing of
openings and repair of castings. Reference may be made to Standard AA-CS-M4 for the relative weldability
characteristics of casting alloys.

TYPICAL PHYSICAL PROPERTIES
TYPICAL PHYSICAL PROPERTIES OF COMMONLY USED SAND

AND PERMANENT MOLD CASTING ALLOYS
These typical properties are not guaranteed, and should not be used for design purposes but only as a basis for general
comparison of alloys and tempers with respect to any given characteristic.
Coeff. of Thermal
Density a Approximate Electrical Thermal Expansion, per ºF × 10–6
Specific lb. per Melting Conductivity Conductivity
Alloy Temper Gravity a cu. in. Range ºF % IACS at 25 ºC, CGS b 68–212 ºF 68–572 ºF
201.0 T6 2.80 0.101 1060–1200 27–32 0.29 19.3 24.7
T7 2.80 0.101 1060–1200 32–34 0.29 — —
204.0 T4 — — 985–1200 — — — —
208.0 F 2.79 0.101 970–1160 31 0.30 12.4 13.4
222.0 T61 2.95 0.107 965–1155 33 0.31 12.3 13.1
242.0 T571 c 2.81 0.102 990–1175 34 0.32 12.6 13.6
T77 2.81 0.102 990–1175 38 0.36 12.6 13.6
295.0 T6 2.81 0.102 970–1190 35 0.33 12.7 13.8
296.0 T6 c 2.80 0.101 970–1170 33 0.31 12.2 13.3
308.0 F 2.79 0.101 970–1135 37 0.35 11.9 12.9
319.0 F 2.79 0.101 960–1120 27 0.26 11.9 12.7
328.0 F 2.70 0.098 1025–1105 30 0.29 11.9 12.9
332.0 T5 c 2.76 0.100 970–1080 26 0.25 11.5 12.4
333.0 F c 2.77 0.100 960–1085 26 0.25 11.4 12.4
T5 c 2.77 0.100 960–1085 29 0.28 11.4 12.4
T6 c 2.77 0.100 960–1085 29 0.28 11.4 12.4
T7 c 2.77 0.100 960–1085 35 0.33 11.4 12.4
336.0 T551 c 2.72 0.098 1000–1050 29 0.28 11.0 12.0
354.0 T61 2.71 0.098 1000–1105 32 0.30 11.6 12.7
355.0 T51 2.71 0.098 1015–1150 43 0.40 12.4 13.7
T6 2.71 0.098 1015–1150 36 0.34 12.4 13.7
T6 c 2.71 0.098 1015–1150 39 0.36 12.4 13.7
T61 2.71 0.098 1015–1150 37 0.35 12.4 13.7
T62 c 2.71 0.098 1015–1150 38 0.35 12.4 13.7
T7 2.71 0.098 1015–1150 42 0.39 12.4 13.7
T71 2.71 0.098 1015–1150 39 0.36 12.4 13.7
C355.0 T61 2.71 0.098 1015–1150 39 0.36 12.4 13.7
356.0 T51 2.68 0.097 1035–1135 43 0.40 11.9 12.9
T6 2.68 0.097 1035–1135 39 0.36 11.9 12.9
T6 c 2.68 0.097 1035–1135 41 0.38 11.9 12.9
T7 2.68 0.097 1035–1135 40 0.37 11.9 12.9
T7 c 2.68 0.097 1035–1135 43 0.40 11.9 12.9
A356.0 T61 2.67 0.097 1035–1135 39 0.36 11.9 12.9
357.0 F 2.67 0.097 1035–1135 39 0.36 11.9 12.9
A357.0 T61 2.67 0.097 1035–1135 39 0.36 11.9 12.9
359.0 T6 2.67 0.097 1045–1115 35 0.33 11.6 12.7
443.0 F 2.69 0.097 1065–1170 37 0.35 12.3 13.4
B443.0 F 2.69 0.097 1065–1170 37 0.35 12.3 13.4
A444.0 F 2.68 0.097 1070–1170 41 0.38 12.1 13.2
512.0 F 2.65 0.096 1090–1170 38 0.35 12.7 13.8
513.0 F c 2.68 0.097 1075–1180 34 0.32 13.4 14.5
514.0 F 2.65 0.096 1110–1185 35 0.33 13.4 14.5
520.0 T4 2.57 0.093 840–1120 21 0.21 13.7 14.8
535.0 F 2.62 0.095 1020–1165 23 0.23 13.1 14.8
705.0 F 2.76 0.100 1105–1180 25 0.25 13.1 14.3
707.0 F 2.77 0.100 1085–1165 25 0.25 13.2 14.4
710.0 F 2.81 0.102 1105–1195 35 0.33 13.4 14.6
711.0 F c 2.84 0.103 1120–1190 40 0.37 13.1 14.2
712.0 F 2.81 0.101 1135–1200 35 0.33 13.7 14.8 d
713.0 F 2.81 0.100 1100–1180 30 0.29 13.4 d 14.6 d
771.0 F 2.81 0.102 1120–1190 37 0.33 13.7 14.8 d
850.0 T5 c 2.88 0.104 435–1200 47 0.43 13.0 e
851.0 T5 c 2.83 0.103 440–1165 43 0.40 12.6 e
852.0 T5 c 2.88 0.104 400–1175 45 0.41 12.9 e
a Assuming solid (void-free) metal. Since some porosity cannot be avoided in commercial castings, the actual values will be
slightly less than those given.
b Cgs units equals calories per second per square centimeter per centimeter of thickness per degree centigrade.
c Chill cast samples; all other samples cast in green sand mold.
d Estimated value.
e Exceeds operating temperature.
Reference: Aluminum, Volume I. Properties, Physical Metallurgy and Phase Diagrams, American Society for Metals, Metals
Park, Ohio (1967). Data for alloy 771.0 supplied by the U.S. Reduction Company, East Chicago, Indiana.

M11*
and Permanent Mold Castings RECOMMENDED HEAT TREATMENTS
Page 1 of 3
RECOMMENDED TIMES AND TEMPERATURES FOR HEAT TREATING COMMONLY USED

ALUMINUM SAND AND PERMANENT MOLD CASTINGS
The heat treat times and temperatures given in this standard are those in general use in the indus-
try. The times and temperatures shown for solution heat treatment are critical. Quenching must be
accomplished by complete immersion of the castings with a minimum delay after the castings are removed
from the furnace.
Under certain conditions complex castings which might crack or distort in the water quench can be
oil or air blast quenched. When this is done the purchaser and the foundry must agree to the pro-
cedure and also agree on the level of mechanical properties which will be acceptable. Aging treat-
ments can be varied slightly to attain the optimum treatment for a specific casting or to give agreed
upon slightly different levels of mechanical properties.
Temper designations for castings are as follows:
F As fabricated. Applies to the products of shaping processes in which no special control over
thermal conditions or strain hardening is employed. (For cast products, this is the as cast
condition in which castings have been cooled from the mold with no special control over thermal
conditions and given no further heat treatments.)
O Annealed. Applies to cast products that are annealed to improve ductility and dimensional
stability.
T4 Solution heat-treated* and naturally aged to a substantially stable condition. Applies to

products that are not cold worked after solution heat-treatment, or in which the effect of cold
work in flattening or straightening may not be recognized in mechanical property limits.
T5 Cooled from an elevated temperature shaping process and then artificially aged. Applies to
products that are not cold worked after cooling from an elevated temperature shaping process or
in which the effect of cold work in flattening or straightening may not be recognized in mechanical
property limits. (Applies to castings which have been naturally cooled from the mold and then
artificially aged.)
T6 Solution heat-treated* and then artificially aged. Applies to products that are not cold worked
after solution heat-treatment, or in which the effect of cold work in flattening or straightening may
not be recognized in mechanical property limits.
T7 Solution heat-treated* and overage/stabilized. Applies to cast products that are artificially
aged after solution heat-treatment to provide dimension and strength stability.
*Solution heat treatment is achieved by heating cast products to a suitable temperature, holding at the
temperature long enough to allow constituents to enter into solid solution and cooling rapidly enough to
hold the constituents in solution.
The T5, T6, and T7 designations are sometimes followed by one or more numbers which indicate changes
from the originally developed treatment.

M11*
and Permanent Mold Castings RECOMMENDED* HEAT TREATMENTS
Page 2 of 3
Solution Heat Treatment b Aging Treatment

Alloy Temper Product a
Metal Temperatures Time Metal Temperatures Time
± 10F c Hours ± 10F c Hours
201.0 T6 S 950–960 2 Room Temperature 14–24
then 980–990 14–20 then 310 20
201.0 T7 S 950–960 2 Room Temperature 12–14
then 980–990 14–20 then 370 5
204.0 T4 S or P 970 10 Room Temperature 5 days
208.0 T4 P 940 4–12 — —
208.0 T6 P 940 4–12 310 2–5
208.0 T7 P 940 4–12 500 4–6
222.0 O i S — — 600 3
222.0 T61 S 950 12 310 11
222.0 T551 P — — 340 16–22
222.0 T65 P 950 4–12 340 7–9
242.0 O k S — — 650 3
242.0 T571 S — — 400 8
242.0 T77 S 960 5 d 625–675 2 minimum
242.0 T571 S or P — — 400 7–9
242.0 T61 S or P 960 4–12 d 400–450 3–5
295.0 T4 S 960 12 — —
295.0 T6 S 960 12 310 3–6
295.0 T62 S 960 12 310 12–24
295.0 T7 S 960 12 500 4–6
296.0 T6 P 950 8 310 1–8
319.0 T5 S — — 400 8
319.0 T6 S 940 12 310 2–5
319.0 T6 P 940 4–12 310 2–5
328.0 T6 S 960 12 310 2–5
332.0 T5 P — — 400 7–9
333.0 T5 P — — 400 7–9
333.0 T6 P 940 6–12 310 2–5
333.0 T7 P 940 6–12 500 4–6
336.0 T551 P — — 400 7–9
336.0 T65 P 960 8 400 7–9
355.0 T51 S or P — — 440 7–9

355.0 T6 S 980 12 310 3–5
355.0 T7 S 980 12 440 3–5
355.0 T71 S 980 12 475 4–6
355.0 T6 P 980 4–12 310 2–5
355.0 T62 P 980 4–12 340 14–18
355.0 T7 P 980 4–12 440 3–9
355.0 T71 P 980 4–12 475 3–6
C355.0 T6 S 980 12 310 3–5
C355.0 T61 P 980 6–12 Room Temperature 8 minimum
then 310 10–12
356.0 T51 S or P — — 440 7–9
356.0 T6 S 1000 12 310 3–5
356.0 T7 S 1000 12 400 3–5
356.0 T71 S 1000 10–12 475 3
356.0 T6 P 1000 4–12 310 2–5
356.0 T7 P 1000 4–12 440 7–9
356.0 T71 P 1000 4–12 475 3–6
A356.0 T6 S 1000 12 310 3–5
A356.0 T61 P 1000 6–12 Room Temperature 8 minimum
then 310 6–12
357.0 T6 P 1000 8 330 6–12
A444.0 T4 P 1000 8–12 — —

520.0 T4 S 810 18 g — —
535.0 T5 k S — — 750 5
*These are temperatures and times that are often used; however, specific practices must be developed, and may vary for
specific configurations and applications.

M11*
and Permanent Mold Castings RECOMMENDED HEAT TREATMENTS
Page 3 of 3
Solution Heat Treatment b Aging Treatment

Alloy Temper Product a
Metal Temperatures Time Metal Temperatures Time
± 10F c Hours ±10F c Hours
705.0 T5 S — — Room Temperature 21 days
or
210 8
705.0 T5 P — — Room Temperature 21 days
or
210 10
707.0 T7 S 990 8–16 350 4–10
707.0 T7 P 990 4–8 350 4–10

711.0 T1 P — — Room Temperature 21 days
or
315 6–8
713.0 T5 S or P — — Room Temperature 21 days
or
250 16
771.0 T5 S — — 355 3–5 h
771.0 T51 S — — 405 6
771.0 T52 i S — — 330 6–12 h
771.0 T53 i S — — 360 4 h
771.0 T6 S 1090 6 h 265 3
771.0 T71 S 1090 6 i 285 15
850.0 T5 S or P — — 430 7–9
851.0 T5 S or P — — 430 7–9
851.0 T6 P 900 6 430 4
852.0 T5 S or P — — 430 7–9
a S = Sand cast P = Permanent mold cast.

b Unless otherwise noted, quench in water at 150–212F.
c Temperature range unless otherwise noted.
d Use air blast quench.
Footnote no longer in use.

Footnote no longer in use.
g Quench in water at 150–212 for 10–20 seconds only.

h Cool in still air outside furnace to room temperature.
i Stress relieve for dimensional stability in following manner: (1) Hold at 775±25ºF for 5 hrs. Then (2) furnace cool to 650ºF for
2 or more hrs. Then (3) furnace cool to 450ºF for not more than ½ hr. Then (4) furnace cool to 250ºF for approximately 2 hr.
Then (5) cool to room temperature in still air outside the furnace.
k No quench required. Cool in still air outside furnace.

and Permanent Mold Castings APPENDIX 1
PLEASE READ THE FOLLOWING ELIGIBILITY REQUIREMENTS PRIOR TO APPLYING FOR REGISTRATION
1. The aluminum or aluminum alloy shall be offered for sale(1) currently and shall have been sold within the previous
12 months, in both cases in commercial quantities(2);
2. The complete chemical composition limits must be disclosed.
3. The composition must be different from that of any casting or ingot for which a designation has already been assigned.
4. The composition limits for the xxx.1 ingot must accompany the request for xxx.0 casting registration. Composition limits
for xxx.1 ingot are identical to those for the corresponding xxx.0 registration except for grain refiner elements and
specific provisions for minimum magnesium limit, maximum iron limit, and maximum zinc limit described in the
E*
registration record, Designations and Chemical Composition Limits in the Form of Castings and Ingot (Pink Sheets).
Ingot with chemical composition limits which differ from, but fall within the limits for a registered or proposed xxx.1
registration may be registered as xxx.2 ingot.
5. Except in the case of rotor and aluminizing alloy ingot, composition limits for ingot will not be accepted for registration
in the absence of limits for castings of the same designation.
6. The product (Sand, Permanent Mold, Die, or Investment Castings) must be shown at the time of registration.
For detailed information on the registration rules and procedures, refer to the registration record, “Designations and
Chemical Composition Limits in the Form of Castings and Ingot” (Pink Sheets).
____________________
FOOTNOTES
PL
(1) Sale of an alloy shall have been made to external users/customers (i.e. internal use and/or transfer of an alloy within a company does not meet the
stated criteria)
(2) Guidelines for compliance with “Commercial Quantity”:
• The alloy has undergone bona fide mill production and is NOT a “laboratory” scale volume used for evaluations or experimental purposes.
• The alloy is cast and fabricated in standard production facility and is NOT a one-time production.
• There is an expected and ongoing commercial demand and/or need for the alloy.
• The alloy must be purchased and sold in a standard business context, which indicates that the alloy is actually “sold” and not “given away” for uses
such as promotional evaluations
ALLOY REGISTRATION REQUEST

CASTINGS AND INGOT
M
Date:
Manager Alloy and Product Standards Registrations
The Aluminum Association, Inc.
1525 Wilson Blvd., Suite 600
Arlington, VA 22209
Re: Request for Registration of a New Casting Alloy
The following Chemical Composition limits are being submitted for registration as a new casting alloy.
SA
Element Casting Ingot(s)

Limits % max (unless shown as a range)
Silicon
Iron
Copper
Manganese
Magnesium
Chromium
Nickel
Zinc
Titanium
Tin
Others, Each
Others, Total
Aluminum Remainder Remainder
NOTE: This form is intended to assist applicants and reviewers of alloy registration requests. It is not intended to cover all
registration requirements and additional information may be requested to complete the registration.
* See: “www.aluminum.org/registrationtemplates” for the latest form. 2-21

and Permanent Mold Castings APPENDIX 2
PLEASE READ THE FOLLOWING ELIGIBILITY REQUIREMENTS PRIOR TO APPLYING FOR REGISTRATION
1. The alloy is registered with The Aluminum Association.
2. The Temper Designation conforms to American National Standard H35.1, “Alloy and Temper Designation System for
Aluminum.”
3. The material is offered for sale in the proposed temper and is available for use by more than one user.
4. The mechanical property limits applicable to the temper are included. (Limits are shown as tentative unless established
in accordance with the data base criteria outlined under “Mechanical Properties”, in Section 6, “Standards Section”
Aluminum Standards and Data). Testing is performed in accordance with the procedures outlined in Section 4, “Quality
Control”, Aluminum Standards and Data.
5. Additional information(1) is provided when characteristics in addition to mechanical properties are specified for the
temper.
6. Metric values, which are derived, based on the established Guidelines(2) are to be included for registration.
For detailed information on the registration rules and procedures, refer to the registration record, “Tempers for Aluminum
and Aluminum Alloy Products” and “Aluminum Standards and Data”.
E*
____________________
(1) Refer to registration record, Tempers for Aluminum and Aluminum Alloy Products (Yellow Sheets), “Tempers Registration”, “Procedure for Individual
Registration of Tempers”.
(2) Refer to registration record, Tempers for Aluminum and Aluminum Alloy Products – Metric Edition (Tan Sheets), APPENDIX A, “Guidelines for Metric
Conversion of Yellow Sheets”.
TEMPER REGISTRATION REQUEST

(For listing in the Yellow Sheets and Tan Sheets)
Date:
PL
Manager Alloy and Product Standards Registrations
The Aluminum Association, Inc.
1525 Wilson Blvd., Suite 600
Arlington, VA 22209
Re: Request for Temper Registration for
wishes to register . The tensile limits were determined in accordance with the requirements shown in
lines 1-6 in the above shaded area. Other mechanical property limits are shown as appropriate.
US CUSTOMARY UNITS
Tensile Strength, ksi Elongation
M
Thickness Percent in
Alloy Temper Product ln. Basis Ult. Yield 2 inches or 4 D Remarks
(Note 2)
(Note 1) (Note 3)
METRIC UNITS
Elongation
SA
Thickness, mm Tensile Strength, Mpa Percent in
50 5D or
Alloy Temper Product Over Thru Basis Ult. Yield mm 5.65 √ A Remarks
(Note 2)
(Note 1) (Note 3)
Note: This form is intended to assist applicants and reviewers of temper registration requests. It is not intended to include
all registration requirements and additional information may be requested to complete the registration.
2-22 * See: “www.aluminum.org/registrationtemplates” for the latest form.

Standards For Aluminium Sand and Permanent Die Casting

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Standards For Aluminium Sand and Permanent Die Casting

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Standards for Aluminum

Standards for Aluminum 18

Sand and Permanent Mold Castings

THE ALUMINUM ASSOCIATION CASTING STANDARDS PROGRAM

This issue supersedes all prior issues.

© Copyright 2008, The Aluminum Association, Inc.

CHAPTER 1, ENGINEERING SERIES (E) Page

E-1 LINEAR TOLERANCES—One Side of Parting Line 1-4

CHAPTER 2, METALLURGICAL SERIES (M)

Sand Casting* Permanent Mold

Additional Tolerance for Additional Tolerance for

1-4 *Formerly AA-CS-E1-92 in previous editions

(E2) ADDITIONAL TOLERANCE, in., mm

Projected Area Sand Casting Permanent

in.2 cm2 in.2 cm2 in. mm in. mm

Over 10 65 thru 50 320 ± .035 ± 0.90 ± .015 ± 0.38

Over 50 320 thru 100 650 ± .045 ± 1.10 ± .020 ± 0.50

*Formerly AA-CS-E2-92 in previous editions 1-5

ADDITIONAL TOLERANCE, in., mm

in.2 cm2 in.2 cm2 in. mm in. mm in. mm

Over 10 65 thru 50 320 ± .035 ± 0.90 ± .025 ± 0.60 ± .015 ± 0.38

1-6 *Formerly AA-CS-E3-92 in previous editions

*Formerly AA-CS-E4-92 in previous editions 1-7

1-8 *Formerly AA-CS-E4-92 in previous editions

Greatest Dimension Permanent Mold Tolerance Sand Tolerance

in. mm in. mm in. mm

For castings over 24 inches (600 mm), consult foundry.

Checking for flatness will be performed only on those surfaces specified.

*Formerly AA-CS-E5-92 in previous editions 1-9

‘a’ Base—Hole diameter or

1-10 *Formerly AA-CS-E6-2000 in previous editions

*Formerly AA-CS-E7-2000 in previous editions 1-11

In determining the amount of tolerance to be specified in a general profile tolerance requirement,

1-12 *Formerly AA-CS-E8-92 in previous editions

TABLE 1: Basic Tolerance

Basic Tolerance up thru 150 mm 1.5 Basic Tolerance up thru 25 mm .8 1.5

Linear Tolerances for cm2 expressed in mm

TABLE 2: Additional Tolerance for Dimensions Across Parting Line

Over 10 thru 50 in. .06 .03

65 thru 320 cm 1.5 .8

Over 50 thru 100 in. .08 .04

320 thru 650 cm 2.0 1.0

Over 100 thru 250 in. .10 .05

650 thru 1600 cm 2.5 1.2

Over 250 thru 1000 in. .15 .07

1600 thru 6500 cm 3.8 1.8

TABLE 3: Additional Tolerance for Cored Features

Over 10 thru 50 in. .05 .03 .04

65 thru 320 cm 1.2 .8 1.0

Over 50 thru 100 in. .07 .03 .06

320 thru 650 cm 1.8 .8 1.5

Over 100 thru 250 in. .09 .05 .08

650 thru 1600 cm 2.2 1.2 2.0

Over 250 thru 1000 in. .13 .07 .12

1600 thru 6500 cm 3.3 1.8 3.0

*Formerly AA-CS-E8-92 in previous editions 1-13

1-14 *Formerly AA-CS-E8-92 in previous editions

Ejector Pin Mark Tolerances, in., mm

in.2 cm2 in. mm

Over 50 thru 100 320 thru 650 ± 0.030 ± 0.80

Over 100 thru 200 650 thru 1300 ± 0.045 ± 1.10

Over 200 1300 CONSULT FOUNDRY

*Formerly AA-CS-E9-92 in previous editions 1-15