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SAE TECHNICAL
PAPER SERIES 2004-01-1022

Role of T7 Heat Treating on the Dimensional

Stability of Automotive A319 Al Alloys
H. Mancha-Molinar
Centro de Investigación y de Estudios Avanzado del IPN

H. F. López
Materials Department, University of Wisconsin-Milwaukee

A. Silva and K. Still

Castech SA de CV

Reprinted From: Advances in Lightweight Automotive Castings

and Wrought Aluminum Alloys
(SP-1838)

2004 SAE World Congress

Detroit, Michigan
March 8-11, 2004

400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760 Web: www.sae.org
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Role of T7 Heat Treating on the Dimensional Stability of
Automotive A319 Al Alloys
Materials Department, University of Wisconsin-Milwaukee
Copyright © 2004 SAE International
ABSTRACT
Alloy A319 is extensively used in the automotive industry.
In the as-cast condition the alloy lacks the required
strength. A solid solution heat treatment (T4) followed by
room temperature quenching improves tensile strength.
Accordingly, engine castings in T4 condition are used in
the manufacture of automobiles. However, A319 alloy is
not thermodynamically stable after solid solution. The
matrix is supersaturated with Cu, and a precipitation
sequence is expected to occur overtime, which leads to
dimensional changes. Alternatively, an aging treatment
(T7) can activate the precipitation reactions to achieve
dimensional stability in castings. In this work, dilatometric
measurements were made during a T7 heat treatment in
order to establish the extent of dimensional changes,
resulting from the precipitation reactions. In addition,
high-resolution electron microscopy was used to follow
up the precipitation reactions.
INTRODUCTION
The use of aluminum alloys in the manufacture of
automotive components currently experiences a great
demand [1], but at the same time it faces unforeseen
problems. Hence, finding creative solutions in order to
achieve high success in the design of high performance
complex castings for long-term service has become a
major challenge for engineers and the metallurgical
community. Historically, engine blocks and cylinder
heads have been manufactured employing gray cast
2004-01-1022
H. Mancha-Molinar
Centro de Investigación y de Estudios Avanzado del IPN
H. F. López
A. Silva and K. Still
Castech SA de CV
irons. Consequently, there is a broad base of knowledge
on the physical-thermal and mechanical response of
these materials when considered for the design of
engine components.
Yet, an equivalent base of knowledge is lacking for cast
aluminum alloys, probably due to their relatively new
applications as substitute materials in components
traditionally made of cast iron. In aluminum alloys, the
existing base of knowledge is still limited in enabling a
rapid optimization of engine designs aimed at high
performance, reliability and reduced processing costs.
Aluminum cast alloys possess technological advantages
over cast iron counterparts such as improved thermal
conductivity, high mechanical properties/weight ratio, and
low fuel consumption rates. Yet, a metallurgical
knowledge base is critically needed to ensure high
performance in highly complex engine designs.
It is well known [2-5] that alloy A319 possess relatively
high mechanical properties at engine operating
o
temperatures (up to 200 C). Apparently, in cast
aluminum alloys, Cu additions impart high temperature
strength. Nevertheless, when these alloys are exposed
to a solid solution treatment to incorporate Cu in the
aluminum matrix, natural aging can lead to dimensional
stability problems. In particular, during service bore
distortion can result due to precipitation reactions in the
Al matrix, which in turn might detrimentally impair engine
performance. Hence, in order to achieve optimum alloy
properties and stability it is necessary to subject these
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alloys to proper thermal cycles in order to develop a
microstructure, which is thermodynamically-
dimensionally stable. In this work, the effect of alloy heat
treating on the exhibited dimensional changes
experienced by an alloy A319 is investigated.
EXPERIMENTAL TECHNIQUES
In this work, dilatometric cylindrical specimens of 10 mm
in diameter and 25.8mm in length long were machined
out of an Al alloy A319 whose composition is given in
Table I. The dilatometer employed in this work was a
DIL 2012 and it was used to measure the linear
dimensional changes exhibited by this alloy after
o
quenching from 485 C to room temperature and then
o
aged at either 220, 240, or 260 C. In addition, high-
resolution transmission electron microscopy (HRTEM)
was employed to unfold the microstructural features
associated with a given heat treatment. The
transmission electron microscope used for this work was
a Philips EM 430.
Table I. Chemical Composition of the A319 alloy
Element Si Cu Fe Mn Mg Ti Sr Al
Content
8.2 3.8 0.56 0.4 0.33 0.12 0.014 Bal
(wt %)
RESULTS AND DISCUSSION
MICROSTRUCTURE. The resultant microstructure of Al-
Si-Mg-Cu alloys (A319), is strongly dependent on several
parameters such as chemistry, melt treatment, cooling
rates, and heat treatments. A typical microstructure for
these alloys is shown in Fig 1. Accordingly, there are
various microstructural constituents, all of which play an
important role on the exhibited mechanical properties. In
particular, Fe-based intermetallics of acicular shape have
the most deleterious effect on the mechanical properties
as they promote appreciable alloy brittleness. This effect
is enhanced when the Mn content in not enough to
modify the morphology of the iron rich phases from
acicular shape into Chinese script.
Silicon phases tend to concentrate in the interdendritic
and intergranular regions. In this case, depending on the
level of modification, Si can be present as acicular
needles, blocky plates, and lamellar or refined fibrous
structures. In particular, the alloy strength increases with
the Si content, but the alloy ductility increases with the
level of Si modification [6]. Secondary dendritic arm
spacing (SDAS) is another feature, which has been
measured and correlated with the alloy properties [7-8].
SDAS is directly related to the solidification rate, with the
smallest SDAS values corresponding to the highest
material strengths and ductilities [9].
The response of these alloys to solid solution heat
treatments can also be related to the exhibited SDAS,
with the smaller SDAS values corresponding to the
smaller particle sizes and lower Cu, Si and Mg
segregation levels. Moreover, grain refining in these
alloys needs to be controlled to avoid the introduction of
non-dissolved particles in the melt that can eventually act
as preferential nucleation sites for gas or shrinkage
porosity.
Although the precipitation sequence can be rather
complex due to the presence of Mg and other elements,
a simplified version of the precipitation events can be
described by considering the Al-Cu binary system. In
this case, the precipitation sequence exhibited during
aging from the supersaturated solid solution can be
described by:
αss Æ GP zones Æ θ´ Æ θ
where the sequence starts with the Al-Cu supersaturated
solid solution αss, which decomposes into very small 2-D
plate shaped coherent precipitates known as GP zones,
and then into the θ´ phase. The GP zones are fully
coherent with the matrix structure and they are aligned in
specific crystallographic directions [10]. The θ´ phase is
a tetragonal three dimensional (3-D) plate-like structure
[10]. Fig 2 shows schematically the various crystal
structures corresponding to the sequence of metastable
Cu-rich precipitates developed during aging. After long
aging times, θ´ eventually disappears, and the most
thermodynamically stable phase, θ forms. The θ phase
is relatively coarse and fully incoherent with the matrix.
These transformation phenomena give rise to
macroscopic changes in the material properties as a
continuous increase in hardness and tensile strength are
accompanied by a decrease in ductility until a peak age
condition (GP zones Æ θ´) is reached. Beyond this point
the mechanical properties revert as the Al alloy starts
softening (θ´ Æ θ).
DILATOMETRY. The experimental outcome from
o
dilatometric measurements at 220, 240 and 260 C is
given in Figs. 3a-c. Notice that these figures include the
predicted thermal expansion curves calculated by using
an expression for thermal expansion in aluminum
o
proposed by Hatch [11]. Accordingly, at 240 C (Fig. 3a),
three curves are plotted, as a third curve named in this
work as “blank” is included which corresponds to a fully
aged condition. This was done in order to obtain the
alloy thermal expansion excluding any precipitation
effects. In turn, it was found that there is a good
correlation between the predictions of the thermal
expansion equation at long times and the experimental
outcome.
The differences observed at short times can be related
to any variations in temperature values measured inside
the furnace of the dilatometer and the real temperature
of the specimen. In this work, an estimation of thermal
expansion considered the values registered inside the
furnace. At long times, when the specimen has reached
thermal equilibrium with the furnace atmosphere, the
temperature values between the experimental
measurements and the predictions become similar in
agreement with the expected behavior.
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The experimental outcome of this work clearly shows
that the total expansion found in the A319 Al alloy can be
attributed to two factors; (a) the thermal expansion
induced by the physical dilatation with temperature; and
(b) the dimensional changes resulting from secondary
precipitation effects within the Al-Cu matrix. Moreover, a
comparison of the magnitudes exhibited by both kinds of
expansions suggests that thermal expansion is the
dominant property. In particular the magnitude of
thermal expansion is strongly dependent on the actual
temperature. Figures 3a-c clearly show that increasing
temperatures give rise to increasing expansions. In
addition, the dimensional changes associated with phase
growth as a result of precipitation reach approximately
similar values for the three temperatures investigated. In
all the cases, dimensional changes of around 50 microns
found between the experimental and theoretical curves
represent, for a specimen of 50800 microns, a thermal
growth due to precipitation of approximately 0.1%.
HRTEM ANALYSIS. In the Al-Cu system, the
precipitation reaction sequence of Cu-rich phases can be
altered by the presence of elements such as Mg and Si,
which interact with other constituents to form various
intermediate quaternary phases. Among the hardening
phases found in Al-Mg-Si cast alloys are β'' and β'
phases. Moreover, in quaternary Al-Mg-Si-Cu systems,
the potential hardening phases become increasingly
complex making the aging response not as predictable
as in other systems. For example, one of the important
phases found in the Al-Mg-Si-Cu system is the
quaternary equilibrium phase denoted as Q [12-15], W
[16], h [17], or λ [18]. This phase is responsible up to a
great extent for the increasing brittleness exhibited by
these alloys. Fig 4 is a schematic representation of the
equilibrium phases present in the Al-Si-Mg-Cu
quaternary systems.
In the Al-Mg-Si compositions can be described in a three
phase space consisting of the equilibrium phases: α
aluminum (Al), β and (Si). Adding Cu, the different phase
spaces expand into a tetrahedron of composition
spaces. Inside each three-dimensional space, a four-
phase equilibrium exists. The four coexisting phases
depend on the chemical composition with high Cu and Si
favoring either the development of (Al)+Q+Mg2Si+(Si) or
(Al)-θ-(Si)-Q domains.
In addition, the complex solidification process itself and
the later heat treatment processing for most commercial
alloys might provide some room for the formation of a
large variety of intermediate metastable phases, and
consequently for a large selection of mechanical and
dimensional properties. The well known rather large
increase in strength reported when Cu additions are
implemented into Al-Mg-Si alloys has been attributed to
the Q phase precursors [19-22]. Also it has been
claimed that such behavior can be ascribed to the θ'
phase precipitation. This appears to be consistent with
the potential for Q and θ stabilization due to the presence
of Cu. High resolution imaging of precipitates [19] has
shown that there are at least two types of metastable
phases, one with an equiaxed cross section due to θ', or
with rectangular cross sections ascribed to β', (i.e.
metastable Q). Both Edwards et al [19] and Sagalowicz
et al [21] have found that rod shaped β' is dominant in
peak aged materials, while lath shaped Q phase
precursors become dominant after overaging.
In order to examine the aging effects on the matrix
microstructure, an alloy was given a full peak aging at
o
230 C for 3 hours and 20 minutes and then compared
with one where aging was performed during service, (i.e.
incomplete and within a non homogeneous temperature
field) and another one with no ageing at all. The
experimental outcome from HRTEM observations on the
solutionized samples with no ageing show evidence of
large crystals with uniform crystallographic atom arrays
within the matrix (Fig 5a), whereas in alloys either
incompletely or fully peak aged various very small atomic
arrays are observed (Figs. 5b-c), being more disordered
in the case of an incomplete non homogeneous ageing
process (Fig. c). Accordingly, it is expected that non-
aged alloys as well as those not uniformly aged will
continue to age during service resulting in dimensional
instabilities.
CONCLUSIONS
In the present work, the thermal expansion properties of
an automotive aluminum alloy A 319 were investigated.
Dilatometric measurements on cylindrical bars exposed
o
to a solid solution heat treatment (T4) at 485 C for 5
hours indicated that:
1. After quenching to room temperature no
secondary phase precipitation was observed
based on HRTEM observations.
o
2. Subsequent aging at 220-240 C (T7) lead to
precipitation of secondary phases with the
corresponding changes in sample dimensions.
It was found that thermal growth due to
precipitation was approximately 0.1%.
3. The changes in specimen dimensions were
corrected to exclude the effect of thermal
expansion through the use of a thermal curve
corresponding to a fully aged specimen, and by
employing a thermal expansion expression for Al
alloys.
4. Specimens which were given an incomplete
aging treatment, or no aging at all were found to
naturally age overtime leading to dimensional
alloy instabilities.
Hence, form these results, it is expected that engine
heads and blocks made of A319 Al alloys that are not
properly heat treated are prone to undergo dimensional
changes during service.
ACKNOWLEDGMENTS
The authors wish to thank Castech and GIS for their
support in the use of experimental facilities.
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REFERENCES
1. Donald W. Macmillan, President, Aluminum-
Based Solutions for the Automotive Industry.
Alcan Global Automotive Solutions, at the 9th
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Technology, October 1998, p. 40-43,
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Si-Cu-Mg casting alloy in T6 temper, Int. J. Cast
Metals Res., 2003, 15, 531-543;
4. Metals Handbook, Vol.2 - Properties and
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M. (Tim) Holt, Technical Ed; C. Y. Ho, Ed.,
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INTERNATIONAL CONFERENCE ON MOLTEN
ALUMINUM PROCESSING November 11-13,
2001, Orlando FL, USA
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Liquid Aluminum-Silicon Alloys", American
Foundrymen's Society, l990, 256 pages.
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Alloys, USA 6th INTERNATIONAL
CONFERENCE ON MOLTEN ALUMINUM
PROCESSING November 11-13, 2001, Orlando
FL, USA
9. Cáceres C H, Svensson L, Taylos J A, Strength-
Ductility Behaviuor od Al-Si-Cu-Mg Casting
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Metallurgy, American Society of Metal, Material
Park, OH, 1984
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Aluminium-Magnesium-Silicon Alloys of the
Duralumin Type," J. Inst. Metals, 76 (1949-50),
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13. H. J. Axon, "Equilibrium Relations at 460°C in
Aluminium-Rich Alloys Containing 0-7% Copper,
0-7% Magnesium and 1.2% Silicon," J. Inst.
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the Tensile Properties of Wrought Aluminium-
Magnesium-Silicon-Copper Alloys," J. Inst. Met.,
86 (1957-58), 325-336. ,
15. D. P. Smith, "The Constitution of Quaternary
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500°C," Metallurgia, 63 (1961), 223-231.
16. D. A. Petrov, "On the Composition of the
Quaternary Phase in the System Al-Mg-Si-Cu,"
Acta PhysicoChimica U.R.S.S., VI(4) (1937),
505-512; D. A. Petrov and N. D. Nagorskaya,
Zhur Obschey Khimi, (1949), 1994-2037
17. G. Phragmen, "On the Phases Occupying in
Alloys of Aluminium with Copper, Magnesium,
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(1950), 489-552.)
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Aluminium Alloy Systems (London, The
Aluminium Development Assoc., 1961), 128-
133]
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"Formation of a Modified ' Phase in Aluminum
Alloy 6061," Scripta Met., 18 (1984), 1347-1350.
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and G. Lapasset, "A Study of the Structural
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Fourth International Conference on Aluminum
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CONTACT
H. F. López
Materials Department
University of Wisconsin-Milwaukee
P. O. Box 784
Milwaukee Wisconsin 53201.
E_mail: hlopez@uwm.edu
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Fe-rich
intermetallic
particle

Si
Fe-rich particle
intermetallic Cu-rich
particle intermetallic
particle

Fig. 1. Typical microstructures found in A319 cast aluminum alloys

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Al Cu

0.4 0.4
04 Al Cu 87

0.607
0.404 0.607
0.404
θ
α (Al)

0.182
0.7
0.202
68
0.5
80 0.202

0.182
0.404
0.404
0.404 0.404

θ´ θ´´

Fig. 2. Schematic representation of crystal structures associated with the precipitation sequence of Cu-rich
phases developed during aging.
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350
Thermal expansion + Growth
300

Expansion, microns
250
Theoretical equation
200

150

100

50

0
0 50 100 150 200 250
Time, min

(a)

350

300 Thermal expansion +

250
Expansion, microns

Theoretical equation
200
Blank (Only Thermal Expansion)
150

100

50

0
0 50 100 150 200
Time, min

(b)
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350

300 Thermal expansion + Growth

Expansion, microns

250
Theoretical equation
200

150

100

50

0
0 20 40 60 80 100 120 140 160

Time, min

(c)

Fig. 3. Dilatometry results at (a) 220, (b) 240 and (c) 260oC for specimens with growth
due to precipitation of theta phases and a specimen without precipitation reactions (blank
curve in 3b); a theoretical curve for pure thermal expansion is included.
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Si

Q
Mg2Si
Cu

θ S

T
Mg

Al

Fig 4. Schematic representation of the potential equilibrium phases occurring in the Al-Si-Mg-Cu quaternary
system.
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(a)

(b)
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(c )

Fig 5. HRTEM micrographs showing at the atomic scale (a) a large crystal after a 5 h solution heat treatment at
485oC with no evidence of any ageing effects, (b) randomly oriented crystals resulting from aging for 3.3
h at 230oC, and (c) ageing process carried out in a non homogeneous temperature field.