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Aluminum 2024-T4
Aluminum 2024-T4 is the premier aerospace-grade aluminum alloy, renowned for its exceptional fatigue strength and excellent damage tolerance. With copper as the primary alloying element, 2024-T4 achieves high strength through natural aging after solution heat treatment. Its superior fatigue performance — among the highest of all aluminum alloys — makes it the material of choice for aircraft wing skins, fuselage panels, and structural components where resistance to crack propagation and cyclical stress is mission-critical.
Mechanical Properties
Density: 2.78 g/cm³
Tensile Strength: 469 MPa
Yield Strength: 324 MPa
Elongation at Break: 20%
Shear Strength: 283 MPa
Fatigue Strength: 138 MPa
Hardness (Brinell): 120 HB
Modulus of Elasticity: 73.1 GPa
Thermal Conductivity: 121 W/m·K
Melting Point: 502–638°C
Coefficient of Thermal Expansion: 23.2 ×10⁻⁶ /°C
Electrical Conductivity: 30% IACS
Advantages
- Exceptional fatigue strength — one of the highest fatigue limits among aluminum alloys; ideal for cyclically loaded aerospace and aircraft structures
- Excellent damage tolerance — high elongation (20%) and good fracture toughness provide superior resistance to crack initiation and propagation
- High strength-to-weight ratio — achieves 469 MPa tensile strength with low density of 2.78 g/cm³
- Good machinability in T4 temper — natural aging (T4) provides a slightly softer condition than T3, resulting in better chip formation than T351
Machining & Manufacturing
| Parameter | Specification | Notes |
| Cutting Speed | Roughing: 700–1,300 SFM (215–400 m/min)Finishing: 1,000–1,600 SFM (305–490 m/min) | - |
| Feed Rate | 0.005–0.016 ipt (0.13–0.41 mm/rev) | Balanced feeds prevent work hardening and promote clean chip formation |
| Tooling | Carbide end mills (AlTiN coated preferred) for production; high-speed steel for prototyping & low-volume work | Sharp tooling essential to avoid BUE |
| Coolant | Premium water-soluble coolant with anti-weld additives | Flood cooling recommended; reduces BUE and improves surface finish |
| Chip Control | Produces short, brittle chips at optimal speeds; gummy chips at low speeds | Golden chip color = optimal, blue = overheating; Avoid smearing Alclad cladding |
| Difficulty Level | Moderate | Sharper tools & higher speeds needed for copper-rich composition; Handle Alclad surface with care |
Common Applications
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