Aluminum alloys reduce automotive mass, energy use, and emissions while supporting strength, comfort, safety, and driving performance. This reference explains the distinction between cast and wrought alloys and lists automotive applications by grade. The tables cover body and closure panels, trim, nameplates, heat exchangers, condenser and radiator components, fasteners, structural extrusions, suspension parts, wheels, brake components, fuel systems, bumpers, seat rails, shock-absorber reinforcements, and other vehicle systems. The article preserves the source’s reported process conditions, material designations, units, and technical relationships for practical engineering reference.
Pure aluminum has low strength and good ductility and is generally unsuitable as a structural material. Alloying it with other metals and applying suitable heat treatment improves strength and overall performance. Aluminum alloys retain the low weight of pure aluminum while achieving much higher strength. Their specific strength can exceed that of many alloy steels, making them useful structural materials.
In automobiles, aluminum alloys reduce vehicle mass, energy consumption, and exhaust emissions while improving driving performance, comfort, and safety. According to their phase diagrams, aluminum alloys are classified as wrought or cast. Wrought alloys contain lower levels of alloying elements. Cast alloys contain more alloying elements and form some eutectic during solidification, improving fluidity and castability.
| Aluminum Alloy | Automotive Application |
|---|---|
| AlMg5.4Mn0.3-W | Inner luggage-compartment panels and automotive trim |
| AlMg25-W | Automotive reinforcement panels with modest strength requirements |
| AlMg0.4Si1.2 | Engine hoods and luggage-compartment lids |
| AlMg5 | Instrument panels, inner door-pillar liners, and rear-seat-back brackets |
| Grade | Application | Grade | Application |
|---|---|---|---|
| 1100 | Interior decorative parts, trim, and nameplates | 6009 | Body sheet-metal parts, sunroof inner panels, load floors, inner and outer hood panels, front baffles, grille inner-panel brackets, inner door panels, shock-absorber reinforcements, and welded parts |
| 1200 | Heat-transfer fins and extruded condenser tubes | ||
| 2008 | Inner and outer closure panels and structural parts | ||
| 2010 | Inner and outer structural parts and closure panels | 6010 | Panels, inner door panels, sunroof panels, spare wheels, grille inner-panel frames, seat frames and rails, and wheels |
| 2011 | Screws | 6111 | Body sheet-metal parts |
| 2017 | Fasteners | 6005A | Body components |
| 2117 | Fasteners | 6022 | Inner and outer panels |
| 2024 | Fasteners | 6051 | Heat exchangers |
| 2036 | Closure panels, seat frames, and load floors | 6016 | Body sheet-metal parts |
| 3002 | Decorative parts, nameplates, and trim | 6063 | Extruded structural material, door frames, window frames, accessories, and related parts |
| 3003 | Brazed heat-exchanger tubes, heater and evaporator fins, and air-conditioning tubes | 6463 | Extruded structural material, window frames, and door frames |
| 3004 | Exterior closure panels and components | 6053 | Fasteners |
| 3005 | Brazed radiator tubes, heaters and edge supports, and evaporator parts | 6061 | Body extrusions, suspension parts, extruded bracket plates, drive-shaft tubes, impact-extruded and forged drive-shaft rollers, spare-wheel carriers, shock-absorber reinforcements, fasteners, extruded brake cylinders, wheels, fuel-delivery systems, bumpers, and heat exchangers |
| 4002 | Composite brazing sheet | ||
| 4032 | Forged pistons | 6151 | Structural parts, wheel spokes, and various brackets |
| 4044 | Composite brazing sheet | 6262 | Structural parts, including drivetrain and engine-system parts and connectors |
| 4104 | Composite brazing sheet | ||
| 4043 | Welding wire and composite brazing sheet | 6082 | General structures and brake components |
| 5005 | Decorative parts, trim, and nameplates | 6262 | Structural parts, brake pistons, brake components, and general anodized screws |
| 5052 | Closure panels and components, and truck shock absorbers | ||
| 5252 | Decorative parts | 6181A | Body panels |
| 5182 | Inner panels, air-cleaner trays and covers, fenders, and heat shields | 7003 | Shock-absorber reinforcements and seat rails |
| 5454 | Wheels, miscellaneous parts, engine accessory brackets, and welded structures | 7021 | Flat regular-polygon bars for shock absorbers and bracket plates |
| 5457 | Decorative parts | 7029 | Bright-finished or anodized flat regular-polygon bars for shock absorbers |
| 5657 | Decorative parts | ||
| 5754 | Inner panels, heat shields, fenders, and load floors | 7072 | Radiator fins and condensers |
| 6591 | Heat exchangers and radiators | 7129 | Flat regular-polygon shock-absorber bars, shock-absorber reinforcements, extruded headrest bars, rail extrusions, and seats |
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