Aluminum 296.0
AA 296.0 · UNS A02960
296.0 (UNS A02960) is a permanent-mold Al-Cu-Si casting alloy in the ANSI/AA 2xx.x family, supplied in T4, T6 and T7 tempers and closely related to 295.0 but cast for improved pressure tightness.
Reference datasheet — 296.0 is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the T6 condition
296.0 tempers and conditions
296.0 is supplied in 3 conditions, soft to hard. T6 is the default FabDigit quotes; the values on this page are for it.
Compare all 3 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
Solution heat treated and naturally aged | Pick when maximum ductility and impact tolerance are needed with moderate strength; also common for parts machined then service-aged. | 131 | 255 | 8.5 | 75 HB | 33 % IACS |
Solution heat treated and overaged (stabilized) | Choose for dimensional stability and reduced residual stress in machined or elevated-temperature parts, at slightly lower yield strength than T6. | 138 | 270 | 4.5 | 80 HB | 38 % IACS |
T6Default Solution heat treated and artificially aged | Standard high-strength condition for pump housings and pressure-tight castings where hardness and machined-surface quality matter. | 179 | 275 | 5 | 95 HB | 35 % IACS |
What is 296.0?
296.0 (UNS A02960) is a permanent-mold Al-Cu-Si casting alloy in the ANSI/AA 2xx.x family, supplied in T4, T6 and T7 tempers and closely related to 295.0 but cast for improved pressure tightness. Typical values are 179 MPa yield, 275 MPa tensile, 5% elongation, 95 HB, 138 W/m·K thermal conductivity and 35% IACS, with service to 150 °C. The 4-5% copper makes fusion welding inadvisable and leaves corrosion protection dependent on coatings. 295.0 is the sand-casting equivalent when tooling cost rules out permanent mold. 296.0 has a density of 2.8 g/cm³ (0.101 lb/in³), heavier than 81% of aluminum grades. It melts at 521°C (970 °F). 296.0 has a yield strength of 179 MPa (26 ksi) and a tensile strength of 275 MPa (39.9 ksi) — weaker than 55% of aluminum grades. Elongation at break is 5% and the elastic modulus is 71 GPa (10.3 Msi).
What is 296.0 used for?
- Pump housings
- Valve bodies
- Pressure-tight hydraulic castings
- Compressor housings and covers
- Gearbox and machinery housings
- Manifolds and fluid-handling castings
Advantages
- Easy to machine — 72/100, better than 80% of aluminum grades
Limitations
- Limited formability — 5/100, worse than 94% of aluminum grades
- Needs corrosion protection — 35/100, worse than 85% of aluminum grades
- Difficult to weld — 25/100, worse than 76% of aluminum grades
296.0 properties
Typical room-temperature values for 296.0-T6; bars are the position among aluminum grades.
Physical3
296.0 has a density of 2.8 g/cm³ (0.101 lb/in³), heavier than 81% of aluminum grades. It melts at 521°C (970 °F).
Mechanical13
296.0 has a yield strength of 179 MPa (26 ksi) and a tensile strength of 275 MPa (39.9 ksi) — weaker than 55% of aluminum grades. Elongation at break is 5% and the elastic modulus is 71 GPa (10.3 Msi).
Thermal6
296.0 is rated for continuous service to 150°C (302 °F). It conducts heat at 138 W/m·K (79.7 BTU/hr·ft·°F), worse than 55% of aluminum grades. Thermal expansion is 22.5 µm/m·K (12.5 µin/in·°F).
Electrical3
296.0 conducts electricity at 35 % IACS, better than 52% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is fair (35/100), worse than 85% of aluminum grades.
Sustainability4
Producing a kilogram of 296.0 takes about 195 MJ of energy and emits 12 kg of CO₂ — less than 86% of aluminum grades. Typical recycled content is 55%.
Manufacturability8
296.0's machinability is very good (72/100, better than 80% of aluminum grades); weldability poor (25/100); formability not recommended (5/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the aluminum family
Yield strength against density for every aluminum grade FabDigit runs. 296.0 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with 296.0
Is 296.0 easy to machine?
Machines very well with carbide tools, high speed and low feed; free-machining chips, but abrasive Si particles favour polished-flute or PCD tooling for long runs.
Can 296.0 be welded?
Fusion welding is not recommended (hot-cracking with 4–5% Cu); repair by 4145/4043 filler only where qualified, or use mechanical fasteners/adhesives.
Can 296.0 be formed, bent or molded?
Permanent-mold (and sand) casting alloy with good fluidity and pressure tightness; provide generous risers and directional solidification to avoid Cu-rich shrinkage porosity; not cold-formable.
296.0 chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| Siimproves fluidity and pressure tightness vs 295.0 | 2 – 3 | 2.5 |
| Cumain strengthening addition | 4 – 5 | 4.5 |
| Fe | ≤ 1.2 | |
| Mn | ≤ 0.35 | |
| Mg | ≤ 0.05 | |
| Ni | ≤ 0.35 | |
| Zn | ≤ 0.5 | |
| Tigrain refinement | ≤ 0.25 | |
| Others (each)total 0.15 max | ≤ 0.05 | |
| Al | balance |
What surface finishes work on 296.0?
Best protected by chromate conversion plus primer/paint; anodizing gives dark mottled color due to Cu/Si, hardcoat acceptable for wear only; polishes to a fair, not mirror, finish.
Surface treatments FabDigit runs on aluminum parts — pick them in the quote configurator or call them out on the drawing. Each links to its datasheet in the surface-finish library (thickness, specs, call-out, material verdicts).
Organic Coating
Equivalent designations
Standards and trade names that resolve to Aluminum 296.0 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- UNS
- A02960
How much does 296.0 cost?
296.0 is a standard-cost aluminum ($$), cheaper than about 71% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
296.0 — frequently asked
What is 296.0 used for?
296.0 is typically used for pump housings, valve bodies, pressure-tight hydraulic castings, compressor housings and covers, gearbox and machinery housings and manifolds and fluid-handling castings. In short: pressure-tight permanent-mold casting; stronger than 295.0; coating-dependent corrosion protection.
What is the yield strength of 296.0?
296.0 has a typical yield strength of 179 MPa (26 ksi) and a tensile strength of 275 MPa (39.9 ksi) — weaker than 55% of aluminum grades. Strength varies by condition: see the 3 listed tempers.
Is 296.0 easy to machine?
Yes — machinability is rated very good (72/100, better than 80% of aluminum grades). Machines very well with carbide tools, high speed and low feed; free-machining chips, but abrasive Si particles favour polished-flute or PCD tooling for long runs.
Can 296.0 be welded?
Not readily — weldability is rated poor (25/100). Fusion welding is not recommended (hot-cracking with 4–5% Cu); repair by 4145/4043 filler only where qualified, or use mechanical fasteners/adhesives.
What surface finishes work on 296.0?
Best protected by chromate conversion plus primer/paint; anodizing gives dark mottled color due to Cu/Si, hardcoat acceptable for wear only; polishes to a fair, not mirror, finish.
Can 296.0 be formed, bent or molded?
Permanent-mold (and sand) casting alloy with good fluidity and pressure tightness; provide generous risers and directional solidification to avoid Cu-rich shrinkage porosity; not cold-formable.
What is the maximum service temperature of 296.0?
296.0 is rated for continuous use to about 150°C (302 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between 296.0-T6 and 296.0-T4?
T6 is the default condition — standard high-strength condition for pump housings and pressure-tight castings where hardness and machined-surface quality matter. T4: pick when maximum ductility and impact tolerance are needed with moderate strength; also common for parts machined then service-aged. Yield strength is 179 MPa in T6 versus 131 MPa in T4.
How much does 296.0 cost?
296.0 is a standard-cost aluminum ($$), cheaper than about 71% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- ASTM B108 / B108M — Aluminum-Alloy Permanent Mold Castings — ASTM International (2019)
- Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingot (Teal Sheets) — The Aluminum Association (2018)
- ASM Handbook Vol. 2 — Properties and Selection: Nonferrous Alloys and Special-Purpose Materials — ASM International (1990)
- Aluminum: Properties and Physical Metallurgy — ASM International (1984)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.