Aluminum ZL402 T1-S
Temper
GB ZL402 · ASTM 771.0
Sand-cast parts stabilized by aging; choose for large or one-off housings where metal-mould tooling is not justified.
Values for the T1-S condition
Other ZL402 tempers and conditions
ZL402 is listed in 3 conditions; see the grade overview at ZL402.
Compare all 3 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
As fabricated | Freshly cast, un-aged condition; strength keeps rising for weeks at room temperature, so machine only after stabilization. | 110 | 190 | 7 | 55 HB | 31 % IACS |
T1-SThis page T1 | Sand-cast parts stabilized by aging; choose for large or one-off housings where metal-mould tooling is not justified. | 140 | 225 | 5 | 62 HB | 34 % IACS |
T1-JDefault T1 | Standard commercial condition: metal-mould casting aged to stable strength — best combination of strength, dimensional stability and surface finish. | 150 | 240 | 5 | 72 HB | 35 % IACS |
What is ZL402 T1-S?
ZL402 T1-S is ZL402 in the T1-S temper — sand-cast parts stabilized by aging; choose for large or one-off housings where metal-mould tooling is not justified. ZL402 T1-S has a yield strength of 140 MPa (20.3 ksi) and a tensile strength of 225 MPa (32.6 ksi) — weaker than 70% of aluminum grades. Elongation at break is 5% and the elastic modulus is 70 GPa (10.2 Msi). ZL402 T1-S has a density of 2.81 g/cm³ (0.102 lb/in³), heavier than 86% of aluminum grades. It melts at 605°C (1,121 °F). T1-J is the default condition FabDigit quotes; T1-S is available on request or by drawing note.
Advantages
- Polishes to a fine finish — 70/100, better than 87% of aluminum grades
Limitations
- Limited formability — 10/100, worse than 80% of aluminum grades
ZL402 T1-S properties
Typical room-temperature values for ZL402 T1-S; 11 are specific to this condition. Other listed values are ZL402 reference data and may not represent this condition. Bars are the position among aluminum grades.
Physical3
ZL402 T1-S has a density of 2.81 g/cm³ (0.102 lb/in³), heavier than 86% of aluminum grades. It melts at 605°C (1,121 °F).
Mechanical13
ZL402 T1-S has a yield strength of 140 MPa (20.3 ksi) and a tensile strength of 225 MPa (32.6 ksi) — weaker than 70% of aluminum grades. Elongation at break is 5% and the elastic modulus is 70 GPa (10.2 Msi).
Thermal6
ZL402 T1-S 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 24 µm/m·K (13.3 µin/in·°F).
Electrical3
ZL402 T1-S conducts electricity at 34 % IACS, worse than 52% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is fair (52/100), worse than 55% of aluminum grades.
Sustainability4
Producing a kilogram of ZL402 T1-S takes about 190 MJ of energy and emits 13.5 kg of CO₂ — less than 89% of aluminum grades. Typical recycled content is 40%.
Manufacturability8
ZL402 T1-S's machinability is very good (70/100, better than 72% of aluminum grades); weldability good (55/100); formability not recommended (10/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with ZL402 T1-S
Is ZL402 easy to machine?
Machines cleanly with sharp PCD/carbide tooling and high speeds; wait for aging to stabilize (1–4 weeks at RT or a short 120–140 °C stabilizing soak) before finish cuts to avoid dimensional drift.
Can ZL402 be welded?
TIG/MIG weldable with 5356 or 5183 filler; the Al-Zn-Mg HAZ naturally re-ages back to useful strength, but chilled restraint and slow cooling are needed to avoid hot cracking and SCC-prone weld toes.
Can ZL402 be formed, bent or molded?
Sand and permanent-mould casting only — the alloy has moderate fluidity and a wide freezing range, so use generous risers, chills and controlled pouring (700–730 °C) to prevent hot tearing and shrinkage porosity; no solution quench is required.
What surface finishes work on ZL402?
Takes chromate/trivalent conversion coatings, clear or hard anodizing and paint well; polishes to a bright machined finish, but Zn-rich segregation can mottle dyed anodic films.
ZL402 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 |
|---|---|---|
| Znprincipal strengthener with Mg (MgZn2) | 5 – 6.5 | 5.8 |
| Mg | 0.5 – 0.65 | 0.57 |
| Crgrain-boundary control, improves SCC resistance | 0.4 – 0.6 | 0.5 |
| Tigrain refiner | 0.15 – 0.25 | 0.2 |
| Siimpurity limit | ≤ 0.3 | — |
| Feimpurity limit | ≤ 0.5 | — |
| Cuimpurity limit | ≤ 0.25 | — |
| Mnimpurity limit | ≤ 0.1 | — |
| Al | balance | — |
ZL402 T1-S — frequently asked
What is ZL402 T1-S used for?
ZL402 T1-S is typically used for general engineering castings, low-stress structural parts, housings and covers, brackets and supports, machine frames and bases and fixture and jig bodies. In short: self-ageing casting alloy; no solution treatment needed; freely machining ZL grade.
What is the yield strength of ZL402 T1-S?
ZL402 T1-S has a typical yield strength of 140 MPa (20.3 ksi) and a tensile strength of 225 MPa (32.6 ksi) — weaker than 70% of aluminum grades. Strength varies by condition: see the 3 listed tempers.
Is ZL402 T1-S easy to machine?
Yes — machinability is rated very good (70/100, better than 72% of aluminum grades). Machines cleanly with sharp PCD/carbide tooling and high speeds; wait for aging to stabilize (1–4 weeks at RT or a short 120–140 °C stabilizing soak) before finish cuts to avoid dimensional drift.
Can ZL402 T1-S be welded?
Yes — weldability is rated good (55/100). TIG/MIG weldable with 5356 or 5183 filler; the Al-Zn-Mg HAZ naturally re-ages back to useful strength, but chilled restraint and slow cooling are needed to avoid hot cracking and SCC-prone weld toes.
What surface finishes work on ZL402 T1-S?
Takes chromate/trivalent conversion coatings, clear or hard anodizing and paint well; polishes to a bright machined finish, but Zn-rich segregation can mottle dyed anodic films.
Can ZL402 T1-S be formed, bent or molded?
Sand and permanent-mould casting only — the alloy has moderate fluidity and a wide freezing range, so use generous risers, chills and controlled pouring (700–730 °C) to prevent hot tearing and shrinkage porosity; no solution quench is required.
What is the maximum service temperature of ZL402 T1-S?
ZL402 T1-S 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 ZL402 T1-J and ZL402-F?
T1-J is the default condition — standard commercial condition: metal-mould casting aged to stable strength — best combination of strength, dimensional stability and surface finish. F: freshly cast, un-aged condition; strength keeps rising for weeks at room temperature, so machine only after stabilization. Yield strength is 150 MPa in T1-J versus 110 MPa in F.
Sources
- ASM Handbook Vol.2 — Properties and Selection: Nonferrous Alloys (Al casting alloys, 771.0) — ASM International (1990)
- ASM Handbook Vol.13B — Corrosion of Aluminum Alloys — ASM International (2005)
Property data is compiled from published supplier and standards handbooks and normalised for comparison. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.