Elevated temperature
High-copper Al-Cu-Mn alloys keep strength and creep resistance better than 6xxx and 7xxx alloys at around 150 – 250 °C, which is why they were chosen for engine and hot-zone parts.
Aerospace · British specification forgings
DTD 5004 Aerospace Aluminium Forgings
"5004" in aerospace forging usually means DTD 5004, a British specification for forging stock and forgings in an aluminium-copper-manganese alloy (nominally 6 % Cu, 0.3 % Mn), solution treated and precipitation treated for service at elevated temperatures. It is not an Al-Mg 5xxx alloy. Metline supplies forgings to DTD 5004A or approved alternatives, worldwide.
- Specification
- DTD 5004 / 5004A (UK)
- Alloy type
- Al-6Cu-0.3Mn, heat-treatable
- Condition
- Solution + precipitation treated
- Closest AA alloy
- 2219 family (confirm)
What DTD 5004 forgings are
DTD specifications were issued by the British Directorate of Technical Development for aircraft materials. Many were later replaced by BS L-series and BS 2L-series documents, but DTD numbers remain on drawings for aircraft, engines and equipment still in production or service.
DTD 5004A covers forging stock and forgings of an aluminium-copper-manganese alloy with nominal 6.0 % copper and 0.3 % manganese, solution treated and precipitation treated, and intended for use at elevated temperatures. That composition places it in the same family as the American alloy 2219 (5.8 – 6.8 % Cu, 0.20 – 0.40 % Mn), which is known for keeping strength from cryogenic temperatures up to roughly 250 – 300 °C and for good weldability.
The similarity is useful for understanding the material, but it does not make the two interchangeable. DTD 5004A has its own composition limits, mechanical requirements and test rules. Any substitution, for example by 2219 forgings to AMS 4143 or ASTM B247, needs written approval from the design authority.
Composition: DTD 5004A nominal and the 2219 reference
The full DTD 5004A limits are in the specification itself, which governs every order. The table shows the published nominal values alongside the registered limits of 2219 for reference only.
| Element | DTD 5004A (nominal) | 2219 (AA limits, reference) |
|---|---|---|
| Copper (Cu) | 6.0 | 5.8 – 6.8 |
| Manganese (Mn) | 0.3 | 0.20 – 0.40 |
| Silicon (Si) | per specification | 0.20 max |
| Iron (Fe) | per specification | 0.30 max |
| Magnesium (Mg) | per specification | 0.02 max |
| Zinc (Zn) | per specification | 0.10 max |
| Titanium (Ti) | per specification | 0.02 – 0.10 |
| Vanadium (V) | per specification | 0.05 – 0.15 |
| Zirconium (Zr) | per specification | 0.10 – 0.25 |
| Aluminium (Al) | Remainder | Remainder |
We supply against the issue of DTD 5004 named on the order and report actual chemistry on the certificate.
Mechanical behaviour
Mechanical requirements for DTD 5004A forgings are set by the specification and depend on section size and test direction. To give a sense of the alloy family, typical values for 2219-T6 forgings are about 400 – 415 MPa tensile strength, about 260 – 290 MPa yield strength and 8 – 10 % elongation. Use the DTD figures, not these reference values, for design and acceptance.
Cryogenic temperature
The 2219 family gains strength and keeps toughness at very low temperature, a reason the US alloy is used for propellant tanks.
Weldability
Unusually weldable for a 2xxx alloy; 2219 is welded with 2319 filler. Check whether welding is permitted on DTD 5004 parts.
Corrosion
Like other copper-rich alloys, corrosion resistance is moderate; forgings are normally anodised, chromate- or chrome-free conversion coated and painted.
Supplied conditions
| Condition | Meaning | Use |
|---|---|---|
| Forging stock (as fabricated or annealed) | Bar or billet for the forge | Supplied to forging houses |
| Solution treated (T4-type) | Solution treated and quenched, naturally aged | Intermediate condition; formability or straightening before final ageing |
| Solution and precipitation treated (T6-type) | Solution treated, quenched and artificially aged | The normal service condition for DTD 5004A forgings |
British specifications describe conditions in words rather than by Aluminum Association temper codes; T4 and T6 in the table are the nearest equivalents. Where the drawing calls up a specific UK condition code, we quote and certify against that code.
Specifications and possible alternatives
| Document | Covers | Note |
|---|---|---|
| DTD 5004 / DTD 5004A | Al-Cu-Mn forging stock and forgings, solution and precipitation treated | Governing UK document when named on the drawing |
| SAE AMS 4143 | 2219-T6 die and hand forgings, rings and forging stock | Possible alternative only with design-authority approval |
| SAE AMS 4144 | 2219-T852 / T851 hand forgings and rolled rings | As above |
| ASTM B247 | Aluminium die, hand and rolled-ring forgings including 2219 | Commercial reference |
Forms and inspection
Closed-die forgings
Near-net shapes for housings, impellers, brackets and fittings, to drawing.
Hand (open-die) forgings
Blocks, discs and bars for machining where quantities are low.
Rolled rings
Rings for casings and flanges.
Forging stock
Extruded or cast-and-homogenised billet for the forge.
- Chemistry, tensile tests and hardness to the DTD sampling rules, on an EN 10204 3.1 certificate
- Ultrasonic inspection to AMS-STD-2154 or the programme document where required
- Macro-etch for grain flow and freedom from laps or folds on first articles
- Heat-treatment records and full traceability from billet to forging
Where DTD 5004 forgings are used
- Engine parts: compressor casings, impellers and housings running warm
- Hot-zone fittings: brackets and fittings near engines and exhausts
- Legacy airframes and equipment: spares and repeat production for UK-designed aircraft and systems
- Defence equipment: forgings for missile and vehicle components specified to DTD documents
How to order DTD 5004 forgings
- SpecifyAlloy and temper, drawing or forging envelope, quantity and the governing specification with its revision (DTD 5004A, or an approved alternative such as AMS 4143).
- ConfirmWe confirm the specification can be met, the tolerance class, test requirements and delivery terms (EXW, FOB, CIF or DAP).
- InspectMaterial is checked for dimensions and surface condition; any extra tests named on the order are carried out or arranged.
- DocumentEach lot ships with a mill test certificate to EN 10204 3.1 showing chemistry and mechanical results, traceable to the cast or lot number.
- Pack and shipExport packing in sealed, moisture-protected cases or on pallets, shipped by sea or air to your port or door.
References and standards
- DTD 5004A – Forging stock and forgings of aluminium-copper-manganese alloy (solution and precipitation treated), UK Ministry of Defence
- SAE AMS 4143 – Aluminum Alloy Forgings, 6.3Cu-0.30Mn-0.18Zr-0.10V-0.06Ti (2219-T6)
- ASTM B247 – Standard Specification for Aluminum and Aluminum-Alloy Die Forgings, Hand Forgings, and Rolled Ring Forgings
- The Aluminum Association – International Alloy Designations and Chemical Composition Limits (Teal Sheets)
- ASM Handbook, Vol. 2 – Properties and Selection: Nonferrous Alloys and Special-Purpose Materials
DTD 5004 aerospace aluminium (aluminum) forgings: questions
Is 5004 an aluminium-magnesium (5xxx) alloy?
Not in this context. DTD 5004 is a British aerospace specification for an Al-Cu-Mn heat-treatable forging alloy with nominal 6 % copper and 0.3 % manganese.
Is DTD 5004 the same as 2219?
The nominal compositions are close, but the documents differ in limits and test requirements. 2219 forgings can replace DTD 5004 parts only with design-authority approval.
What condition are DTD 5004 forgings supplied in?
Normally solution treated and precipitation treated (the T6-type condition). Forging stock and solution-treated intermediate conditions are also available.
Why is this alloy used at elevated temperature?
High-copper Al-Cu-Mn alloys retain strength and resist creep better than 6xxx and 7xxx alloys at around 150 – 250 °C.
Do you supply DTD 5004 forgings internationally?
Yes. Metline supplies forgings worldwide from Mumbai, certified to the specification on your order, with export packing.
Need DTD 5004 forgings or an approved alternative?
Send the drawing, specification issue and quantity. We will confirm feasibility and documentation.
