Joining
Use fasteners or solid-state joining. Fusion welds melt and coarsen the dispersoid structure, cutting strength in the weld zone.
Heat-resistant aerospace extrusions
8009 H112 Aluminium Profile Extrusions
8009 extrusions are rods, bars and solid shapes pressed from consolidated powder of the Al-8.6Fe-1.8Si-1.3V alloy. They keep their strength at 250 – 315 °C, so they suit warm-zone brackets, fins, fasteners and engine-bay parts where normal aerospace extrusions soften. Metline sources 8009-H112 extrusions to AMS 4309 on enquiry for customers worldwide.
- Alloy type
- Al-Fe-V-Si, dispersion strengthened
- Temper
- H112
- Standard
- AMS 4309
- Forms
- Rod, bar, solid profiles
What are 8009 extrusions?
8009 is an aluminium alloy that cannot be made by normal casting. Its high iron and vanadium content must be frozen into a very fine structure by rapid solidification, then consolidated from powder into a billet that is extruded at high pressure. The result is a profile whose strength comes from stable silicide particles, not from ageing.
This matters for parts that sit near engines, exhausts or aerodynamically heated surfaces. A 2024 or 7075 extrusion loses strength progressively when held above about 150 °C, because its precipitates over-age. 8009 retains its structure, so a bracket designed at room temperature still has most of its capacity after thousands of hours at 250 °C.
An earlier version of this page listed a 3xxx-type chemistry (manganese 0.8 – 1.3 %), a solution-heat-treatment schedule and decorative uses such as guardrails, doors and windows. None of that applies to 8009; it is a specialist aerospace material and is not supplied for architectural profiles.
8009 chemical composition (wt %)
AMS 4309 names the alloy by its nominal composition. Certified analysis is supplied with each lot.
| Element | Nominal (AMS 4308 / 4309 title) | Approximate range | Role |
|---|---|---|---|
| Iron (Fe) | 8.6 | About 8.4 – 8.9 | Forms the Al12(Fe,V)3Si dispersoids that carry strength at temperature |
| Silicon (Si) | 1.8 | About 1.7 – 1.9 | Stabilises the cubic silicide phase |
| Vanadium (V) | 1.3 | About 1.1 – 1.5 | Slows coarsening of the dispersoids |
| Copper, magnesium, zinc | — | Low impurity levels | Not used for strengthening |
| Aluminium (Al) | Remainder | Remainder | About 88 % |
From powder to profile
- Rapid solidificationMolten alloy is cooled at extremely high rates, for example by planar-flow casting onto a chilled wheel or by atomisation, so the iron and vanadium cannot form coarse needles.
- Powder or flakeThe ribbon or droplets are broken down into flake or powder with a very fine internal structure.
- ConsolidationThe powder is degassed, canned and hot-pressed into a dense billet.
- WorkingThe billet is hot rolled into sheet or plate, extruded into rod and profiles, or forged.
- No age hardeningThe product is delivered in H112 (as-fabricated). Strength comes from the dispersoids, not from a solution-and-age heat treatment.
Extrusion of 8009 requires higher pressure than 6xxx alloys and lower speeds, and die design must account for the alloy's limited hot ductility. This is why the range of shapes is narrower than for conventional alloys.
What AMS 4309 covers
8009 extrusion supply range
- Round rod
- Up to 89 mm (3.5 in) diameter, per AMS 4309
- Rectangular and solid shapes
- Cross-sectional area up to about 64.5 cm² (10 in²)
- Length
- Up to about 2.5 m (100 in) under AMS 4309
- Temper
- H112
- Testing
- Chemistry and room-temperature tensile; elevated-temperature tests and ultrasonic inspection on request
- Machining
- Cut lengths, machined blanks and finished parts to drawing on request
Earlier claims of open profiles up to 850 mm wide and lengths up to 28 m described a conventional extrusion press, not a powder-metallurgy alloy, and have been removed.
| Shape | Typical use for 8009 | Note |
|---|---|---|
| Round rod | Fasteners, pins and turned engine parts | Most common form |
| Flat and rectangular bar | Brackets, fins and stiffeners | Machined to final shape |
| Hexagon bar | Nuts and fittings for warm zones | On enquiry |
| Angle, tee and channel | Stiffeners for warm panels | Small sections only, on enquiry |
| Machined profiles | Complex parts cut from rectangular bar | Often more economical than a custom die |
Properties at room and elevated temperature
Research on extruded spray-formed 8009 reports room-temperature tensile strength around 415 MPa and yield around 345 MPa, with both falling gradually as temperature rises. Rapidly solidified product can reach somewhat higher values. Design to the minimums in AMS 4309 and to elevated-temperature data agreed with the supplier.
| Property | 8009-H112 | 2024-T3511 | 7075-T6511 |
|---|---|---|---|
| Room-temperature tensile (indicative) | ~415 – 460 MPa | ~480 MPa | ~570 MPa |
| Room-temperature yield (indicative) | ~345 – 410 MPa | ~360 MPa | ~505 MPa |
| After long exposure at 250 °C | Little change | Significant loss | Severe loss |
| Creep resistance at 200 – 300 °C | Good | Fair | Poor |
| Weldability (fusion) | Poor | Poor | Poor |
| Density | About 3.0 g/cm³ | 2.78 g/cm³ | 2.81 g/cm³ |
The mechanical and processing figures on an earlier version of this page (310/280 MPa minimum, water quench from 480 °C) described a heat-treatable alloy and did not apply to 8009.
Design and fabrication notes
Machining
Machines cleanly; expect higher tool wear from the hard intermetallic particles. Carbide or PCD tools are recommended.
Forming
Limited cold formability. Bend warm if needed and test first.
Temperature limits
Do not stress-relieve or process above about 450 °C. Do not heat-treat as for 2xxx or 7xxx alloys; it brings no benefit.
Corrosion
Free of copper and zinc, so general corrosion resistance is good; standard conversion coatings and paints apply.
Galvanic contact
Isolate from carbon-fibre composites and stainless steel with sealant or barrier layers, as for any aluminium alloy.
Where 8009 extrusions are used
- Brackets, clips and fittings in engine bays and nacelles
- Missile and projectile fins exposed to aerodynamic heating
- Fasteners and pins for warm structures where titanium would otherwise be used
- Compressor-section parts in small turbines and auxiliary power units
- Heat-exchanger headers and supports in bleed-air systems
How to order 8009 extrusions
- SpecifyAlloy and temper, section drawing or size, and length, quantity and the governing specification with its revision (AMS 4309).
- ConfirmWe confirm the specification can be met, the tolerance class, any extra tests and the delivery terms (EXW, FOB, CIF or DAP).
- InspectMaterial is checked for dimensions, straightness and surface condition; tests named on the order are carried out or arranged with a third party.
- 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 wooden cases, coils on pallets or reels, shipped by sea or air to your port or door.
References and standards
- SAE AMS 4309 – Aluminum Alloy Extrusions 8.6Fe-1.8Si-1.3V (8009-H112), Powder Metallurgy Product, Strain-Hardened
- SAE AMS 4308 – Aluminum Alloy Sheet (8009-H112), Powder Metallurgy Product
- NASA Technical Reports Server – dispersion-strengthened Al-Fe-V-Si alloys
- ASM Handbook, Vol. 2 – Properties and Selection: Nonferrous Alloys and Special-Purpose Materials
8009 aluminium (aluminum) extrusions: frequently asked questions
What sizes does AMS 4309 cover?
Round extrusions up to 89 mm (3.5 in) diameter and rectangular or other solid shapes up to about 64.5 cm² (10 in²) cross-section, in lengths up to about 2.5 m.
Can 8009 profiles be heat treated to increase strength?
No. 8009 is not age-hardenable. It is supplied in H112 and its strength comes from dispersoids formed during rapid solidification.
Why choose 8009 over 2618 for hot parts?
2618 is a precipitation-hardened alloy that slowly loses strength with long exposure above about 150 °C. 8009 is thermally stable, so it holds strength better over long service at 200 – 315 °C.
Are hollow 8009 profiles available?
Rarely. Powder billets are usually extruded into solid sections; hollow parts are typically machined from rod.
Can 8009 be used for building profiles?
It is not suitable or economical for that. Architectural profiles use 6060, 6063 or 6005A.
Need a heat-resistant aluminium extrusion?
Share the section, service temperature and specification, and we will confirm whether 8009 or an alternative fits.
