Riveting
The standard joining method, using 2117-T4 or 2017 rivets. Aircraft-style practice with sealant in faying surfaces works well for race structures.
High-strength heat-treatable sheet
2024 O / T4 Aluminium Sheet for Automotive Use
2024 sheet is a high-strength aluminium-copper-magnesium alloy supplied annealed (O) for forming and heat treatment, or solution treated and naturally aged (T3, T4) for maximum strength. In vehicles it is used for highly stressed brackets, panels and motorsport structures rather than mass-produced body panels. Metline supplies bare and clad 2024 sheet to customers worldwide.
- Alloy
- 2024 (Al-Cu-Mg)
- Tempers
- O, T3, T4, T42
- Thickness
- About 0.5 – 3.5 mm sheet
- Standards
- ASTM B209 · EN 485 · AMS
Is 2024 sheet used for car bodies?
Not for mainstream body panels. Production car bodies use 5xxx sheet (5182, 5754) for inner parts and 6xxx sheet (6016, 6111, 6022) for outer skins, because those alloys form well, resist corrosion and can be welded. 2024 is roughly 60 – 70 % stronger than a paint-baked 6xxx panel, but it needs corrosion protection and cannot be fusion welded.
That combination makes 2024 sheet a specialist material in the automotive world. It is used in motorsport monocoques, crash structures and floor panels joined by rivets and adhesives; in high-strength brackets and gussets; in armoured and special-purpose vehicles; and in trailer or race-transport bodies built with aircraft-style riveting.
Two delivery conditions matter. 2024-O is soft and formable; parts are pressed in O, then solution heat-treated, quenched and naturally aged by the user (to T42). 2024-T3 / T4 sheet arrives at full strength and is used flat or with gentle bends.
2024 chemical composition (wt %)
| Element | Minimum | Maximum |
|---|---|---|
| Silicon (Si) | — | 0.50 |
| Iron (Fe) | — | 0.50 |
| Copper (Cu) | 3.8 | 4.9 |
| Manganese (Mn) | 0.30 | 0.9 |
| Magnesium (Mg) | 1.2 | 1.8 |
| Chromium (Cr) | — | 0.10 |
| Zinc (Zn) | — | 0.25 |
| Titanium (Ti) | — | 0.15 |
| Others, each / total | — | 0.05 / 0.15 |
| Aluminium (Al) | Remainder |
Alclad 2024 sheet carries a thin layer of high-purity aluminium (typically about 2 – 5 % of thickness per side) roll-bonded to each face. The cladding corrodes sacrificially and protects the copper-rich core, at the cost of slightly lower strength.
Mechanical properties of 2024 sheet
| Temper / thickness | Tensile strength | Yield strength (0.2 %) | Elongation (min.) | Hardness (typ.) |
|---|---|---|---|---|
| O, 0.4 – 3 mm | ≤ 220 MPa | ≤ 140 MPa (EN) / ≤ 97 MPa (ASTM) | 12 – 13 % | ≈ 47 HB |
| T4, 0.4 – 1.5 mm (EN 485-2 min.) | ≥ 425 MPa | ≥ 275 MPa | 12 % | ≈ 120 HB |
| T4, 1.5 – 3 mm (EN 485-2 min.) | ≥ 425 MPa | ≥ 275 MPa | 14 % | ≈ 120 HB |
| T3, typical | ≈ 483 MPa | ≈ 345 MPa | ≈ 18 % | ≈ 120 HB |
| T42 (heat-treated by user from O), typical minimum | ≈ 425 MPa | ≈ 260 MPa | ≈ 15 % | — |
Values summarised from EN 485-2 and ASTM B209 and rounded; exact minimums depend on thickness band, cladding and standard edition. The certificate gives the guaranteed and measured values.
Physical properties
- Density
- 2.78 g/cm³
- Modulus of elasticity
- 73 GPa
- Thermal conductivity
- about 120 W/m·K (T3)
- Melting range
- about 502 – 638 °C
Forming and heat treating 2024 sheet
- Form in O or freshly quenched (W)O-temper 2024 bends to about 0 – 1 × thickness. Parts can also be formed within an hour or two of quenching, before natural ageing starts, or kept refrigerated to delay ageing.
- Solution heat treatHeat to about 490 – 495 °C, soaking according to thickness, in an air or salt-bath furnace with accurate temperature control.
- QuenchRapid water quench within seconds of leaving the furnace to retain copper in solution.
- AgeNatural ageing at room temperature for about four days gives T42. Artificial ageing to T62 raises yield strength and improves stress-corrosion resistance.
- ProtectAnodise, conversion coat and prime the finished part.
T3 / T4 sheet has limited formability (inside bend radii of about 2.5 – 4 × thickness, depending on gauge), so complex shapes are better pressed in O.
2024 sheet supply and tolerances
Typical supply range
- Thickness
- About 0.5 – 3.5 mm sheet; thicker plate available separately
- Width and length
- Standard 1,000 – 1,500 mm widths and 2,000 – 4,000 mm lengths, or cut to size
- Form
- Flat sheet, coil and cut blanks
- Cladding
- Bare or Alclad
- Tolerances
- EN 485-4 or ASTM B209 / ANSI H35.2; flatness to the same standards
- Surface
- Mill finish with PVC film or interleaving paper
Joining, machining and corrosion protection
Adhesive bonding
Structural epoxies bond 2024 well after anodising or another suitable pretreatment.
Welding
Arc welding is not recommended: hot cracking and strength loss. Earlier claims that 2024 sheet is easy to weld are incorrect.
Machining
T3 / T4 sheet machines and routes cleanly; O is gummy.
Corrosion
Use Alclad for bare exposure, or anodise and paint bare 2024. Avoid contact with steel or carbon fibre without isolation.
Temperature
Keep long-term service below about 120 °C for T3 / T4 to avoid over-ageing.
Automotive uses of 2024 sheet
- Motorsport chassis: riveted and bonded monocoque panels, bulkheads and floors
- Brackets and gussets: high-strength mounting plates cut or pressed from sheet
- Special vehicles: specialist and defence vehicle structures that follow aircraft design practice
- Race transport and trailers: riveted lightweight body panels
- Prototype parts: pressed and heat-treated components for performance testing
For production hoods, doors, roofs and inner panels, specify 5182, 5754 or 6016 body sheet.
2024 sheet compared with body-sheet alloys
| Property | 2024-T3 | 6016-T4 + paint bake | 5754-O | 7075-T6 |
|---|---|---|---|---|
| Typical yield strength | ~345 MPa | ~180 – 200 MPa | ~100 MPa | ~500 MPa |
| Formability (as delivered) | Low | Good | Very good | Low |
| Weldability | Poor | Good | Excellent | Poor |
| Corrosion resistance | Fair (Alclad good) | Good | Excellent | Fair |
| Typical automotive role | Motorsport, brackets | Outer panels | Inner panels, structure | Bumper beams (extruded), race parts |
How to order 2024 sheet
- SpecifyTemper (O, T3 or T4), bare or Alclad, thickness, width and length, quantity and end use.
- Confirm the standardASTM B209, EN 485 or the AMS specification on your drawing.
- QuoteWe confirm availability, tolerances, certification and delivery terms (EXW, FOB, CIF or DAP) for your plant or port.
- Process and inspectSheets are cut, filmed or interleaved and checked for thickness, flatness and surface.
- Document and shipEach lot ships with an EN 10204 3.1 mill test certificate, heat or lot traceability and a packing list, in seaworthy export packing. Third-party inspection can be arranged on request.
References and standards
- ASTM B209 – Aluminum and Aluminum-Alloy Sheet and Plate
- EN 485-2 – Sheet, strip and plate: mechanical properties
- EN 485-4 – Sheet, strip and plate: tolerances on shape and dimensions for cold-rolled products
- EN 573-3 – Aluminium and aluminium alloys: chemical composition and form of wrought products
- The Aluminum Association – International Alloy Designations and Chemical Composition Limits (Teal Sheets)
2024 aluminium (aluminum) sheet for automotive: frequently asked questions
Why is 2024 sheet not used for normal car body panels?
It cannot be fusion welded, needs corrosion protection and forms poorly in T3 / T4. 5xxx and 6xxx sheet give adequate strength with far easier production.
What is the difference between 2024-O and 2024-T4?
O is annealed: soft (under 220 MPa tensile) and formable. T4 is solution treated and naturally aged, with at least about 425 MPa tensile strength.
Can I heat treat 2024-O after forming?
Yes. Solution treat at about 490 – 495 °C, quench rapidly in water and age naturally for about four days to reach T42.
What is Alclad 2024?
2024 sheet with a thin pure-aluminium layer bonded to each side for corrosion protection. It is the normal choice when the sheet will be exposed without paint.
How is 2024 sheet joined?
By riveting, bolting and adhesive bonding. Arc welding is not recommended.
Can Metline supply 2024 sheet worldwide?
Yes, bare or clad, cut to size, with EN 10204 3.1 certificates and export packing.
Need 2024 sheet?
Send the temper, size, cladding and quantity. Our team will reply with availability and a delivered quotation.
