T-1 ALUMINUM APPLICATIONS FOR BOATS AND YACHTS

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7/01T-1ALUMINUM APPLICATIONS FOR BOATS AND YACHTSTable of ContentsREFERENCED ORGANIZATIONS . 1REQUIREMENTS - MATERIALS . 1PAINTING . 3BI-METALLIC CONNECTIONS . 3.

T-17/01T-1ALUMINUM APPLICATIONS FOR BOATS AND YACHTSThis technical information report provides information on the use of aluminum for constructing outboard boats using rivetedconstruction, outboard boats using welded construction, and inboard powered boats and yachts using welded construction. Thereport recognizes that every design and construction problem cannot be covered or foreseen. Qualified naval architects and/ormarine engineers and aluminum production technical staff should be consulted before building a boat or yacht with inboardpower.REFERENCED ORGANIZATIONSABYC - American Boat & Yacht Council, Inc., 3069 Solomons Island Road, Edgewater, MD 21037 Phone: (410) 956-1050.Fax: (410) 956-2737. Web site: www.abycinc.org.Aluminum Association, 900 - 19th Street NW (#300), Washington, DC 20006-2168. Phone: (202) 862-5100. Fax: (202) 8625164. Web site: www.aluminum.org. This association publishes the following materials:1.2.3.Aluminum Standards and DataSpecifications for Aluminum StructuresEngineering Data for Aluminum StructuresNFPA - National Fire Protection Association, One Batterymarch Park, PO Box 9101, Quincy, MA 02269-9101. Phone: (617)770-3000. Fax: (617) 770-0700. Web site: www.nfpa.org.USCG - United States Coast Guard, CFR - Obtain the Code of Federal Regulations and other government publications from theSuperintendent of Documents, United States Government Information, POB 371954, Pittsburgh, PA 15250-7954. Phone: (202)512-1800. Fax: (202) 512-2250. An excerpted edition of the CFR is available from ABYC, Inc., 3069 Solomons Island Road,Edgewater, MD 21037. Phone: (410) 956-1050. Fax: (410) 956-2737. Web site: www.abycinc.orgREQUIREMENTS - MATERIALSThe aluminum alloys listed in TABLE 1 are shown with numeric designations. These aluminum alloys are selected for theirresistance to salt water corrosion, and are the only aluminum alloys recommended for building boats and yachts.TABLE 1 – Aluminum Alloys Recommended for Building Boats and YachtsOUTBOARD BOATSRivetedCOMPONENTS1.Hull2.Hullstretch formed3.Hullnon-stretch formed4.5.TransomTransom-flat6.DeckingOUTBOARD BOATSWeldedINBOARD BOATSWelded5086-H116, H1176061-T4 5050-H34, H365052-H32 to H365086-H116, H1176061-T4, T6 5050-H365052-H32 to H365086-H116, H1176061-T63003, 3004 (temperdepending onapplication)5005-H1545050-H365052-H365086-H116, H1176061-T4, T6 5086-06061-T45052-H32, H345086-H116, H1176061-T6same as hullsame as hullsame as hullsame as hull 2001 American Boat & Yacht Council, Inc.1

T-17/01TABLE 1 – Aluminum Alloys Recommended for Building Boats and Yachts el10. Keel/extruded11. Keel/formed sheet INBOARD BOATSWeldedsame as hull6061-T4, T66062-T4, T6 6061-T46063-T6 5082-H345086-H116, H1175154-H34same as keel 5052-H345086-H116, H117LongitudinalsSplash railsChineStemEngine bedsBulkheadsBulkhead stiffenersStruts21. Rudders22. Rivets OUTBOARD BOATSWelded6061-T4, T66063-T5, T65050-H345052-H32, H345086-H116, H1176061-T4 12. Frames13.14.15.16.17.18.19.20.OUTBOARD BOATSRiveted6061-T4, T66063-T5, T65050-H365052-H32, H345154-H34same as keelsame as keel same as keelsame as keel 25. Castings/no particularstrength required same as hullsame as hullsame as hullsame as hullsame as hull5086-H116, H1176061-T6same as strutsWith 5050 & 5052 sheet,use 6053-T61, 3003-F.With 5086 sheet, use6053-T61.With 6061 sheet, use6061-T6, 6053-T6123. Fasteners24. Castings/for strength5086-H116, H1176061-T6same as hull355-T6, or356-T6, or357, sand & permanentmold43-F, orF214-F, sand andpermanent moldA214-F permanent mold13, 43, 218, 360 die26. Welding wire27. Fuel tanks28. Potable water tanks 2001 American Boat & Yacht Council Inc.2 355-T6, or356-T6, or357, sand & permanentmold43-F, orF214-F, sandA214-F, permanent mold13, 43, 218, 360 dieWith 3003 sheet, use1100, 4043. With 5052 sheet, use5356, 5154, 5052. With 5086 sheet, use5183, 5356. With 6061 sheet, use4043, 5154, 5356See Note 1. 6061-T6 bolts & nutsSee Note 6.355-T6, or356-T6, or357, sand & permanentmold43-F, orF214-F, sandA214-F, permanent mold13, 43, 218, 360 dieWith 3003 sheet, use1100, 4043. With 5052 sheet, use5356, 5154, 5052. With 5086 sheet, use5183, 5356. With 6061 sheet, use4043, 5154, 5356See Note 1.See Note 2. Not recommended. SeeABYC H-23.

T-17/01TABLE 1 – Aluminum Alloys Recommended for Building Boats and Yachts (cont.)OUTBOARD BOATSRivetedOUTBOARD BOATSWelded29. Fuel piping & fittings30. Potable water pipe &fittings31. Sea water pipe &fittingsINBOARD BOATSWelded Alclad 3003, 3003- H18 Alclad 6061-T6 Alclad 6063, T6See Note 3.Not recommended. See ABYCH-23same as fuel piping & fittingsSee Notes 3, 4, and 5.NOTES: (1) With high silicon casting alloys such as 43, 356, and 357, use 4043 filler wire when welding to thin sheet. The5000 series filler alloys can be used in welding to wrought alloys in heavy sheet or plate gauges. With 214 cast alloy, 5000series fillers such as 5254, 5356, and 5183 are preferred to 4043.(2) For gasoline fuel tanks, refer to the USCG Title 33 CFR Section 183.510, and ABYC H-24, Gasoline FuelSystems. For diesel fuel tanks, refer to ABYC H-33, Diesel Fuel Systems. The National Fire Protection Association (NFPA)302, Motorcraft, also contains requirements for both gasoline and diesel fuel tanks.(3) If suitable aluminum alloy or stainless steel valves are not obtainable, use non-ferrous tubing and connect toaluminum tank by insulated flange or stainless steel nipple. For fuel systems, see ABYC H-24, Gasoline Fuel Systems. Forthru-hull fittings see ABYC H-27, Seacocks, Thru-hull Fittings, and Drain Plugs.(4) Stainless steel or plastic is recommended. Metallic sea valves or fittings should be galvanically compatible withor isolated from the hull.(5) Refer to ABYC H-27, Seacocks, Thru-hull Fittings, and Drain Plugs.(6) These materials are suitable for the following applications: Hardware to deck and hull; guard rails to hull; strutto hull, and water intake scoops to hull. 18-8 stainless steel fasteners can be used for above-water applications and should beused for fastening the engine to the engine bed.PAINTINGSurface preparation, cleanliness, profile, atmospheric conditions at time of application and coat thickness should be in conformitywith the printed instructions of the particular paint manufacturer. The paint manufacturer should be consulted regardingpreparation and application techniques and requirements. Selection and application of anti-fouling paints on aluminum requirespecial attention. Anti-fouling paints containing copper or mercury in any form (i.e., oxide chloride or mercuro-organiccompounds) are not to be used on aluminum under any circumstances because the mercury will destroy the aluminum by formingan amalgam. If applied to aluminum hulls, anti-fouling paints containing copper may cause galvanic corrosion. A barrier coatshould be applied following the paint manufacturer recommendations.BI-METALLIC CONNECTIONSAluminum may become anodic and corrode when in contact with other metals commonly used in marine applications. Thisphenomenon is referred to as galvanic corrosion, and is likened to the action of a wet battery. The severity of galvanic corrosionof aluminum is potentially greater when coupled to copper or copper-bearing alloys, such as bronzes and brasses, than whencoupled to steel, stainless steel, or nickel alloys. Bi-metallic connections between aluminum and other metals are undesirable, butsometimes unavoidable. Through appropriate design, galvanic corrosion of aluminum in these bi-metallic connections can becontrolled. The means of control in practice depends to a certain extent upon the particular application and expected serviceconditions. Greater care must be taken to control galvanic corrosion of dissimilar metals under water, as compared to abovewater applications, because seawater is a good conductor of corrosion current. See ABYC E-2, Cathodic Protection.The most frequently used method of preventing dissimilar metal corrosion is to separate or insulate the dissimilar metals bymeans of non-metallic, chemically-inert materials of high electrical resistance. Accordingly, the galvanic current flow is stifledand corrosion controlled. FIGURE 1 illustrates a means of insulating dissimilar metal joints between aluminum and steelthrough the use of non-metallic, inert materials. The various non-absorbent insulating materials employed include natural andsynthetic rubbers, plastic tapes, caulking compounds, mastics, and mixed organic polymers. The names of some proprietarycompounds of 2001 American Boat & Yacht Council, Inc.3

T-17/01these materials include Neoprene, Fairprene, Presstite, P.A.W. Tape, and Alumalastic. An alternative method of insulatingdissimilar metals in above-water and underwater applications is to paint the surfaces of both metals with a corrosion-inhibitivepaint.Bi-metallic connections between aluminum and copper, or copper-rich alloys, such as the brasses or bronzes, should be avoidedwherever possible and many parts normally made in brass or bronze alloy have been redesigned in aluminum alloy or stainlesssteel for this reason. Where aluminum to copper joints cannot be avoided, control of galvanic corrosion is achieved through theuse of insulating materials as described above and by painting.The use of wood treated with preservatives containing copper compounds in contact with aluminum should be avoided. Inaddition, surfaces of wet or unseasoned woods in contact with aluminum should be painted with aluminum-pigmented paint.FIGURE 1 – CONNECTIONS OF DISSIMILAR METALSAluminum plateAluminum stiffenerSealing compoundNon absorbentinsulating gasketmin. thickness 1/32"Galvanized steelground barSteel rivets hammered down onsteel side, scratched, brushedand sprayed with aluminum orzinc to a thickness of about0.005", followed by several coatsof a zinc chromate paint.Sealing compoundAt least 1" clearanceWood deckSteel deckInside 2001 American Boat & Yacht Council Inc.4Weather side

T-17/01TABLE 2 – TYPICAL MECHANICAL PROPERTIES(1) FOR WROUGHT ALLOYS – For properties not listed, contact youraluminum supplier.Alloy and Temper3003-B145005-H154*5050-05050- si)in 2 inches(percent)1/16 0031,00012HARDNESSBrinellNumber(500 kg load;10 mm )(psi)MODULUSModulus 010.0 x 10610.0 x 10610.0 x 10610.0 x 10610.0 x 10610.2 x 10610.0 x 10610.2 x 10610.2 x 10610.3 x 10610.3 x 10610.3 x 10610.2 x 10610.2 x 10610.2 x 10610.2 x 10610.2 x 10610.2 x 10610.2 x 10610.2 x 10610.2 x 10610.0 x 10610.0 x 10610.0 x 106*Pattern sheetNOTES: (1) Properties listed are for information only and are not guaranteed.(2) Ultimate bearing strength with edge distance 2.0 times rivet diameter.(3) Based on 500,000,000 cycles of completely reversed stress using the R.R. Moore type of machine and specimen.(4) Average of tension and compression moduli; compression modulus about two percent greater than tensionmodulus.TABLE 3 – MECHANICAL PROPERTY LIMITS FOR EXTRUSIONS – For properties not listed, contact your aluminumsupplier.Alloy and hes)Area(squareinches)AllUp thru 0.2490.250 and overUp to 1.000Up thru 0.1240.125-1.000Up thru 5Up thru 5AllUp thru 5AllAllAllAllAllAllUp thru 32AllAllUp thru ,00030,00030,00039,00035,00030,00031,000Yield StrengthMinimum(psi)Elongation(2) in 2inches or 4D(3)(percent 14,00011,00012,000168108810121212NOTES: (1) The thickness of the cross section from which the tension test specimen is taken determines the applicablemechanical properties. For material 1-1/2 inches or less in thickness, when not tested in full section, the tension test 2001 American Boat & Yacht Council, Inc.5

T-17/01specimen is taken from the center of the section. For material over 1-1/2 inches in thickness, the specimen is taken midwaybetween the center and the surface. Specimens are taken parallel to the direction of extrusion.(2) For material of such dimensions that a standard test specimen cannot be taken, or for material thinner than0.062 inch, the test for elongation is not required.(3) “D” represents specimen diameter.TABLE 4 - TYPICAL MECHANICAL PROPERTIES FOR DIE-CASTING ALLOYS - For properties not listed, contact youraluminum supplier.AlloyTensile Strength(psi)Yield Strength (offset 0.2%)(psi)Elongationpercent in2 0027,00027,0002.09.08.03.0Endurance LimitR.R. Moore typespecimen500,000,000 cycles(psi)19,00019,00028,00020,000Shearing Strength(psi)25,00017,00023,00028,000TABLE 5 - TYPICAL MECHANICAL PROPERTIES FOR PERMANENT MOLD ALLOYS - For properties not listed, contactyour aluminum supplier.Alloy andTemperTensileStrength(psi)Tensile YieldStrength(offset 0.2%)(psi)Elongationpercent in 2inchesCompressiveYield Strength(offset 0.2%)(psi)BrinellHardness(500 kg load10 mm ball)ShearingStrength(psi)35643 FA214F356-T6355-T6Almag 0-EnduranceLimit R.R.Moore E 6 - TYPICAL MECHANICAL PROPERTIES FOR SAND CASTING ALLOYS - For properties not listed, contactyour aluminum supplier.Alloy andTemperTensileStrength(psi)Tensile YieldStrength(offset 0.2%)(psi)Elongationpercent in 2inchesCompressiveYield Strength(offset 0.2%)(psi)BrinellHardness(500 kg load10 mm ball)ShearingStrength(psi)35743 FF214F356-T6356-T51355-T6Almag 0028,00022,000 2001 American Boat & Yacht Council Inc.6Endurance LimitR.R. Moore ,0009,00010,0008,000

T-17/01TABLE 7 - MECHANICAL PROPERTY LIMITS(1) FOR PIPE - For properties not listed, contact your aluminum supplier.Alloy and TemperPipe Sizein inches6061-T66061-T66063-T63003-H18under 1”1” and overAllunder 1”Ultimate StrengthMinimum(psi)42,00038,00030,00027,000Yield tion in 2 inches or4D(2)(percent minimum)12108-NOTES: (1) Specimens tested parallel to the direction of working.(2) “D” represents diameter of cut-out specimen.(3) Mechanical property limits are shown for un-clad pipe. Clad pipe properties are slightly lower.TABLE 8 - MECHANICAL PROPERTY LIMITS FOR RIVETS AND WELDING WIREFor Rivets(1)3003 – F6053 - T616061 - T6For Welding Wire(2)110040435052515451835356555455565654NOTES: (1) Mechanical property limits can be obtained directly from manufacturer or through handbooks.(2) For weld properties, contact the various aluminum producers as many factors determine efficiency.TABLE 9 - RECOMMENDED RIVET DIAMETERSMaterial Thickness(1) in inches0.028 to 0.036Over 0.036 to 0.048Over 0.048 to 0.064Over 0.064 to 0.080Over 0.080 to 0.104Over 0.104 to 0.128Over 0.128 to 0.188Over 0.188 to 0.20Over 0.20 to 0.25Over 0.25 to 0.30Over 0.30 to 0.35Over 0.35 to 0.40Over 0.40 to 0.55Over 0.55 to 0.70Rivet Diameter in /47/8NOTES: (1) Thickness referred to is that of thinnest component.(2) The edge distance for riveting should normally be 2D (where D rivet diameter) and never less than 1-1/2D.With these edge distances, the bearing strength of aluminum alloys may be taken as 1.8 times the tensile strength. The rivetpitch should not be less than 3D. For water-tightness, the maximum is 4D or 10T (i.e., the thickness of thinnest material inthe joint), whichever is smaller.(3) Check with rivet manufacturers for special conditions and problems. 2001 American Boat & Yacht Council, Inc.7

T-17/01* * * * *Origin and Development of ABYC T-1, Aluminum Applications for Boats and Yachts.ABYC T-1, originally issued as ABYC S-1, was approved for publication in the late 1960’s. An update was issued in 1973. In1998, the designation of the document was changed from S-1 to T-1. The July 2001 update is the work of the TechnicalInformation Project Technical Committee.* * * * *ABYC technical board rules provide that all reports, including standards and technical information reports, are advisory only.Their use is entirely voluntary. They are believed to represent, as of the date of publication, the consensus of knowledgeablepersons, currently active in the field of small craft, on performance objectives that contribute to small boat safety.The American Boat & Yacht Council assumes no responsibility whatsoever for the use of, or failure to use, standards ortechnical information reports promulgated by it, their adaptation to any processes of a user, or any consequences flowingtherefrom.Prospective users of the standards and technical information reports are responsible for protecting themselves against liability forinfringement of patents.The American Boat & Yacht Council standards and technical information reports are guides to achieving a specific level ofdesign or performance, and are not intended to preclude attainment of desired results by other means. 2001 American Boat & Yacht Council Inc.8

thru-hull fittings see ABYC H-27, Seacocks, Thru-hull Fittings, and Drain Plugs. (4) Stainless steel or plastic is recommended. Metallic sea valves or fittings should be galvanically compatible with or isolated from the hull. (5) Refer to ABYC H-27, Seacocks, Thru

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