The 8000 Series aluminium alloys represent a specialized group of aluminium alloys that do not fall under the conventional alloying categories (1000–7000 series).
These alloys are engineered by adding elements such as lithium (Li), iron (Fe), silicon (Si), copper (Cu), magnesium (Mg), and other trace elements to deliver application-specific performance.
Unlike other aluminium series, the 8000 series is purpose-designed, meaning each alloy is developed to meet unique requirements such as high electrical conductivity, enhanced strength, superior barrier properties, elevated temperature stability, or extreme lightweight performance.
Typical Chemical Composition
| Element | Typical Range (%) |
|---|---|
| Aluminium (Al) | Balance |
| Iron (Fe) | 0.3 – 1.5 |
| Silicon (Si) | 0.1 – 0.8 |
| Lithium (Li) | 0.5 – 3.0 (selected grades) |
| Copper (Cu) | 0.1 – 2.5 |
| Magnesium (Mg) | 0.1 – 1.5 |
| Manganese (Mn) | 0.1 – 0.8 |
| Zinc (Zn) | ≤ 1.0 |
| Other Trace Elements | ≤ 0.5 |
Mechanical & Physical Properties
(Typical values – vary by alloy and temper)
Physical Properties
Density: 2.55 – 2.75 g/cm³ (Al-Li alloys even lower)
Melting Point: 480 – 660°C
Thermal Conductivity: 180 – 235 W/m·K
Electrical Conductivity: High (especially conductor grades)
Elastic Modulus: 70 – 80 GPa
Coefficient of Thermal Expansion: 20 – 23 × 10⁻⁶ /°C
Non-magnetic
High Reflectivity
Mechanical Properties
Tensile Strength: 90 – 520 MPa
Yield Strength: 40 – 480 MPa
Elongation: 3 – 30%
Hardness (HB): 25 – 150
Fatigue Resistance: Moderate to good (grade-dependent)
Strengthening & Metallurgical Behavior
Strengthening Mechanisms
Solid solution strengthening (Fe, Si, Mg additions)
Precipitation hardening (Al-Li and Cu-bearing grades)
Work hardening (rolling and cold deformation)
Metallurgical Characteristics
Iron forms dispersed intermetallic particles, improving strength without severe ductility loss
Lithium additions reduce density and increase elastic modulus
Fine grain structures improve formability and surface finish
Not primarily designed for extreme strength, but for functional optimization
Key Characteristics
1. Functional Performance-Driven Alloys
Designed for conductivity, thermal efficiency, or barrier performance rather than load bearing
2. Excellent Thermal & Electrical Conductivity
Ideal for cables, heat exchangers, and battery systems
3. Superior Foil & Thin Gauge Formability
Can be rolled into ultra-thin foils (< 10 microns)
4. Lightweight & High Efficiency
Al-Li grades significantly reduce structural weight in aerospace
5. Good Corrosion Resistance
Stable oxide layer ensures long service life in most environments
Refining & Processing Properties
Processing Methods
Continuous casting
Hot rolling & cold rolling
Foil rolling
Extrusion (selected grades)
Precision alloying for specialty performance
Heat Treatment
Mostly non-heat-treatable
Al-Li grades are heat-treatable
Weldability
Generally good
Al-Li alloys require controlled welding procedures
Surface Treatments
Anodizing
Cladding
Coating & laminating (especially for foil)
Chemical conversion coatings
Available Forms
Foils (Ultra-Thin & Heavy Gauge)
Sheets & Plates
Coils
Electrical Rods & Wires
Extruded Profiles
Clad & Laminated Products
Aerospace-Grade Forgings (Al-Li)
Applications of 8000 Series Aluminium
1. Packaging Industry
Food packaging foil
Pharmaceutical blister packs
Aseptic packaging
Flexible laminated packaging
2. Electrical & Power Industry
Electrical conductors
Transformer windings
Cable sheathing
3. Heat Transfer Systems
Heat exchangers
Radiator fins
HVAC components
4. Aerospace & Defense
Aircraft fuselage panels (Al-Li grades)
Cryogenic fuel tanks
Satellite structures
5. Battery & Energy Systems
Lithium-ion battery casings
Energy storage systems
Thermal management plates
Advantages of 8000 Series Aluminium
Broad range of specialized properties
Excellent electrical & thermal performance
Superior foil rollability
Lightweight with high efficiency
Good corrosion resistance
High recyclability
Cost-effective for mass applications
Why Choose 8000 Series Aluminium?
The 8000 Series aluminium alloys are chosen when functional performance outweighs structural strength requirements.
Whether the application demands exceptional conductivity, ultra-thin foil capability, lightweight aerospace structures, or advanced thermal efficiency, the 8000 series provides tailored solutions that no other aluminium family can match.
From food packaging and electrical grids to next-generation aerospace and energy systems, 8000 series alloys enable performance, efficiency, and sustainability at scale.