BAC Specification Aluminum Alloys Controls & Processes

BAC 5602

Heat Treat of Aluminum Alloys

BMS Specification – Heat Treatment Process for Aluminum Alloys
Solution Heat Treating | Precipitation Hardening (Aging) | Annealing

AS9100D / ISO 9001

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Quick Specification Facts

Spec Number BAC 5602

Material Aluminum Alloys

Spec Type BAC (Boeing Process Specification)

Category Controls & Processes

Process Type Heat Treatment (Solution, Aging, Annealing)

Issuing Org The Boeing Company

Applicable Forms Bars, Sheet, Plate, Forgings, Extrusions, Tubing

Certification AS9100D / ISO 9001 with full MTR traceability

Specification Overview

BAC 5602 is a Boeing process specification that establishes the requirements for heat treatment of aluminum alloys used in aerospace manufacturing. Issued by The Boeing Company, this specification defines the procedures, equipment, and process controls required for solution heat treating, precipitation hardening (aging), and annealing of aluminum alloy materials and parts.

Compliance with BAC 5602 ensures that aluminum alloy components achieve the required mechanical properties—including tensile strength, yield strength, and hardness—through controlled and repeatable thermal processing. The specification is widely referenced in Boeing production programs and by suppliers throughout the commercial and military aerospace supply chain. Proper adherence to BAC 5602 requirements is critical to maintaining material integrity, dimensional stability, and long-term fatigue performance in flight-critical aluminum structures.

Heat Treatment Processes Covered

Solution Heat Treating

Precipitation Hardening

Artificial Aging

Quenching

Annealing

Process Control

BAC 5602 provides detailed requirements for each heat treatment process, including temperature ranges, soak times, quench media and methods, aging temperatures and durations, and furnace qualification requirements. All processes must be performed using certified and calibrated equipment by approved processors.

Applicable Aluminum Alloy Series

Alloy Series	Primary Alloying Element	Common Grades	Typical Treatment
2xxx	Copper (Cu)	2024, 2014, 2219	Solution + Aging (T3, T4, T6, T8)
6xxx	Magnesium + Silicon (Mg/Si)	6061, 6063, 6082	Solution + Aging (T4, T6)
7xxx	Zinc (Zn)	7050, 7075, 7175, 7475	Solution + Aging (T6, T73, T7351)
1xxx / 3xxx / 5xxx	Pure Al / Mn / Mg	1100, 3003, 5052	Annealing (O temper)

Applicable alloys, process parameters, and temper designations are defined in the current revision of BAC 5602. Consult the specification directly for precise requirements. Aero-Vac provides full mill test reports (MTRs) with certified chemistry and mechanical properties for every order.

Key Properties & Specification Details

Property / Attribute	Details
Specification Number	BAC 5602
Issuing Organization	The Boeing Company
Specification Type	Process Specification (Heat Treatment)
Category	BMS, Controls & Processes, Specifications
Material Covered	Aluminum Alloys (2xxx, 6xxx, 7xxx series and others)
Processes Defined	Solution Heat Treating, Precipitation Hardening, Aging, Quenching, Annealing
Applicable Forms	Bars, Sheet, Plate, Forgings, Extrusions, Tubing, Structural Parts
Equipment Requirements	Qualified and calibrated furnaces, quench tanks, and process control systems
Industry Application	Boeing commercial and military aerospace programs
Temper Designations	T3, T4, T6, T73, T7351, T8, O (per applicable alloy)
Certification Available	AS9100D / ISO 9001, Certificate of Conformance, MTR

Typical Applications

Aerospace Structural Components: Wing spars, fuselage frames, bulkheads, ribs, and skin panels fabricated from heat-treated aluminum alloys per BAC 5602 for Boeing commercial and military aircraft programs.

Machined Parts & Fittings: Precision-machined brackets, fittings, housings, and connectors requiring controlled mechanical properties achieved through solution heat treating and aging per BAC 5602.

Forgings: Aluminum alloy forgings used in landing gear components, engine pylons, and other high-load structural applications where BAC 5602 heat treatment ensures optimal strength-to-weight ratio.

Extrusions & Bars: Extruded structural sections, bars, and rod stock processed per BAC 5602 for use in Boeing aircraft assembly and subcontractor fabrication programs.

Defense & Military Programs: Aluminum components for military aircraft, rotorcraft, and defense systems requiring Boeing-approved heat treatment documentation and process compliance.

Frequently Asked Questions – BAC 5602

What is BAC 5602 and what does it cover?

BAC 5602 is a Boeing process specification that establishes the requirements for heat treatment of aluminum alloys used in aerospace manufacturing. It defines the procedures, equipment qualifications, and process controls for solution heat treating, precipitation hardening (aging), quenching, and annealing of aluminum alloy materials and parts. Compliance with BAC 5602 ensures that aluminum components achieve the required mechanical properties—such as tensile strength, yield strength, and hardness—necessary for Boeing commercial and military aircraft programs. The specification falls under the BMS Controls & Processes category and is referenced throughout Boeing's supply chain.

What aluminum alloys are covered by BAC 5602?

BAC 5602 applies to a broad range of heat-treatable aluminum alloys commonly used in aerospace manufacturing. This includes the 2xxx series (copper-based, such as 2024 and 2219), the 6xxx series (magnesium-silicon-based, such as 6061), and the 7xxx series (zinc-based, such as 7050, 7075, and 7175), among others. Non-heat-treatable alloys (such as 1xxx, 3xxx, and 5xxx series) may be addressed for annealing processes. The specification provides specific temperature ranges, soak times, quench requirements, and aging parameters for each applicable alloy and temper designation.

Does Aero-Vac supply aluminum material compliant with BAC 5602 with full certifications?

Yes. Aero-Vac supplies aluminum alloy material processed in accordance with BAC 5602 heat treatment requirements, fully traceable to mill test reports (MTRs) confirming chemical composition and mechanical properties. We are AS9100D/ISO 9001 certified with a 99.6% quality rating. Every order ships with certificates of conformance, material certifications, and chemical/mechanical test reports. Electronic delivery of all documentation is available for fast turnaround. If your Boeing program requires additional process documentation or special approvals, our quality team can coordinate as needed.

What forms and sizes of BAC 5602 aluminum does Aero-Vac stock?

Aero-Vac maintains inventory of BAC 5602-compliant aluminum alloys in multiple product forms including bars (round, flat, and square), plate, sheet, extrusions, forgings, and tubing. Common grades stocked include 7075, 7050, 2024, and 6061 in a wide variety of standard sizes and tempers. We can provide custom-cut lengths, discs, and blocks from our in-house processing facility at the Port of Kalama. For non-standard dimensions or specialty tempers, our team can source from our global supplier network. Contact us with your specific size requirements for a prompt quote with availability and lead time.

What are the typical lead times for BAC 5602 aluminum material?

In-stock BAC 5602-compliant aluminum material is typically available for same-day or next-day shipment. For custom-cut or specially processed orders, our standard lead time is 2–4 weeks—significantly faster than the industry average of 8–12 weeks. Specialty forgings or items requiring mill production may require 4–8 weeks depending on quantity and form. We prioritize urgent aerospace and Boeing program requirements and will always provide honest, upfront delivery estimates. Rush processing is available on select items.

Can Aero-Vac provide value-added processing for BAC 5602 aluminum material?

Yes. Aero-Vac operates a complete in-house processing facility at our Port of Kalama location. For BAC 5602 aluminum alloys, we offer precision saw cutting (including disc and ring cutting), surface grinding, trepanning, turning, and milling. We also provide comprehensive mechanical and non-destructive testing services in-house. Having all capabilities under one roof allows for faster turnaround, tighter quality control, and reduced overall cost compared to using multiple vendors. Contact us to discuss your specific processing requirements for BAC 5602-compliant aluminum components.

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