Advanced Metalworking Solutions for
Naval Systems that Go in Harm's Way

Aluminum Alloy 2519 Material Evaluation for the Advanced Amphibious Assault Vehicle


The objective of this project was to develop and demonstrate extrusion and forging technology, weld procedures and corrosion protection techniques to enable the successful implementation of high-strength aluminum alloy 2519 (2519) armor plate in the construction of the Advanced Amphibious Assault Vehicle (AAAV) and possibly other combat vehicle platforms.

Technical Approach

  • Develop extrusion and forging technology for 2519 to enable weight reduction
  • Develop alternative weld methods, such as friction stir welding (FSW), for achieving satisfactory plate-to-plate butt welds
  • Apply advanced, low maintenance corrosion protection schemes


  • High-Strength 2519 extrusions vs. 6061 extrusions (40-percent higher strength)
  • Increased ductility of butt weldments using FSW, thus leading to easier fabrication of the overall structure and reduced manufacturing time
  • Identification of a cost-effective corrosion protection scheme capable of protecting the vehicle in the intended service environment
  • Provide cost savings through weight reduction, improved manufacturing technology and life cycle extension


The goal was to transition the technologies to the AAAV Program Office for implementation into the rollout of the AAAV prototypes.




Walter Zeitfuss