Request A Quote | Credit Application | Have a question?

TOLL-FREE: (800)-444-0311 

Author: admin

Differences Between Cast and Wrought Aluminum Alloys

Posted on by admin

Aluminum alloys are categorized into two groups – cast aluminum and wrought aluminum alloy. These designations are based on the type or processing used to create each. At Howard Precision Metals, we are your leader for the supply of cast aluminum alloys used in making cast aluminum plate. You can trust our knowledge, experience, and resources, to help you obtain the quality aluminum cast and wrought products you need for your commercial or industrial applications.

Cast Aluminum Alloys

Cast aluminum alloys have aluminum as the primary metal with other alloying elements added. This group of alloys can be divided into heat-treatable and non-heat treatable cast aluminum alloy. In addition, these alloys have a comparatively low tensile strength, but help create cost-efficient products. The exceptional casting characteristics of this type of aluminum alloy is due to the significant presence of silicon in its composition.

Some of the beneficial characteristics of aluminum alloys that make them ideal as cast aluminum alloys include:

  • Ability to control grain structure
  • Good fluidity
  • Low melting point
  • Ability to strengthen through heat treatment
  • Low solubility of gasses
  • Good surface finish

At the same time, a cast aluminum alloy has some potential negative characteristics. These alloys are susceptible to shrinkage effects due to its high shrinkage characteristics. These alloys, including cast aluminum plate, also possess low ductility and are vulnerable to heat cracking. They also have a high solubility of hydrogen gas.

Wrought Aluminum Alloys

Wrought aluminum alloys also have aluminum as the primary metal. These alloys are used mostly for shaping processes such as extrusion, forging, and rolling. They are both heat-treatable and non-heat-treatable. Wrought alloys of aluminum represents about 85% of all aluminum alloys.

The alloying elements such as silicon, copper, zinc, and magnesium provide a heat-treatable alloy’s initial strength. They can be strengthened further through heat treatment. Non-heat-treatable forms have alloying elements such as silicon, manganese, and magnesium as their initial strength. These alloys can be strengthened further through strain hardening or cold working.

Differences Between Cast and Wrought Aluminum Alloys

Cast aluminum is a type of aluminum alloy with casting characteristics. Wrought aluminum, on the other hand, is ideal for shaping and machining after heat treatment.

Additional differences between these two types of aluminum alloys include:

Percentage of Alloying Elements

Wrought aluminum is an alloy that has been worked on by processes of mechanical working. These can include extrusion, rolling, and forging. On the other hand, cast aluminum is formed by the pouring of heated, molten aluminum in dies or patterns. Cast aluminum has a larger percentage of alloying elements in its constitution. In wrought aluminum, about 85% of its make up is aluminum.

Internal and External Defects

The important difference between wrought and cast aluminum alloys is that wrought aluminum alloys are usually free of external and internal defects, whereas cast aluminum alloys have many external and internal defects.

Melting Point

The melting point of cast aluminum alloy, including cast aluminum plate, is low, which gives it high cost-effectiveness, while the melting point of wrought aluminum alloy is high, giving it low cost-effectiveness.

Tensile Strength

The tensile strength of wrought aluminum alloy is higher than that of cast aluminum alloy.

Thickness

Cast aluminum alloys are typically thicker and heavier, while wrought aluminum alloys may be obtained down to a foil thickness.

Precision

Because of its low tensile strength, cast aluminum alloys achieve high precision due to the numerous external and internal defects. The ability of wrought aluminum to be processed on the other hand, allows it to undergo drilling, milling, grinding, and more, which means it is ideal for dimensional accuracy and precision parts.

Numbering Systems

There are two numbering systems for aluminum alloys. The categorizing of aluminum alloys uses a familiar four-digit number system. This system is used for the classification of wrought aluminum alloys and also a number of cast plates.

On the other hand, the classification for alloys used for the production of cast aluminum parts is different. Although this system also uses four digits, a decimal point is included between the third and fourth digits. Sometimes cast alloys are only given three numbers for their classification because the decimal is often zero.

Cast aluminum alloys offer a wider range of shapes and have a lower price per pound, while wrought aluminum alloy is better for processing with better mechanical properties. High-end applications in the aerospace and aviation fields make use of the surface finishes possible with wrought aluminum alloy.

Due to the different performance capabilities between cast and wrought aluminum alloys, they are used in different applications. Wrought aluminum can be seen in various aspects of the construction and ship building industries, and also for airframes, impellers, engine blades, landing gear parts, and propeller blades. Cast aluminum alloys are used often in the agricultural, automotive, and construction industries, including for pistons and transmissions, cylinder heads, engine boxes, hubs, instrument housings, turbine blades, window fittings, supercharger pumps, and farm equipment.

To learn about the cast aluminum plate and extruded aluminum products and services we offer at Howard Precision Metals, call us today at 800.444.0311 or request a quote.

Factors to Consider When Selecting an Aluminum Grade

Posted on by admin

Aluminum is offered in an array of grades and specifications which provide various strengths which are ideal for certain applications. One of the first factors to consider when choosing an aluminum grade is the use of the metal. Knowing the application allows you to determine the different types of aluminum grades which may be suitable. At Howard Precision Metals, we are your source for a wide array of aluminum alloy grades and products that are able to meet the structural needs of your applications.

For instance, aluminum alloy 2014 is ideal if you need strength, fatigue resistance, and machining capabilities, but it does not offer much corrosion resistance. On the other hand, aluminum alloy 1100 is preferred if your application does not have particular strength requirements, but does need weldability and corrosion resistance. Alloy 2011 is optimal for machining on lathes. Alloy 5052 provides one of the highest levels of fatigue resistance you will find among the different types of aluminum grades.

When evaluating aluminum grades for an application, consider the following factors to ensure you choose the best one for your requirements:

  • Strength
  • Machining
  • Weldability
  • Corrosion Resistance
  • Workability or Formability
  • Common end-use applications
  • Heat Treatment

Strength

Strength, which is an important factor for the selection of an aluminum grade in structural applications, is measured by the stress a material can sustain until it experiences deformation (yield strength) or breaking (tensile strength). If the stress applied to the material is lower than the yield strength, the material will return to its original shape when the load is removed. Plastic (permanent) deformation occurs when the stress is greater than the yield strength. Once that barrier is exceeded, the material will not return to its original shape when the load is removed.

Machining

Machining involves a process cutting with a cutting tool to remove small portions of material from a metal. If the aluminum alloy has good machinability, the cutting tool requires little power to cut and will also produce a good finish. This is an important factor in the selection of many different types of aluminum grades, particularly when the application requires less human labor and effort, higher accuracy, higher production, higher reliability, enhanced efficiency, and greater profits.

Weldability

Weldability is ideal when the application requires complex metal forming since it work-hardens significantly slower than other aluminum grades. If you choose aluminum alloy 1100, as a commercially pure aluminum grade, it will possess the softness and ductility that gives it exceptional workability.

The weldability of aluminum is important for many applications. Poor weldability of an aluminum alloy will not work when critical operational features of an application require a strong welded connection. Some of the applications that require good weldability include the manufacturing of chemical equipment, siding, cooking utensils, decorative trim, awnings, storage tanks, and more. As an example, the 3003 aluminum grade alloy possesses excellent weldability, good resistance to corrosions, and moderate strength.

Corrosion Resistance

The resistance to corrosion possessed by an aluminum alloy determines how well that alloy can resist deterioration due to oxidation or chemical reaction. Thus, it is a very important factor in the selection of an aluminum grade when the material will be subject to such conditions.

As an example, applications that are exposed to saltwater and marine atmospheres require exceptional corrosion resistance. Other applications that require good corrosion resistance include cooking utensils, aircraft parts, transportation industry parts, home appliances, and bulk processing food equipment.

Workability or Formability

Workability and formability are important factors to consider when the application requires good or excellent fatigue and strength resistance, along with a good strength-to-weight ratio. As an example, the transportation industry requires these characteristics in aluminum alloy for various parts and structural components used in aircraft.

Various aluminum grade products that may benefit from the characteristics of formability and workability include round bar, rectangular bar, square bar, flat plate and sheet, square tube, and hexagonal bar. Additional products and applications that often require these characteristics in aluminum alloy include luggage racks, construction tube, air cylinders, and lawn furniture.

Common Applications of Aluminum Grades

Knowing the applications of the aluminum alloy will help determine the best aluminum grade to choose. The various applications that call for different types of aluminum grades include general fabrication, general machining, metal spinning, aerospace, and architectural, among others.

Heat Treatment

It is important to know the heat treatability of certain aluminum grades when the application requires it for strength and other characteristics. The heat treatment process heats or cools the metal to extreme temperatures in order to achieve results such as the softening or hardening of the material. As mentioned, heat treating, enhances the strength of a metal, including aluminum alloy, increasing its ductility or flexibility.

In conclusion, if you have one or more applications that require the selection of the optimal aluminum grade, consider the factors mentioned above before making your selection.

Although we do not stock every grade of Aluminum, we do know which grades are typically used for most applications at that point you design engineer can walk you through the best alloy choice. To learn about the different types of aluminum grades we offer to match the requirements of your industry applications, call us today at 800.444.0311 or request a quote through the form on our website.

What is Aerospace Aluminum? Aluminum Alloys Used in the Aerospace Industry

Posted on by admin

Aluminum alloys are often the metal of choice for aerospace components designed by engineers due to its high-strength and corrosion resistance properties. In comparison to steel, it is a lightweight metal that carries enough strength to serve as the ideal option in many aerospace applications. At Howard Precision Metals, we have your aluminum aerospace needs covered with a selection of alloys that are tailored to aerospace applications, including those for commercial, private, and military aircraft. As you read on, we discuss the variety of Aluminum Alloys typically used, but in many critical components there is additional testing of the aluminum that is required to insure against failure, such as ultrasonic testing.

Aluminum in Aircraft

The vast majority of the airframe of modern aircraft is made from aluminum in terms of weight. For instance, aluminum is the preferred material option for wing, fuselage and supporting structures of military transport/cargo aircraft and commercial airliners. U.S. Navy aircraft use structural components made from fabricated wrought aluminum. Aluminum casting technology is a major focus now, with this technology able to create intricate shapes and achieve innovative designs, which keeps manufacturing costs to a minimum.

Aluminum in Spacecraft

Since the first aircraft was launched into space, aluminum has been a prominent material used for space structures. It is ideal because of its light weight and its capability to handle the powerful loads and stresses that occur during the launch and operation of spacecraft. Aluminum has been used extensively on many of the famous space missions in history, including those involving Apollo, Skylab, the International Space Station, and the Space Shuttles. Aluminum alloys perform exceptionally compared to many other metals in terms of dampening, minimizing weight, thermal management, and mechanical stability.

Aluminum Grades for Aerospace Applications

The aluminum grade you choose will depend on your specific aerospace application. Machinability and corrosion resistance are some of the key factors to consider when evaluating aluminum alloys for aerospace applications.

Alloy 2014 – A beneficial alloy choice for framework due to its strength and machinability. However, it does not provide the level of corrosion resistance other aluminum grades do. Therefore, it should not be used in environments with high corrosive environments or environmental stressors.

Alloy 2024 – 2024 Aluminum alloy is used extensively for aerospace and aircraft components. It possesses high tensile strength, is treatable, and stress resistant. It can also be heat treated. Aluminum 2024 plate and sheet are ideal for aerospace applications involving structures, aircraft wings, and repairs.

Alloy 3003 – This alloy possesses good weldability and corrosion resistance. It is not heat treatable but is one of the more common aluminum alloys used for aircraft and aviation applications.

Alloy 5052 – As another aluminum alloy not suitable for heat treatment, 5052 does have a high fatigue strength compared to other aluminum alloys. It possesses good formability and corrosion resistance properties and is used commonly for fuel tanks in aircraft.

Alloy 6061 – 6061 Aluminum alloy may be welded and brazed. It is a workable alloy with superb corrosion resistance. It is commonly used in the fuselage and wings.

Alloy 6063 – This alloy is an excellent choice for architectural structures and anodizing requirements. High corrosion resistance and high tensile properties are some of the features of this alloy. It is an alloy often used for aesthetic purposes.

Alloy 7050 – 7050 aluminum alloy is a great option for military aircraft and wing skins. This alloy may be reheated and is applicable for military aircraft and wing skins. It possesses a superb strength-to-weight ratio.

Alloy 7068 – Used extensively for aircraft applications, this alloy is one of the strongest available aluminum alloys for aerospace applications. It is a popular alloy grade for applications that involve exposure to high level environmental stressors. It possesses a high level of strength and corrosion resistance.

Alloy 7075 – Aluminum alloy 7075 has average corrosion resistance and high fatigue resistance. It compares to the strength of steel due to the high level of zinc in its composition. It is ideal for highly stressed parts such as fuselages.

Benefits of Aluminum for Aerospace Applications

Due to its high strength-to-weight ratio and other excellent properties, aluminum has been the preferred metal choice for aerospace projects. The various additional benefits afforded by aluminum includes:

  • Highly formable, enabling easy fabrication of small aerospace components
  • Durable under highly stressed condition, and pressure and temperature extremes
  • Cost-effective compared to other metals due to its lightweight properties.
  • High electrical conductivity

Aluminum Products Commonly Used for Aerospace Components

The types of aluminum products frequently used in aerospace parts include aluminum plate, sheet, and bar. Other products include aluminum pipe, tube, and other shapes. The versatility of aluminum alloys in the aerospace industry allows for its use in the construction of less costly and more reliable aircraft.

From now on, when you hear the term aerospace aluminum, remember that some of the key properties of this type of aluminum are its resistance to corrosion, light weight, and strength. These properties are vital for the safety and efficiency of aerospace vehicles.

For information about the aerospace aluminum we offer for aerospace industry applications, call us today at 866.602.3788 or request a quote.

What Aluminum Alloys Can Be Anodized?

Posted on by admin

Although many aluminum grades possess sufficient corrosion resistance and appearance for certain applications, sometimes it is desirable to enhance these properties. This is accomplished through the process of anodizing. The metal coating process of anodizing increases the quantity of aluminum oxide on the aluminum substrate surface. This has the effect of potentially increasing the metal’s ability to prevent corrosion and change its appearance. At Howard Precision Metals, we offer an extensive array of products made from aluminum alloys to meet the needs of your industrial applications.

Applications That Utilize Anodized Aluminum

Anodized aluminum is perfect for many applications in the architectural and construction industries. The colors of anodized aluminum do not peel, chip, or fade after exposure to sunlight making them highly suitable for many consumer, industrial, and commercial applications. Some common applications include construction items for the exteriors of buildings, doors, window frames, vents, and more.

Some aluminum alloys are better suited to anodizing than others. Different aluminum alloys contain varying types and amounts of alloying metals which result in coatings with different properties – some more desirable and some less desirable.

What Aluminum Alloys May Be Anodized?

The series 5XXX, 6XXX, and 7XXX series aluminum alloys are the most ideal for undergoing the anodizing process.

The Effect of Anodizing on Various Aluminum Alloys

On most aluminum alloys, the anodizing process can increase the size of the aluminum oxide layer. However, the amount of protection afforded by the aluminum oxide coating may be lacking the desired amount on some aluminum alloys. Also, after the anodization process, the layer of aluminum oxide may leave behind an unattractive dark grey, brown, or yellow color.

Below is what is likely to happen with the different aluminum series types when they are anodized:

1XXX Series

This is the pure aluminum series. When anodized, the aluminum oxide layer formed is somewhat shiny and clear. Due to the fact that the pure aluminum is relatively soft, the anodized aluminum may lack certain mechanical properties that are present in other aluminum alloys and be damaged easily.

2XXX Series

Aluminum alloyed with copper is what defines this alloy series. The addition of copper produces a hard and very strong aluminum alloy, enhancing the mechanical properties of the aluminum. However, the copper makes the alloys less than adequate for anodization. When 2XXX series aluminum alloys are anodized, a generally unappealing yellow colored oxide layer result. Also, the layer produced by anodizing delivers inadequate protection to the underlying aluminum alloy.

3XXX Series

This series of aluminum alloy consists of aluminum alloyed with manganese. The anodized layer produced provides reasonable protection for the substrate, but also produces an unappealing brown color. The brown color produced may also vary between the various grades and substrates. Thus, it can be challenging to maintain a similar color throughout various 3XXX series aluminum alloy metals.

4XXX Series

With the 4XXX series, silicone is alloyed with aluminum. The aluminum oxide layer produced from anodization protects the material very well. At the same time, the 4XXX aluminum alloy series possesses a gray color that is aesthetically unappealing. Oftentimes, 4XXX alloys are used to weld 6XXX alloys and other alloys. However, after anodizing these welded assemblies, the color of the base material will not match the weld metal.

5XXX Series

In this series, the aluminum is alloyed with manganese. Upon anodization, the alloys obtain a clear and strong oxide layer. Therefore, the 5XXX series of alloys is great for anodizing. However, it is important to take note of the following considerations when anodizing this aluminum alloy series.

For example, some of the alloying elements (silicone and manganese) must be kept inside a certain range. The types of anodization processes used with the 5XXX series is also important. A 4XXX series alloy may be used as welding filler metal instead of 5XXX to ensure the weld does not have a different color than other parts of the anodized assembly.

6XXX Series

The 6XXX alloy series has magnesium and silicon alloyed with the aluminum. This is an excellent series for the anodization process. Upon anodization, the oxide layer offers superb protection and it is also transparent in appearance. Along with being a great candidate for anodizing, the 6XXX series is also commonly used in structural applications due to its great mechanical properties.

7XXX Series

Zinc is the primary alloying element used in the 7XXX series of aluminum alloys. It responds the anodization process very well. The oxide layer is clear and provides superb protection against corrosion. If the level of zinc becomes excessive, the layer of oxide produced by anodization can change to a brown color.

For information about the extensive array of aluminum alloys we offer to help you meet the demands of your applications, give us a call today at 800.444.0311 or ask us for a quote using the form on our website.

Difference Between Cast Aluminum and Extruded Aluminum

Posted on by admin

If you are looking at manufacturing options for products or items needed for industrial or commercial projects that involve a decision between extruded aluminum and cast aluminum, we cover these two forming methods here. So, what is the difference between extruded aluminum and cast aluminum? Before laying out the differences, it is important to understand what each process involves. At Howard Precision Metals, we are your trusted source for custom extruded aluminum products that are required in numerous industry applications.

What is Die Casting?

The die casting process that creates aluminum products involves the melting of aluminum ingots, filling a die with the molten metal using a piston or power cylinder, and allowing the solidification of the aluminum as it cools in the die mold’s shape. The process is actually more involved than this, including steps such as adding alloying elements and deburring. However, the overall process is still straightforward.

Die castings is much different than the process for making cast aluminum plate as it produces near net shapes that may be completed in a wide array of sizes and can create intricate geometries for various applications – an engine block is one example. Once you create a tool steel die mold, you can cast the product many times over before the mold becomes non-useful due to deterioration. Various factors determine how many times you can reuse a mold, including the permissible tolerances for the final product, the part’s shape, and the processing conditions.

What is Extruding?

Custom extruded aluminum products are manufactured by forcing an aluminum billet at very high temperature through a die to achieve the intended cross-sectional form. Then, the extruded piece may be cut to the required length and undergo additional modifications, such as adding bolt holes or connection for joining various parts together.

Comparing the Two Processes

Die casting of aluminum or any metal is a different process that extrusion. In the die casting process, molten metal is injected with force into mold, referred to as a die. These dies may consist of complex shapes such as those with irregular cross-sections.

Custom extruded aluminum has advantages over aluminum shapes made from die casting. With some materials such as aluminum alloys containing zinc and magnesium, the extruded components have a rigidity similar to die cast parts, but often a higher ductility. Also, the costs for tooling with extrusion are often lower than for die casting.

On the other hand, die casting has some advantages over aluminum. Parts made through die casting are less elastic and have greater stiffness values than parts made through extrusion. Also, components made through die casting are often completely finished with surface textures and require little finish machining to complete the part.

One of the major benefits of die casting it is not restricted to creating components that have a uniform cross section. With extruded parts, additional cross-sectional changes or slots, holes and other design features require other machining services that carry an additional expense. During die casting, all the intended features of the piece can be incorporated into the mold in a one-step manufacturing process. However, a benefit that extrusions bring is strength. Typically, the process of elongating the grain and heat treating after extruding adds strength to the alloy. Die cast parts have the potential of porosity as well, which extrusions do not. There are pros and cons to each process, so it is best to consider all the benefits of each.

Choosing the Process Best for Your Project

Here is a short summary of the advantages and disadvantages of the die casting and extrusion processes:

Extrusion

  • Size of the billet limits the size of the shape
  • Wide range of shapes possible, but must have consistent cross-section (2 dimensional)
  • Produce a very smooth surface finish
  • Work hardening during forming increases the strength of the end product
  • A flexible process with minimal effort needed to make changes
  • Generally, less expensive than die casting which also makes it more ideal for short production runs
  • Extrusion dies cost less than molds for die casting, and new extrusion profiles can be easily made

Die Casting

  • Can produce larger finished pieces than through the extrusion process
  • Produces more intricate shapes than through extrusion (3 dimensional)
  • Produces a rough surface finish and can show imperfections, such as seams
  • Products manufactured through die casting are generally not as strong as extruded products. Also, porosity is possible if air gets trapped in the mold
  • Changes to a die mold can be costly and time consuming, taking several weeks for new mold preparation in some cases
  • Often more expensive than extrusion and often used in high production requirements to offset the higher upfront costs
  • Die molds are more time-consuming and costly than extrusion dies and usually require replacement more often

Whether you choose custom extruded aluminum production or cast aluminum plate production (or other shape production) will depend on the specific requirements of your project. Each processing method carries different manufacturing costs and results in different mechanical properties for the pieces produced.

If you need aluminum extrusions in the form of plate or other shapes, we are the premier aluminum extrusion supplier you can trust. For information about how we can help you with your custom extruded aluminum needs, give us a call today at 800.444.0311 or leave us a request for quote through our online form.

Why Do Machinists Prefer MIC-6® to Other Cast Plate Products?

Posted on by admin

MIC-6 has several trade named competitive products in the aluminum industry, including ALCA-5, K-100S, ATP-5 and Formodal Cast Aluminum Tool & Jig Plate. These products are similar in mechanical properties, and tolerances, but there is a reason engineers come back to Mic-6 time after time. Manufactured from an aluminum alloy with fine-grain characteristics, Mic-6 is free from internal stresses and is known as the flattest product in the industry. The internal stability of this material helps ensure its minimal movement while undergoing the machining process. At Howard Precision Metals, Inc., we are your premier source for MIC-6 cast aluminum tooling plate.

MIC-6 combines some of the best features machinists look for when machining cut aluminum plate. Within the cast plate industry, this tooling plate material is subjected to one of the most advanced manufacturing methods. The making of MIC-6 fosters inter-plate consistency and lowers the potential of material stability disruption through a process of stress entrapment. The stress relieving properties and granular structure of this plate facilitate the removal of metal at high speeds with minimal or zero distortion often present in flat-rolled metals. MIC-6 aluminum tooling plate possesses a number of beneficial features, including its machining qualities, light weight, smooth surface, flatness tolerance, and absence of tension, and contaminants.

MIC-6 – A Machined Product

As a machined product, Mic-6 tool and jig plate has a flat surface and a surface finish of at least 32 micro-inches on each side. This plate may be machined easily with minimal distortion issues involved. The tolerances of this plate may be maintained in the thousandths with the use of a proper aluminum machining process.

As an accurately machined and exceptional quality aluminum plate, MIC-6 has undergone a thermal stress relieving treatment that gives it dimensional stability when machined. The plate may typically be heated to temperatures up to 800°F (427°C) and, once cooled, the plate reverts to its original dimensions with minimal distortion based on the amount of machining performed. As a result of thermal treatment, the hardness will vary significantly with the thickness, but the plate will still keep its positive machining features.

MIC-6 Characteristics and Tolerances for Machining

Categorized as a 7000 series aluminum alloy, cast aluminum tool & jig plate is about one-third the weight of steel plate. MIC-6 is made using aluminum alloy with a very fine-grain structure with no internal stresses. Its lightweight characteristic often precludes the need for the use of heavy equipment for handling and installation, and it also reduces stress on connections. The plate is highly corrosion-resistant and requires no anti-corrosion coating as a result. Once a tool made from tool & jig plate is no longer useful or needed, the material has a higher salvage rate value than steels. When flatness and minimal machining distortion is required, where strength is not a concern, MIC-6 is ideal.

As a plate that is machine finished top and bottom to exceptionally tight tolerances, cast aluminum tool & jig plate is ideal for applications that require flatness and tight dimensional control.

Cast aluminum tool & jig plate also provides excellent corrosion resistance, good anodization characteristics, and superb machining consistency. It is guaranteed in terms of vacuum and pressure integrity. It features and benefits make it ideal for applications involving aerospace and automotive fixtures, assembly and machining jigs & fixtures, and blow & injection molding.

MIC-6 vs. 6061 for Machining

Compared to 6061 aluminum alloy rolled plates, MIC-6 cast aluminum tooling plate provides superior flatness and dimensional stability. It is a fully stress-relieved product and free cutting aluminum alloy with outstanding machining features. In a range of high speed operations, it produces small, uniform chips. It comes with both sides machined with a thickness tolerance of +/-.005″ and can be provided with a surface finish of 20 RMS or greater. It also has PVC protection on each side.

MIC-6 Applications

MIC-6 cast aluminum tool & jig plate may be used in a wide range of applications, some of which include the following:

  • Tooling
  • Jigs and fixtures
  • Base plates
  • Rubber and plastic molds
  • Gauges
  • Templates
  • Chip printers
  • Assembly jigs and fixtures
  • Index tables
  • Welding fixtures
  • Vacuum chucks
  • Printing machinery
  • Electronics
  • Drill jigs
  • Templates
  • Printing machinery components
  • Aircraft assembly components
  • Automotive tooling
  • Vacuum chambers
  • Foundry patterns
  • Prototypes
  • Electronic components
  • Medical instrumentation
  • Food machinery components
  • CNC routing tables
  • Packing machinery
  • Automation components.

Where stability and flatness are a requirement, you can rely on the effectiveness of MIC-6 cast aluminum tool & jig plate.

At Howard Precision Metals, we have been in business for over 90 years and today we are a full-fledged, 100% state-of-the-art aluminum service center, recognized by leading producers for our tight cutting tolerances and dedicated to meeting all of your aluminum alloy product needs, including those involving MIC-6 aluminum cast tool & jig plate. Our team is here to help you get the best aluminum alloy product for your application every time.

For more information about the MIC-6 aluminum cast tool & jig plate product we offer, in addition to other aluminum alloy products, call us today at 866.602.3788 or request a quote.

A Comparison of 6063 vs. 6061 for Aluminum Extrusions

Posted on by admin

The vast number of choices available when it comes to extruded aluminum alloys can make the process of choosing the best one a little complex at times. Aluminum extrusions come in various forms and understanding the needs of your application will help ensure you select the optimal material. By comparing two of the most commonly used alloys for extrusions in the aluminum alloy family – 6063 aluminum and 6061 aluminum can help in making the right choice. At Howard Precision Metals, we are your source for exceptional quality aluminum extrusions stock that are ideal to fulfil a range of industrial applications.

Aluminum and its various alloys constitute some of the most adaptable and versatile materials available on the market. Let’s look below at what aluminum extrusions are and then briefly cover the 6063 and 6061 aluminum extrusions.

What are Aluminum Extrusions?

A metal that has been extruded, has been formed into a pre-determined shape according to the cross-sectional profile of the die used. With this method, the number of finished forms possible is virtually endless. The extrusion process not only allows you to create numerous kinds of shapes, but it can also create a piece stronger than aluminum shapes made in other ways.

6063 Alloy for Aluminum Extrusions

6063 aluminum is primarily alloyed with silicon and magnesium, in addition to trace quantities of copper, iron, chromium, manganese, and zinc. It has solid mechanical properties and is both weldable and heat treatable. These characteristics have made it the most popular extruded aluminum alloy for thin wall, and architectural applications. A major reason for the popularity of 6063 is its ease of extrudability and anodizing responsiveness. It also produces a great surface finish.

When 6063 is welded, often through tungsten inert gas welding, it often loses as much as 30% of its strength. However, heat treating can restore a great percentage of that strength. This aluminum alloy is normally of medium strength compared to other aluminum alloys and provides fair machinability, good corrosion resistance, and good workability.

Applications that are visually and cosmetically sensitive are good candidates for 6063 aluminum extrusions due to the alloy’s excellent ability to produce exceptional quality surface finishes. This aluminum alloys accepts acid etching to produce a matte appearance. It also polishes nicely, yielding an exceptionally reflective characteristic that may be enhanced through bright dip anodization.

6063 aluminum extrusions stock may be found in various architectural applications, including roofs, window frames, sign frames, door frames, furniture, tubing, and pipes. Additional elements that incorporate 6063 include corners, angles, premium casework, trim, and face nosing. It is also used for automotive applications such as ornamental trim components, and luggage rack roof rails.

6061 Alloy for Aluminum Extrusions

6061 aluminum, which is supplied as 6061 aluminum plate and extruded aluminum other shapes, is a precipitation-hardened grade that is alloyed most of the time with magnesium and silicon, in addition to chromium, iron, titanium, zinc, and copper. The alloy is often subjected to heat treatment that enhances it grain structure and resulting durability and strength. This alloy is known for its corrosion resistance, weldability, and other mechanical properties, making it a close second only to 6063 for use is extruded aluminum applications.

When material strength is of primary concern,6061 manifold quality extruded bar, or 6061 aluminum plate are a good choice. For this reason, 6061 is used for so many commonly used items and components, including automobiles, construction elements, motorcycles, bicycle frames, camera lenses, and firearms. It is also the major alloy used in the design of hydraulic manifolds and aircraft parts.

Comparing 6063 to 6061 Aluminum Extrusions

Aluminum 6063 and 6061 cover most of the aluminum extrusions used for various applications. However, there is a difference between the two alloys and how they relate to the extrusion process. Aluminum 6063 is somewhat more ideal for the extrusion process, but 6061 is typically stronger. So, if strength is the determining factor for an application, 6061 may be the optimal choice between the two.

On the other hand, when it comes to workability, corrosion resistance, and surface quality, 6063 is the better options. Aluminum alloy 6061 is also more machinable than 6063, but both alloys are weldable. If there is a question or any uncertainty about the better option between 6063 and 6061 aluminum extrusions, a seasoned metal supplier can provide advice based on years of experience working with aluminum extrusions.

Each alloy is suited more for certain applications and less for others based on each alloy’s various characteristics. Selecting the right material requires a proper evaluation of the application and project and the specific material properties and performance characteristics that suit it better. As indicated above, 6063 and 6061 aluminum alloys possess similar chemical compositions, but possess some different qualities.

If you need aluminum extrusions made from 6063, 6061, or another aluminum alloy, we are your source for a wide range of aluminum extrusions stock to meet the requirements of your industry applications. Call our team at Howard Precision Metals today at 800.444.0311 or request a quote through our convenient online form to learn how we can serve your aluminum extrusion needs.

What are the Benefits of Aluminum Sheet Metal?

Posted on by admin

Aluminum sheet metal is a highly versatile type of metal sheet that may be used in various applications and industries. It has chemical and structural properties that make it highly desirable and useful among other metal sheet options. At Howard Precision Metals, we do not level coil in for 10,000 lbs order like many other distributors do, instead we put our sawing expertise to work on sheet products. What do you do when you need a .125” thick sheet product cut to +/-.005” tolerance? You call the experts in tight tolerance cutting. Today, with the numerous electronics applications there is a need for sheet metal to be cut into thousands of small pieces to precise tolerances. That is where Howard Precision Metals and their sawing experience comes in handy.

What is Aluminum Sheet Metal?

The production of aluminum sheet metal is carried out when aluminum material is pressed and rolled under high pressure. Aluminum sheets are generally lightweight but also possess sufficient strength to be useful in numerous industry applications. Aluminum metal sheet is exceptionally versatile and is easy to manufacture, making it among the most popular of the metal sheets available on the market.

Different coatings and surface finishing’s are also available for aluminum sheet metal.

Prior to purchasing aluminum metal sheet, it is important to know the important features that characterize this metal. Some of the most significant benefits of aluminum metal sheet are as follows:

Lightweight

Aluminum sheet is about 1/3 the weight of steel sheet, making it one of the lightest metal sheets on the market. This makes the sheet easy to handle and it also helps reduce the weight of structures when this is important for cost.

Corrosion Resistance

Corrosion is a problem in many environments and industry settings. Aluminum is one those materials that does not easily corrode. It takes exceptional aggressive corrosive forces to cause corrosion in aluminum sheet with some alloys having more corrosive resistance than others.

Strength

Although aluminum sheet metal is lightweight, it is also quite strong at the same time. Because of its strength, combined with its lightweight feature, it is highly useful in various industrial applications. It is a durable and cost-effective shape for handling forces and stresses produced in a number of structural applications.

Formability

The melting point of aluminum sheet meal is relatively low. As a result, it can be formed easily into various shapes when it is placed under a certain level of heat.

Usable for Sensitive Applications

Aluminum metal sheet is ideal for use in food and chemical packaging. It does not react with many other materials too easily and therefore there is no concern for the aluminum sheet to negatively affect the food.

Reflectivity

Aluminum sheet metal is ideal for applications involving lighting due to its reflectivity, which means it reflects light and heat away from its surface.

Fireproof

When exposed to fire, aluminum sheet metals are resistant to burning, with only a thin layer of the sheet metal becoming affected. Also, when exposed to intense heat, aluminum sheet metal does not emit toxic gas.

Recyclable

Aluminum sheet is also recyclable – this is one of the characteristics of aluminum sheet that is most recognized and used. Many aluminum metals in use today have been recycled.

Offered in Multiple Thickness

You can choose aluminum sheet metal in various thicknesses and sizes as it comes in multiple dimensions.

Affordably Priced

Even though aluminum metal sheet offers a range of benefits, it is not very expensive when compared to many other metal options. However, its affordability does not diminish its quality and usefulness for a wide array of applications. Aluminum sheet metal is simply the ideal choice for many companies seeking a lightweight, yet strong and flexible metal.

Applicable for a Range of Industrial Uses

Many times, the use of aluminum sheet will be based on the thickness of the metal chosen. Small scale applications tend to utilize thinner sheets of aluminum. This is where the subject of sheet metal gauge becomes important. The gauge of sheet metal allows you to know its thickness and whether it is ideal for your application.

As a highly versatile metal, aluminum sheet is used in a vast array of applications in numerous industries. The applications to which this form of aluminum is applied range from small and sensitive to large scale.

As a metal that is useful in so many industries, you can actually find this metal almost everywhere. It is commonly used for cookware and for packaging in the food and beverage industry. Aluminum sheet is also often used for the bodies and framing of motor vehicles. This metal sheet is also often used in the building and construction industry for items that include sidings, drains, and much more.

Aluminum metal sheet is also ideal for the purpose of manufacturing metal nameplates and other similar items. Aluminum sheets are used often for making motor vehicle number plates due to the fact they are available at a reasonable cost and are corrosion resistant, lightweight, and require minimal maintenance.

To learn how our team at Howard Precision Metals can supply you with the aluminum sheet metal you need for your applications, give us a call today at or send us a request for quote.

Advantages and Disadvantages of Direct Extrusion

Posted on by admin

Extrusion is a process that produces shapes that have an unchanging cross-sectional profile as material is pushed through a die. The materials that are used to form objects in this process, include aluminum, among others. The process creates uniform shapes. When aluminum is pushed through a mold, for example, it takes the shape of the mold, producing custom or stock aluminum extrusions. Complex cross-sections can also be produced through this process.

At Howard Precision Metals, a leader among aluminum extrusion suppliers, we offer our customers with a wide range of aluminum products, which includes aluminum extrusions stock. These shapes are ideal for use in an array application in various industries.

The process of extrusion can actually strengthen aluminum. Extrusions may be created from other materials as well, including stainless steel, other metals, ceramics, plastics, and concrete.

Now, let’s look at direct aluminum extrusion and its advantages and disadvantages.

Direct Aluminum Extrusion

The most common method of extrusion involves the use of the direct aluminum extrusion presses. This method involves the placement of a billet of heated aluminum into a walled container. The aluminum is pressed through the mold (or die) with a ram. This part of the process involves a tremendous amount of pressure, which may be in the range of 100 to 15,000 tons or more. The size of the shape that may be produced through this process is proportional to the pressure capacity of the aluminum press used.

During this step of the process, a dummy block of material is positioned between the heated aluminum billet and the ram in order to prevent these elements from contacting one another. The action of the billet and ram moving forward in the same direction has led to this method being called the forward aluminum extrusion process.

The ram applies pressure, and the aluminum billet is pushed through the hole of the mold. When 6061-T6511 aluminum extrusions stock is manufactured, water quenching is then applied to the hot extruded aluminum profiles. They are then stretched and cut to the desired length. This is the most frequently used method of generating aluminum extrusions.

Advantages of Direct Extrusion

There are a number of advantages to direct extrusion, including:

  • Can extrude longer workpieces
  • Operational flexibility
  • Low cost per component
  • Continuous operation
  • During hot extrusion, modifications after the process are easy due to the product’s heated condition
  • May use various kinds of raw materials
  • High production volumes are possible
  • Good surface finish
  • Good compounding (mixing)
  • Cold extrusion produces good mechanical properties

The direct extrusion method is the most common one in use to produce stock aluminum extrusions. This direct extrusion method is simple in nature and allows for the production of more intricate shapes. Despite the need for greater force with this method, its ability to produce more complex shapes is the reason why this method is often preferred during the manufacturing process.

Disadvantages of Direct Extrusion

One of the drawbacks of the direct extrusion process is that the force required to extrude the material (the billet) is greater than what is needed through indirect extrusion. The reason for this is the frictional forces that are introduced as the billet travels through the entire length of the container. The greatest level of force occurs at the beginning of the direct extrusion process and it steadily decreases. The butt end of the billet is not used due to the fact that at the billet’s end the force is increased significantly because of the thin material at this stage and that it flows radially to depart from the die.

Friction, as alluded to above, is an issue with direct extrusions because of the type of motion that occurs between the cylinder walls and heated metal billet. Lubricants may be used to reduce this friction. With direct extrusion, the process is completed quickly, and the cylinder is cooled prior to additional extrusion in order to reduce equipment damage.

A Reliable Source for Your Aluminum Needs

At Howard Precision Metals we know the ins and outs of aluminum as one of the biggest 100% aluminum service centers in the nation. We have more precision high speed saws than any of our competitors. Regardless of the size required, we are capable handling your requirements for stock aluminum extrusions and cutting your aluminum plate. We serve customers in an array of industries with the aluminum skills, resources, and experience our team possesses.

If you are in need of aluminum extrusions, aluminum sheet, or aluminum plate, we are here to help as a trusted source among aluminum extrusion suppliers. Give our team at Howard Precision Metals a call today at 800.444.0311 or send us a request for quote to learn how we can serve you with our aluminum products.

What Are the Advantages of Working With Aluminum 2024?

Posted on by admin

Just as steel, aluminum is one of the most frequently used and commonly available metals for commercial projects and applications. It is applied to applications involving everything from consumer products to aircraft parts and systems. Aluminum 2024 is one of the more common alloys used among those available. This alloy possesses exceptional strength and great resistance to fatigue. Because of these attributes, 2024 aluminum is widely used to support and enhance structural applications in the aerospace industry. It is the ideal alloy when you need a material having a beneficial strength-to-weight ratio. At Howard Precision Metals, we have all of your 2024 aluminum needs covered.

Properties of 2024 Aluminum

Aluminum alloy 2024 was created nearly a century ago in 1931. Due to its advantageous properties and characteristics is used extensively in aircraft design applications. This alloy is now used widely in place of alloy 2017-T4 for these applications.

The properties that make 2024 aluminum beneficial include its stress corrosion cracking resistance, strength, stiffness, and shearing resistance. This alloy, whether in the form of 2024 aluminum plate or 2024 aluminum bars, also functions well under extreme temperature conditions. Although it does have a reduced atmospheric resistance to corrosion when in close proximity to the sea, this issue may be solved through anodizing or other surface treatments.

From a heat-treated condition 2024 aluminum alloy is annealed for about two hours within the temperature range of 399 to 427 degrees Celsius. Subsequently, the material is cooled slowly in the furnace. On the other hand, aluminum 2024 may be annealed between cold working applications for 2 hours at 343 degrees Celsius and cooled in the air.

2024 Aluminum Benefits

Copper is the alloying element on aluminum alloy 2024. This alloying element gives 2024 additional strength and fatigue resistance. The alloy has properties that gives it the ability to withstand high levels of stress and strain for prolonged periods of time. Along with a high yield strength of 50,000 psi, 2024 has the characteristics that make it ideal for aircraft and marine parts and fittings, hydraulic cylinders, structures, hardware, transportation components (truck wheels, for example) and others that can benefit from high resistance to fatigue. Aluminum 2024 sheet is the ideal choice for some military and aircraft applications that involve highly elevated temperatures in engine areas.

Aluminum 2024 can be flash, spot, or seam welded and has high machinability. It has favorable workability properties and is heat treatable. This alloy maybe be extruded and provided in sheet and plate form.

2024 Aluminum Aircraft Industry Applications

The different structural applications in the aircraft industry that can benefit from aluminum 2024 include hydraulic manifolds, tension members, wing skins, fuselages, hydraulic manifolds, rips, and tension members. Aircraft engine parts are also commonly made from 2024 aluminum. The skins of fuselages in military and commercial applications can benefit from Alclad forms of this alloy.

If your application requires 2024 in the form of 2024 aluminum plate or 2024 aluminum bars, we have you covered at Howard Precision Metals.

Machinability and Forming

In its heat-treated and annealed state, 2024 alloy has good machining capabilities. At the same time, the alloy may not be hot-formed.

Aluminum 2024 is ideal for areas that required fatigue resistance and structural strength. We offer 2024 aluminum plate in 1/4 to 6 in. thicknesses. In addition at Howard Precision, we stock these thicknesses with plus side tolerances as we have found it to be the preference by our customers. Various applications can make use of these plates, including fuselage structures, tension members, ribs and shear webs, and hydraulic manifolds.

2024 Heat Treatment for Greater Strength

Alloy 2024 along with other aluminum alloys in the 2xxx, 6xxx, and 7xxx series may be subjected to heat treatment operations. When done on 2024, the alloy is heated to a pre-set temperature that enables the homogenizing or mixing of the elements of the alloy into the base metal. After this, the metal is subjected to solution heat treating in which the metal is quenched is a solution that maintains the position of the elements.

Aluminum alloy 2024 may not be subjected to just any type of welding due to the possibility of reduced corrosion resistance as a result. If inert gas is not used in welding the alloy, the heat treatment process should be performed once again. Aluminum 2024 maybe forged, but in order to maintain the necessary corrosion resistance, another heat treatment is required.

With the cooling down of 2024 aluminum alloy, copper atoms and other elements precipitate from the solution. As the compounds interact with the superstructure of the aluminum metal, the alloy gains strength by aging. In accordance with the heat treating and aging process applied, aluminum 2024 by be given designations that include 2024-T6, 2024-T-9, 2024-T59, or others.

At Howard Precision Metals, we are the preferred choice for an aluminum supplier. Here to help you fulfill the requirements of your projects and applications. This includes 2024 aluminum plate, 2024 aluminum bar, and more for aerospace, aircraft, commercial, and other industrial applications. For more information about how our team can serve your aluminum alloy requirements, call us today at 800.444.0311, or request a quote through our website.

Howard Precision Metals Inc., 8058 North 87th Street,
Milwaukee, WI 53224
RapidScan Secure
We are certified to the requirements of ISO 9001:2015

Phone: (414) 355-9611

Ryerson Family of Companies
Copyright © Howard Precision Metals, Inc.