Aluminum extrusions have progressed into indispensable components across a multitude of applications, spanning from industrial machinery to consumer electronics. Their widespread use is attributed to the combination of lightweight properties, high strength, and corrosion resistance. The success of a custom extruded aluminum design, however, extends beyond mere functionality. It hinges on the careful selection of the appropriate aluminum extrusion alloy. Each aluminum grade brings distinct properties to the table, and the art lies in choosing the right alloy to ensure your extrusion design can meet the specific demands of your application.
Aluminum Alloy Categories and Optimal Series for Square Bar Extrusions
Aluminum grades are systematically categorized into series, ranging from 1xxx to 7xxx. When it comes to square bar custom extruded aluminum, the 1xxx and 6xxx series emerge as the most fitting alloy categories. The 1xxx series, exemplified by 1050 Aluminum, is non-heat-treatable, offering superb workability and corrosion resistance.
On the flip side, the 6xxx series introduces alloys such as 6005A, 6061, and 6063, each catering to diverse needs. 6005A, with its exceptional extrudability and medium strength, caters specifically to open or hollow extrusion designs. 6061, serving as a flexible substitute for low carbon steel, delivers medium to high strength, exceptional weldability, and heat-treatability, making it appropriate for both solid and hollow extrusions. In the meantime, 6063 stands out as the prime choice for intricate geometries or thin-walled designs, ensuring cost-efficiency and providing superior surface finishes.
Delving into Specific Alloy Characteristics and Tempers
A deeper exploration of specific alloy characteristics reveals nuances that significantly impact the decision-making process. As an example, 6351 Aluminum offers higher strength than 6061, coupled with impressive resistance to corrosion and impact. 6463 Aluminum is distinguished for its bright, high-quality, mirror-like finishes, medium strength, and exceptional extrudability, making it particularly fitting for decorative applications. At the same time, 6360 Aluminum earns recognition for its high quality, bright finishes, machinability, and solid corrosion resistance, making it the alloy of choice for complex shapes.
Understanding aluminum alloy tempers is equally vital in optimizing the strength of square bar extruded aluminum shapes. The tempering process, encompassing treatments such as T1, T2, T3, T4, T51, T6, and T61, plays a key role in determining the specific properties of the aluminum alloy. Whether it involves artificial aging, natural aging, or a combination of both, choosing the optimal temper enhances the overall performance of the extrusion, ensuring it fulfills the desired specifications of your application.
Factors Guiding Alloy Selection and Comprehensive Design Insights
There are multiple factors involved when it comes to the decision-making process for the selection of the right aluminum extrusion alloy for square bar applications. Pivotal steps include having an all-inclusive understanding of the various aluminum alloys, considering the complexity of the extrusion process, and considering the specific properties the end product requires.
The selection process is further refined with formability and strength considerations, surface finish requirements, and cost evaluations. For example, if your product requires high levels of toughness and strength, alloys from the 7000 series may be optimal. On the other hand, if resistance to corrosion and lightweight characteristics take precedence, alloys from the 5000 series might be the best choice.
In addition to alloy considerations, design factors for extruded aluminum shapes such as wall shape complexity, thickness, and end-use (structural or non-structural) play a key role. Extrusions with thin walls and intricate geometries may necessitate the use of certain aluminum alloys such as 6360 or 6063 to ensure minimal distortion and uniform shapes. The prerequisites for strength, finishing requirements, and potential use as a heat sink should also impact the selection of the alloy.
Howard Precision Metals’ Commitment to Excellence
At Howard Precision Metals, our dedication to excellence is reflected in our aluminum square bar inventory, which includes sizes from .25″ to 6.0″ square. Customized to meet strict quality specifications, our aluminum square bars are designed to meet the requirements of various industries, including medical, construction, aerospace, and automotive. Should you require help in sourcing aluminum square bars or have inquiries about alloys, our experienced sales professionals are ready to answer your questions guide you through the process.
The versatility of aluminum extrusions has propelled them into essential roles across consumer electronics and industrial machinery applications due to their lightweight nature, high strength and resistance to corrosion. The core of successful extrusion design lies in a scrupulous aluminum alloy selection, evaluating the distinct properties of each grade. The 1xxx and 6xxx series emerge as optimal choices for square bar custom extruded aluminum, offering a spectrum of alloys that address various application needs. Digging deeper into specific alloy tempers, characteristics, and design factors further refines the selection process.
Are you eager to explore the optimal aluminum extrusion alloy for your square bar applications? Call our team today at 866.602.3788 or request a quote on our website to begin the process. We are dedicated to providing you with the knowledge and expertise necessary to make informed decisions for your extrusion needs.
