When it comes to manufacturing aluminum, choosing the right alloy is crucial for achieving optimal results. Different aluminum alloys have different properties that affect machinability, workability, weldability, hardness, strength, and thermal conductivity. As we all know some alloys will perform better than others in each of these situations. In this post, we’ll take a closer look at the best aluminum alloys for machining, welding, forming and stamping.
6061 is a popular aluminum alloy that is known for its excellent machinability and weldability. It has good corrosion resistance and is widely used for structural applications. 6061 aluminum can be easily machined using standard techniques and is suitable for both manual and CNC machining. It is a heat-treated alloy that has average strength providing good machinability but still allowing it to be easily formed and stamped into a component. When we look at all the alloys we will talk about today, 6061 is the most versatile of the alloys for multiple applications. That is why it is the most common Aluminum alloy specified.
7075 is a high-strength aluminum alloy that is commonly used in aerospace and automotive applications. It has excellent machinability but is more difficult to work with than 6061 due to its high strength. It also has good corrosion resistance and is heat treatable, allowing for further improvements in its mechanical properties. 7075 is suitable for CNC machining and is often used in the production of aircraft parts and high-stress components. Because 7075 contains copper and zinc, it is not suitable for welded structural application as the welding process creates microcracks that impact the tensile strength of the weld zone. This is one of the reasons some airplane components are riveted.
2024 is another popular aluminum alloy that is widely used in aerospace applications. It has good machinability and can be easily worked with using standard techniques. 2024 is also heat treatable, so depending on the temper designation, your strength is on the high compared to other Aluminum alloys. However, it is not as strong as 7075 and is not suitable for high-stress applications. 2024 is often used in the production of aircraft skins, structural components and higher-pressure manifold applications.
6063 Aluminum Alloy
6063 is a popular aluminum alloy that is used for extrusion and architectural applications. It has good corrosion resistance and is machinable using standard techniques. It is not considered a good machining alloy, but as long as you are not doing deep drilling you will be fine. 6063 also has good thermal conductivity and is suitable for heat transfer applications. 6063 is a highly extrudable alloy, lending itself to complex shapes like heat sinks with thin fins, window frames, door frames, and other architectural components. The strength of 6063 is significantly lower than the above alloys, and typically not specified in structural applications.
5052 Aluminum Alloy
5052 is a popular aluminum alloy that is commonly used in marine and automotive applications. It has good workability and weldability and is highly resistant to corrosion in seawater. 5052 is also easily formable, making it a great choice for applications that require complex shapes. Because 5052 is not heat treated, successfully rolling forming bending and stamping are often processes done to 5052 sheet and plate. End uses for 5052 include fuel tanks, signs, cabinets and other general sheet metal parts
5083 Aluminum Alloy
5083 is a high-strength aluminum alloy that is commonly used in marine applications. It has good machinability and weldability and is highly resistant to corrosion in seawater. 5083 is also heat treatable, allowing for further improvements in its mechanical properties. It is often used in the production of boat hulls, decks, and other marine components.
Understanding the properties of different aluminum alloys is important for choosing the right one for your machining needs which we will now focus on. Factors to consider include the alloy’s strength, machinability, corrosion resistance, and thermal conductivity. When selecting an aluminum alloy for machining, it is important to balance these factors to achieve the desired results.
In addition to the previously mentioned alloys, there are several other aluminum alloys that are commonly used in machining applications, such as 2011, 2017, 5052, and 6060. Let’s take a closer look at these alloys and what makes them suitable for machining.
2011 Aluminum Alloy
2011 is a free-machining aluminum alloy that is ideal for high-speed machining operations. It is all about the excellent machinability this alloy offers in the screw machine process and other bar-fed CNC machines. 2011 has comparable strength to 6061, but other than that, it is limited. This alloy is only produced as Cold Finished bar, giving it tight dimensional tolerancing. 2011 is often used in the production of screws, bolts, and other small components.
2017 Aluminum Alloy
2017 is a high-strength aluminum alloy that is commonly used in aerospace and military applications. It has good machinability and is often used in the production of aircraft parts and other high-stress components. 2017 is also heat treatable, allowing for further improvements in its mechanical properties. It has good corrosion resistance and is suitable for use in harsh environments.
When selecting an aluminum alloy for machining, it’s important to consider not only the alloy’s properties but also the specific machining process that will be used. Different machining processes, such as turning, milling, or drilling, require different properties from the alloy. For example, milling requires an alloy with good thermal conductivity to dissipate heat, while drilling requires an alloy with good machinability to reduce tool wear.
It’s also important to consider the surface finish requirements of the final product. Some alloys may be more prone to surface defects, such as burrs or chatter marks, than others. Choosing an alloy that is well-suited to the specific machining process and surface finish requirements can help ensure a high-quality final product.
In addition to the properties of the alloy itself, the machining process itself can also affect the machinability of the alloy. Factors such as cutting speed, feed rate, and tool geometry can all affect the performance of the alloy during machining. It’s important to optimize these parameters for each specific alloy and machining process to achieve the best results.
In conclusion, selecting the right aluminum alloy for your manufacturing process depends on a variety of factors, including the specific application, the manufacturing process, and the desired aesthetics of your finished part. While 6061, 7075, and 2024, and are all popular choices for machining, other alloys such as 2011, 2017, 6063, 5052, and 5083 are also well-suited for certain applications. By understanding the properties of these alloys and optimizing the type of manufacturing performed, you can achieve optimal results and produce high-quality parts.
