Aluminum Components

Aluminum alloys have long been favored in various industries for their exceptional properties and machinability. These lightweight materials exhibit excellent strength-to-weight ratios, corrosion resistance, and thermal conductivity.

Aluminum alloys are highly regarded for their exceptional machinability. Their low density and excellent thermal conductivity allow for efficient material removal and reduce tool wear during machining operations. Aluminum alloys possess good chip formation characteristics, improving surface finish and reducing production time. Furthermore, these alloys exhibit high ductility, allowing for easy forming and shaping without sacrificing structural integrity.

One of the most significant advantages of aluminum alloys is their impressive strength-to-weight ratio. With a density of approximately one-third that of steel, aluminum alloys provide exceptional strength while maintaining lightweight properties. This makes them particularly desirable for applications where weight reduction is crucial, such as aerospace, automotive, and sporting equipment industries.

Aluminum alloys naturally form a thin oxide layer on their surface, providing excellent corrosion resistance. This oxide layer acts as a protective barrier, preventing the alloy from reacting with the surrounding environment. This characteristic is especially beneficial in marine, construction, and chemical processing industries, where exposure to harsh conditions is common. Additionally, aluminum alloys can be further enhanced through surface treatments or protective coatings to enhance their corrosion resistance.

Another advantageous feature of aluminum alloys is their high thermal conductivity. This property enables efficient heat dissipation, making them ideal for heat exchangers, radiators, and electronic cooling systems. The excellent thermal conductivity of aluminum alloys allows for faster heat transfer and contributes to energy efficiency in various applications.

Because of its machining characteristics, aluminum is a common and cost-effective choice for many precision-machined components.  Aluminum is a good choice for electrical, medical, aerospace, and industrial applications where light weight, low cost, and an excellent cosmetic appearance are desired.

There are many alloy choices when it comes to aluminum.  2011, 2017, and 2024 are common alloys that provide excellent machinability.  They are often referred to as screw machine-grade alloys.  This is because the chips (“swarf” or the metal that is machined off of the bar) tend to break up into small pieces rather than become stringy and bunch up around the cutting tools or on the part being machined.  These grades of alloy are also recommended when your finished part is going to be anodized or hard-coated.  All 2000-grade aluminum has mediocre corrosion resistance, so anodization is recommended.  

6000 series alloys are commonly used to manufacture machined components.  These alloys have good machinability, but the chips tend to be more stringy than that of the screw machine grade (e.g., 2011, 2014)  alloys.  The 6000 series of aluminum are the alloys preferred when parts are going to be anodized or hard coated.  The 6000 series offer excellent corrosion resistance. If you plan on hard coating your aluminum component, a 6000 series alloy is recommended because of the high heat used in processing.

If high strength is required, then you might consider 7075. Cost will be higher, but this alloy is often a good choice for aerospace and medical applications.  This alloy can also be hardcoat anodized to improve corrosion and wear resistance.