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7 Types of Aluminum Alloys: Properties and Applications

7 Types of Aluminum Alloys: Properties and Applications
Austin Peng
Published 13 Oct 2024
Table of Content

Aluminum is one of the most commonly used types of metal, and there are different types of aluminum alloys. They offer excellent mechanical properties, so they are mostly opted for in different applications.

If you are looking for some information on aluminum alloys, the guide below can help you.

What is Aluminum Alloy?

Aluminum alloy is made by combining different metal elements in limited quantities into the main metal, which is aluminum itself. Aluminum is lightweight and resists corrosion.

Aluminum alloys are formed by melting the aluminum and some other elements and then combining them together. Once the metal solidifies, an aluminum alloy is achieved.

The elements that are usually added to aluminum for alloying are iron, zinc, silicon, copper, and magnesium. These elements add strength, corrosion resistance, and electrical conductivity to the aluminum alloy.

Properties of Aluminum

CNC Machining Aluminum Process

The main reason behind selecting aluminum for different applications is the properties offered by it. Some of these properties of aluminum are as follows:

Corrosion Resistance

Aluminum is corrosion resistant due to the layer of oxide it has. Hence, applications where aluminum parts are subjected to corrosive chemicals or moisture may find aluminum to be suitable due to its corrosion-resistant properties.

Lightweight

The weight of aluminum is very light; it weighs hardly one-third of what steel weighs. Hence, the cost of manufacturing is very less due to the lightweight properties it has.

Hence, it is used in many applications like automobiles and aerospace as it helps to reduce the weight and increase the load capacity.

Excellent Thermal Conductivity

Aluminum conducts electricity as well as heat. It offers thermal and electrical conductivity higher than copper and is therefore used in power transmission lines. It is also used for heatsinks and various appliances.

7 Types of Aluminum Alloys

There are seven grades of aluminum, each having its own properties, and these are discussed below.

1xxx Series

7 Types of Aluminum Alloys: Properties and Applications

The 1xxx series is the purest aluminum alloy, which is 99% pure aluminum and has a tensile strength ranging between 10 to 27 Ksi.

It is not suitable for heat treatments but can be welded. It has high conductivity for heat and electricity and resists corrosion. It is therefore chosen for piping and making chemical tanks.

2xxx Series

7 Types of Aluminum Alloys: Properties and Applications

The 2xxx series consists of copper as a primary element for alloying and has a high proportion of manganese and silicone.

It has a strength of 27 to 62 Ksi, and this grade is highly machinable, followed by the ability to maintain its strength even in high temperatures. This grade of aluminum is suitable for aerospace applications.

3xxx Series

7 Types of Aluminum Alloys: Properties and Applications

The 3xxx series has manganese and magnesium, followed by aluminum. It offers high strength and remains durable when subjected to high temperatures.

However, it is not suitable for heat treatments and has a tensile strength of 16 to 41 Ksi. It is suitable for the packaging of consumer goods.

4xxx Series

7 Types of Aluminum Alloys: Properties and Applications

The 4xxx series of aluminum has silicon, which reduces the melting point of this alloy, making it suitable for heat treatments. Silicon itself is not heat treatable, but due to the magnesium and copper content, it offers a better response to heat treatments.

5xxx Series

The 5xxx grade has magnesium and is very strength-oriented, resistant against alkaline as well as corrosion. Hence, it is highly suitable for marine applications and is easily formable as well as weldable.

6xxx Series

The 6xxx series offers silicon and magnesium combined with aluminum. This aluminum grade is highly weldable, formable and even suitable for heat treatment.

It is the most commonly used series and offers excellent corrosion resistance and strength. It is mostly used in truck frames and boats.

7xxx Series

The 7xxx series is the strongest aluminum alloy, and it is opted as a commercial-grade aluminum alloy. It has two groups of aluminum alloys: one group is composed of magnesium, copper, and zinc, and one has zinc and magnesium.

It has a high level of strength and is lightweight. It is very commonly used for high-stress components, and structures of aircraft.

Common Types of Aluminum Alloys Used in Machining

The common types of aluminum alloys used in machining processes are as follows:

Aluminum 6061-T6

7 Types of Aluminum Alloys: Properties and Applications

Aluminum 6061 is composed of magnesium and silicon and is suitable for multiple applications that require corrosion resistance, strength, and weldability.

It is suitable for extrusion, and when you apply a T6 temper, it gets more durable and stronger. It also can be anodized for a better aesthetic look.

Aluminum 7075-T6

7 Types of Aluminum Alloys: Properties and Applications

Aluminum 7075 is very well equipped with high strength and has alloying elements like zinc and copper.

It is used in applications like aircraft, spacecraft, etc. It is moderately weldable and can withstand stress.

Aluminum 5052

7 Types of Aluminum Alloys: Properties and Applications

Aluminum 5052 is a type of aluminum alloy that has the ability to resist corrosion and has moderate strength.

It is opted for applications that are subjected to salt water and hence are used in marine applications. It is from the series of 5xxx and hence cannot be submitted to heat treatment.

Aluminum 6063

Aluminum 6063 has magnesium and silicon and hence it is suitable for architectural applications. It offers high ductility and is very much compatible with die casting. Also, due to its magnesium and silicon composition, it is highly corrosion-resistant.

How to Choose the Right Aluminum Grade?

Costs

Some of the factors that you must consider when choosing the right grade of aluminum are as follows:

Rating of Machinability

Aluminum alloy’s machinability is identified from its machinability rating. The aluminum 6061 and 7075 are highly machinable, and you can create precise components using these types.

Cost and Availability of Material

The cost of aluminum grade needs to be analyzed when you are choosing it for your project and it is a very important component that comes within your budget.

Moreover, availability is also a concern, and it should be consistently available so that you don't have to worry about it later on when you need it for further manufacturing.

Heat Treatment

Heat treatment uses high temperatures and it helps to improve the strength of the aluminum alloys.

However, not every grade of aluminum is suitable for heat treatment, and it is important for you to choose the right grade if you are looking for heat treatments.

Applications of Aluminum

7 Types of Aluminum Alloys: Properties and Applications

Aluminum is very common and is used almost in most applications. Its applications in different industries are discussed below:

Aerospace Industry

The aerospace industry needs aluminum alloys that are strong and lightweight. These alloys offer affordability and have an exceptional strength-to-weight ratio. When used in aircraft, aluminum adds strength to its structure.

Medical Industry

Aluminum components are also used in the medical industry due to the biocompatibility and cleanliness they offer.

Medical tools and instruments used in surgery and orthopedics are made using aluminum. Also, containers and trays used for medical processes are even made using aluminum.

Automobile Industry

The automobile industry uses aluminum due to its lightweight characteristics. It is also durable and offers environment friendliness.

Components for cars are made using the die-casting process, which is made of aluminum. These components are rugged and agile, offering excellent durability.

Electronic Applications

In the electronic industry, aluminum offers versatility. Various consumer electronics have aluminum components within them. They are known for their excellent thermal compatibility and are used in manufacturing heat sinks and graphic processors.

Conclusion

Aluminum alloy is a versatile material with excellent properties and is widely used in multiple applications.

It has various grades, and each grade has its properties and suitability for different applications. If you are looking for aluminum components using different grades, you can get in touch with DEK.

FAQs

Do aluminum alloys rust?

Aluminum does not rust. However, over a long period, it may end up corroding, but that is very rare.

Which aluminum alloy has better machinability between 6061 and 7075?

6061 is more machinable than 7075 due to its less strength and hardness.

What is the cost and availability of aluminum alloys?

The cost and availability of aluminum alloys vary on different factors, like the composition of the alloys and application requirements.

What are aluminum forms?

There are different forms and grades of aluminum, and it has a series ranging from 1xxx to 7xxx, such as 6061, 5052, and 7075.

How is Aluminum 6061-T6 different from pure aluminum?

Aluminum 6061-T6 is an aluminum type which is hardened by precipitation.

Which aluminum is stronger, 5052 or 6061?

6061 is stronger than 5052 as 5052 has the least strength compared to all the types of aluminum alloys.

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Austin Peng
Co-founder of DEK
AUTHOR
Hello! I'm Austin Peng. I manage a factory that specializes in CNC machining, injection molding, and sheet metal fabrication for small quantity production and rapid prototyping solutions. When I'm not immersed in work, I love diving into football matches, exploring new travel destinations, enjoying music, and staying updated on the latest tech trends. Feel free to chat with me about anything, whether it's work or life!

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