ALUMINUM / CNC MACHINING / High strength-to-weight ratio

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Aluminum

CNC Machining / Light Weight + Corrosion Resistance

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Introduction

Aluminum is a versatile material with properties that make it ideal for CNC machining. It has excellent machinability as well as good corrosion and chemical resistance. The metal is also characterized by a high strength-to-weight ratio and good heat and electrical conductivity. After machining, aluminum has a low risk of deformation or defects and is easy to polish and color.

Because of these properties, aluminum is a popular choice for many metal products and components, including auto parts, aircraft parts, electronic enclosures, optical reflectors, lighting fixtures, engine parts, cooking utensils, medical devices, handles and knobs and more.

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Subtypes

Aluminum 6061-T6

Aluminum 6061 is one of the most commonly available heat-treatable aluminum alloys for commercial use. It sets the standard for a medium-to-high strength, lightweight, economical material. It is also famous for its structural strength and toughness, good surface finish, great corrosion resistance to atmosphere and sea water, perfect machinability, and its ability to be easily welded and joined.

Aluminum 6061 is used extensively as a construction material, most typically in the manufacture of marine and automotive components.

Aluminum 6063-T6

Aluminum 6063, an aluminum-magnesium-silicon heat-treatable alloy, has excellent resistance to corrosion, good workability and weldability. Mostly used in extruded architectural shapes, electrical components and conduit, and seamless and structural tube and pipe, aluminum 6063 has a finer grain structure than 6061 and will provide the best cosmetic appearance after anodizing.

Aluminum 7075-T6

Aluminum 7075 is a cold-wrought alloy and the strongest of the aluminum alloys, or as strong as some lower-grade steel products, but it is lighter in weight. This alloy can be easily shaped, chipped and manipulated by machines. However, it is considered a poor choice for welding, but can be joined by resistance welding.

As a result of these well-balanced properties, 7075 alloy sheet and plate products are commonly used in products where strength, corrosion resistance and high stress-reduction capabilities are important, such as rock-climbing equipment, hang glider airframes, bike frames, gears, regulating valve parts and shafts. Because it can be highly polished, 7075 alloy is also widely used in mold tool manufacture, particularly in the plastics industry.

Aluminum 5052-H32

Aluminum 5052 alloy is one of the higher strength, non-heat-treatable alloys. Good workability makes it very useful in forming operations. It has very good corrosion resistance, especially to salt water, and can be easily welded. Its high fatigue strength makes it an excellent selection for structures that need to withstand excessive vibrations. However, this alloy is rated only fair for machinability, so it is not the best choice for extensive machining operations without oil lubricants.

Due to its light weight, high strength and attractive finishing capabilities, it can be used to make smaller, thinner components, such as those used in consumer electronics. Aluminum 5052 is regularly used in general sheet metal work.

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Surface Finish

Anodizing

Anodizing protects metal by increasing the thickness of its surface oxide layer.

Anodizing is often used to color parts, improve durability and enhance corrosion resistance. It also provides better adhesion of lubricants to raw metal and reduces galling of threaded components.

Plating

Plating is a process where a conductive surface is covered with a thin layer of metal. It

is commonly used to prevent corrosion, increase durability, alter surface friction, and improve appearance.

Abrasive Blasting

Abrasive blasting is a finishing process where a media is propelled at a high

velocity against a part’s surface to smooth or roughen it, or to remove contaminants, often in preparationfor painting or another finishing process.

Polishing

Polishing is one finishing loose abrasive process, used to generate surfaces with very

high tolerances in geometry, surface integrity, and roughness characteristics, either through physical rubbing of the part or by chemical interference.

Brushing

Brushing is used to deburr and remove surface defects from metal parts. Although

suitable for a handful of metals, brushing is most commonly applied to aluminum.

Powder Coating

Powder coating forms a durable, wear resistant and corrosion resistant layer

on the surface of parts. Powder coating can be used to apply colors to parts and is compatible with any metal.

Painting

Painting is commonly specified by engineers to enhance a part’s appearance and

corrosion resistance. In addition, painting can have a protective effect on parts. For example, surface painting is an effective method to protect metal from oxidation and corrosion.

Surface Grinding

Surface grinding is a process that creates a precise, smooth flat-surface by

moving a workpiece back and forth under an abrasive grinding wheel. They are commonly used when making machine tools, reference surfaces, jig plates, and optical platforms.

Laser Marking

Laser marking is a low-cost method of adding text, logos, and graphics to parts.

Similarto engraving, but using a CO2 or fiber laser.

Design Recommendations

✔ Aluminum 6061-T6 is the most common material for CNC Machining because of its low risk of deformation and impurities, its stability and because of its excellent oxidation.

✔ For Aluminum 7075, oxidation and especially hard oxidation are not recommended, as the material is prone to stains.

ALUMINUM / CNC MACHINING / High strength-to-weight ratio, Perfect machinability