Aluminum Grades Compared: Common Types of Aluminum in Custom Fabrication
The choice of which aluminum grade to use for a custom fabrication project depends on the specific production requirements (tolerances, design complexity, etc.) as well as the application of the end product. Additionally, we consider many functional attributes and performance factors such as strength, corrosion resistance, formability, and of course cost.
Regardless of the project, selecting the right grade of aluminum is imperative if you want to minimize manufacturing errors and ensure that the final product performs as expected. Below we discuss some of the common aluminum grades and types used throughout the industry today, along with the material advantages they offer to the fabrication process.
An Overview of the Basic Aluminum Grades Commonly Used in the Fabrication Industry
Aluminum alloys come in many different types and compositions, with three of the most common grades being 1000 series, 3000 series, and 6000 series aluminum. The grade of the aluminum is essentially an easy, more convenient way to determine which materials are best suited for your unique end-use application and price point.
For example, 1100 is a lower-cost (and in some ways higher-strength) material than 6061. However, it does not offer reliable performance for high-temperature applications, thus 6061 being one of the most common aluminums for general-use consumer and commercial applications.
A Closer Look at Aluminum Types: Material Properties, Advantages, and Product Applications:
1000 Series Aluminum
Beginning with 1000 series aluminum, this material is considered “commercially pure” unalloyed aluminum. In other words, these alloys consist of at least 99% pure aluminum. 1000 series aluminum materials offer exceptional corrosion resistance and electrical/thermal conductivity along with great finishing qualities and good welding characteristics.
Due to its unique molecular makeup, some of the most common uses of 1000 series aluminum is in the manufacturing of industrial chemical processing equipment, electrical conductors, and specialized aerospace components. It’s also an effective material for cladding other types of corrosion-prone alloys. One of the most common types of 1000 Series aluminum used for today’s fabrication projects is 1100 aluminum.
1100 Aluminum:
- Material Properties:
- Commercially pure aluminum with excellent corrosion resistance.
- Relatively low strength but highly formable.
- Advantages:
- Commonly used for applications where corrosion resistance is critical, like food packaging and chemical handling equipment.
- Easy to work with due to its excellent formability.
3003 Aluminum:
- Material Properties:
- The addition of manganese makes 3003 aluminum higher strength without extensively raising material cost.
- Good strength for the cost but not the greatest corrosion resistance.
- Advantages:
- A widely available and relatively low-cost aluminum material suitable for many types of custom fabrication.
6000 Series Aluminum
6000 series aluminum alloys predominantly rely on magnesium and silicon as their key alloying components. 6000 series alloys combine impressive strength and with great material properties for fabrication such as good formability, weldability, and machinability. Their strength can be further enhanced through heat treatment for suitability in a wider range of high-strength commercial and industrial applications.
These alloys are widely employed in architectural, marine, and various general applications. Among the wide range of 6000 series alloys, 6061 and 6063 aluminum are notably prevalent, serving as versatile choices for a multitude of applications.
6061 Aluminum:
- Material Properties:
- Alloyed with magnesium and silicon.
- Good strength and excellent corrosion resistance.
- Easily machinable and weldable.
- Available in various tempers for different applications.
- Good strength and excellent corrosion resistance.
- Advantages:
- Versatile and widely used for structural components, frames, and automotive parts.
- Offers a good balance between strength, workability, and cost.
- Suitable for both T6 (heat-treated) and T4 (naturally aged) conditions for various needs.
6063 Aluminum:
- Material Properties:
- Alloyed with magnesium and silicon.
- Excellent extrudability, making it ideal for complex shapes.
- Moderate strength and good corrosion resistance.
- Suitable for anodizing.
- Advantages:
- Mainly used in extruded shapes like architectural profiles and window frames.
- Easy to form and anodize, making it a popular choice for aesthetic applications.
7000 Series Aluminum
7000 series aluminum contains zinc as its primary alloying element. 7000 series aluminum grades are generally harder to cast but offer superior hardness and dimensional stability. They also provide good machinability, surface finishing qualities, and fair corrosion resistance.
Aluminum 7075:
- Material Properties:
- Alloyed with zinc and small amounts of magnesium and copper.
- High strength and hardness.
- Excellent fatigue resistance.
- Less corrosion-resistant compared to other alloys.
- Advantages:
- Used in applications requiring high strength-to-weight ratios, such as aircraft structures and high-performance sporting goods.
- Typically heat-treated for maximum strength (T6 temper).
Pennsylvania’s Leading Aluminum Fabrication Service Provider
Alloy Fabrication has proudly served Pennsylvania and the greater Mid-Atlantic Region with quality industrial aluminum fabrication services since 1987. From structural fabrications to custom steel tanks, tubular components and other complex weldments, we can manufacture virtually any custom aluminum industrial component in-house.
