Aluminum Sheet Metal Fabrication
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About Aluminum for Sheet Metal Fabrication
Aluminum works well for sheet metal applications because it is lightweight and easy to use. However, it cannot be ignored that not all aluminum alloys are suitable for metal plate structures. Some high-strength grades of aluminum can break or tear before bending. The greater the difference between a material’s yield strength and tensile strength, the harder it will be to bend. Some of the more common grades of aluminum used for sheet metal parts are listed below.
Aluminum is a material widely used in sheet metal parts. The right alloy can be formed very easily and produce low-cost, high-strength and lightweight parts. Aluminum sheet metal parts can be found in the aerospace and transportation industries, as well as many other industries.
Sheet Metal Aluminum at a Glance
| Application | Aluminum has a wide range of applications from prototyping to automotive to aerospace. |
| Advantages | Good strength-to-weight ratio, good mechanical properties, excellent formability |
| Disadvantages | Difficult to weld, not all alloys are suitable for forming, pricing varies greatly depending on alloy |
| Minimum Lead Time | 3 days |
| Price Range | Low - High ($-$$$) |
| Standard Tolerances | +/- 1.0 degree tolerances are possible on bent features and a cutout accuracy of +/- 0.020” (0.508 mm) |
| Sheet Thickness | Maximum of 3/8” (9.525mm) and a minimum of 0.0126” (0.32 mm) |
Aluminum 5052
This aluminum alloy has magnesium as its main alloying element. Because it does not contain copper in its composition, it has excellent corrosion resistance. Although 5052 cannot be heat-treated, it has the highest strength of any unheated alloy. The alloy also has better formability than the Series 3 alloy. It is commonly used in fuel tanks, highways and road signs.
Aluminum 5052 Standard Gauges
| Material | Standard Sheet Thicknesses |
|---|---|
| Aluminum 5052 H32 | 0.020”, 0.025”, 0.032”, 0.040”,0.050”, 0.063”, 0.080”, 0.090”, 0.100”, 0.125”, 0.160”, 0.188”, 0.250”, 0.375”, 0.500” |
Aluminum 6061
This is one of the most “versatile” aluminum alloys. The main alloying elements are magnesium and silicon, which can accept heat treatment. Bending aluminum 6061 after reaching a high tempering level is not recommended, as it is likely to break at this point. This aluminum alloy can be used in sheet metal parts, but requires some care and preparation.
Aluminum 6061 Standard Gauges
| Tensile Strength, Yield (MPa) | Elongation at Break (%) | Hardness (Shore D) | Heat Deflection Temperature (°C) | Glass Transition Temperature (°C) | Color |
|---|---|---|---|---|---|
| 45.6 | 110 | 80 | 72.5 | HB-5VA | Gray |
Finishes
FINDTOP’s aluminum for sheet metal fabrication can be finished in a number of different ways. Some of the available options are listed below.
Anodizing: Anodizing is one of the more popular surface finishes available for sheet metal aluminum parts. Choose between normal and hard-coat anodizing. These surface finishes improve the aesthetics of the part while also enhancing its wear resistance.
Metal plating: Aluminum can be plated with a wide range of metals to increase its corrosion resistance, increase wear resistance, or improve overall aesthetics.
Cost-saving Design Tips
To reduce costs when designing aluminum sheet parts, try the following cost-saving design tips:
Keep parts simple: Reduce complex features and geometry that require additional tools, setup, and manipulation. Complex aluminum sheet metal parts are usually more expensive to manufacture.
Choose the right alloy: As mentioned earlier, some sheet metal alloys are better suited to deformation. Although it is possible to bend high-strength alloys, the required pretreatment and post-processing can incur costs.
Optimize material use: Reduce material waste by considering the nested design of sheet metal parts. Use the remaining cuts in the larger material plate.