Aluminum Extrusion Manufacturing

A Guide to Selecting Aluminum Alloys for Extrusion Projects

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Type: Aluminum Extrusion
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A Guide to Selecting Aluminum Alloys for Extrusion Projects

Choosing the right aluminum alloy is critical to the success of any extrusion project. Different alloys offer unique combinations of strength, formability, and corrosion resistance, tailored to specific applications. Below is a comprehensive guide to help manufacturers navigate alloy selection:

1. Understanding Alloy Series for Extrusion

Aluminum alloys are categorized by their major alloying elements, with the 6xxx series being the most popular for extrusion due to their excellent formability and mechanical properties. Key series include:

6xxx Series (Mg & Si): E.g., 6061, 6063. Known for high extrudability and good corrosion resistance.

2xxx Series (Cu): E.g., 2024. High strength but lower extrudability, used in aerospace.

7xxx Series (Zn): E.g., 7075. Ultra-high strength, suitable for structural components in automotive and defense.

2. Key Factors in Alloy Selection

Mechanical Requirements: Tensile strength, yield strength, and ductility vary by alloy. For example, 6061-T6 offers higher strength than 6063-T5, making it preferable for load-bearing structures.

Extrudability: Alloys like 6063 are easier to extrude into complex shapes, while high-strength alloys like 7075 require more robust extrusion equipment.

Corrosion Resistance: Marine or outdoor applications benefit from 6063 or 5xxx series (Al-Mg) alloys, which resist saltwater and atmospheric corrosion.

Heat Treatment: Some alloys (e.g., 6061, 2024) can be heat-treated to enhance strength, while others (e.g., 5xxx series) rely on work hardening.

3. Popular Aluminum Alloys for Extrusion and Their Applications

Table: Common Aluminum Alloys for Extrusion with Properties and Uses

Alloy
Temper
Primary Properties
Typical Applications
6063
T5/T6
Good extrudability, moderate strength, excellent surface finish for anodizing.
Window frames, architectural trim, decorative profiles.
6061
T6/T651
Higher strength than 6063, good corrosion resistance, weldability.
Industrial frames, automotive parts, bicycle frames.
6005A
T6
Medium strength, good formability, ideal for structural applications.
Trusses, beams, furniture components.
7075
T6/T651
Ultra-high strength, excellent fatigue resistance, but lower extrudability.
Aircraft components, high-performance machinery parts.
5052
H32
Good corrosion resistance (especially to saltwater), moderate strength.
Marine hardware, chemical equipment, fuel tanks.
2024
T3/T4
High strength, good fatigue resistance, but limited corrosion resistance.
Aircraft skins, wing components, high-stress mechanical parts.

4. Alloy Selection Case Study: Automotive vs. Architectural Applications

Automotive: A manufacturer designing lightweight chassis components might choose 6061-T6 for its high strength and impact resistance, while ensuring the alloy can be extruded into complex shapes for crash absorption.

Architecture: For curtain wall systems, 6063-T5 is preferred for its ease of extrusion into slim profiles, combined with anodizing compatibility for aesthetic and protective finishes.

5. Collaborating with Extrusion Experts

Selecting the right alloy requires balancing multiple factors. Partnering with an experienced aluminum extrusion manufacturer—like our factory—can help optimize material choice. We offer custom alloy consultations, die design support, and prototyping to ensure your project meets performance and cost objectives.

Conclusion

The right aluminum alloy can transform an extrusion project from concept to high-performance reality. By evaluating mechanical needs, extrudability, and end-use requirements, manufacturers can unlock the full potential of aluminum extrusion technology. Contact us to discuss how our alloy expertise can enhance your next project.

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Aluminum Extrusion

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Customized

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Alloy	Temper	Primary Properties	Typical Applications
6063	T5/T6	Good extrudability, moderate strength, excellent surface finish for anodizing.	Window frames, architectural trim, decorative profiles.
6061	T6/T651	Higher strength than 6063, good corrosion resistance, weldability.	Industrial frames, automotive parts, bicycle frames.
6005A	T6	Medium strength, good formability, ideal for structural applications.	Trusses, beams, furniture components.
7075	T6/T651	Ultra-high strength, excellent fatigue resistance, but lower extrudability.	Aircraft components, high-performance machinery parts.
5052	H32	Good corrosion resistance (especially to saltwater), moderate strength.	Marine hardware, chemical equipment, fuel tanks.
2024	T3/T4	High strength, good fatigue resistance, but limited corrosion resistance.	Aircraft skins, wing components, high-stress mechanical parts.