4 Things You Didn’t Know about Aluminum (Updated for 2024)

Last updated on February 9th, 2024 at 10:09 am

The world’s most abundant metal, aluminum has many important uses across industries. And aluminum has long been a staple material here at Approved Sheet Metal.

Understanding this metal’s unique properties will help you leverage aluminum fabrication to best meet your needs-and this helpful guide will get you started!

What’s Your Aluminum IQ?

How much do you know about aluminum? Here are a few key facts that’ll have you on your way to becoming an aluminum expert. (You can leave the actual aluminum fabrication to us.)

1. 5052 aluminum is the best choice for both prototype and low volume production sheet metal fabrication services

When ordering aluminum parts, many customers request 6061 because they know it’s the preferred grade for CNC machining. However, when it comes to sheet metal fabrication, 5052 is generally the best choice.

5052 is more readily available in sheets than 6061 or 7075, so it’s easier to source. It’s also more ductile than other grades, making it less likely to crack when forming a tight radius, hem, or offset. When possible, we always recommend using 5052 for aluminum fabrication rather than the more rigid grades.

2. Aluminum is cost-effective and compatible with many finishing options

If your budget is limited, aluminum may be the best choice for your parts. Aluminum is less expensive to buy in sheets than other metals. And because it’s rust-proof, you don’t have to post-treat it with a metal finish or a powder coat to ensure the longevity of your part.

If you do wish to apply a finish, however, you’re in luck: aluminum has the most finishing options of any common sheet metal material. Unlike stainless steel, it can be anodized and chromated.

3. Welding aluminum requires a high level of expertise

Aluminum is much harder to weld than steel or stainless steel due to characteristics that make its performance during welding unpredictable:

• Aluminum has high thermal conductivity, making it sensitive to heat fluctuations.
• Aluminum alloys are coated with an oxide layer that has an extremely high melting point. Specialized welding equipment may be required to create a temperature high enough to melt the oxide and enable a complete fusion.

However, if you need us to weld aluminum, we’ve got you covered. Approved Sheet Metal has the expertise and the equipment to deliver excellent results.

(Note that in many cases, when welding is requested, fasteners may be a more efficient and cost-effective option. As we like to say, the best welding is often no welding!)

4. Aluminum gauges differ from stainless steel gauges

The gauges for ferrous metals like steel and stainless steel differ from the gauges for nonferrous metals such as aluminum. Steel and stainless steel use the Manufacturers’ Standard Gauge, and aluminum uses the Brown & Sharpe Gauge (also known as the American Wire Gauge).

For example, 10 gauge stainless steel has a gauge thickness listed at 0.134″, and 10 gauge aluminum has a gauge thickness listed at +/- 0.102″.

We recommend listing both the decimal dimension and the gauge in the title block of your drawing to avoid confusion. Better yet, supply a CAD-drawn 3D model along with your RFQ for maximum clarity.

Approved Sheet Metal 6061-T6 vs 5052-H32

Common Aluminum Alloys We Fabricate at Approved Sheet Metal

The most common alloy we use for aluminum fabrication is 5052. We also use 7075 and 6061, although not nearly as frequently.

If you’re a regular reader of our blog, you’ll remember our Stainless vs. Galvanized Steel showdown, where the two steel types faced off in the ring to see which contender would perform the best in each of several categories.

Now, we’ll let the aluminum alloys-5052, 6061, and 7075-duke it out!

(We can consider this the Lightweight Division since aluminum weighs one-third less than steel.)

Which alloys will take home the prizes for strength, formability, weldability, and rust resistance? Let’s see how they all perform.

5052 Aluminum Alloy	6061 Aluminum Alloy	7075 Aluminum Alloy	WINNER
Strength	GOOD	GOOD	EXCELLENT	7075 🥊
Formability	EXCELLENT	FAIR	FAIR	5052 🥊
Weldability	EXCELLENT	EXCELLENT	GOOD	5052, 6061 (tie) 🥊
Rust Resistance	GOOD	GOOD	GOOD	TIE 🥊

Notes on Heat Treating AluminumWhen it comes to heat treating aluminum, here’s what to know about the different alloys:

• 6061-T0: Annealed state; easily formable and can be heat treated to T4 or T6 condition
• 6061-T4: Harder than T0; can be formed easier then T6 while maintaining good strength
• 6061-T6: Excellent strength but harder to form; requires a much larger bend radius to prevent cracking
• 7075-T0: Annealed; easily formable; can be heat treated to T6 condition
• 7075-T6: Excellent strength but harder to form; requires a much larger bend radius to prevent cracking

Did we mention that we offer same-day availability for all of our aluminum alloys?Check out our full range of inventory and our same-day materials! Then, go ahead and request a quote.

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Aluminum for Sheet Metal Fabrication FAQ

What is the best aluminum grade for sheet metal fabrication services?

For sheet metal fabrication, the best choice of aluminum grade is generally 5052. It’s more readily available in sheets, more ductile, and less likely to crack when forming tight radii, hems, or offsets compared to other grades like 6061 or 7075.

Is aluminum a cost-effective option for parts, and does it require additional finishing?

Yes, aluminum is cost-effective, especially when buying in sheets. It’s less expensive than many other metals. Additionally, aluminum is rust-proof, eliminating the need for post-treatment with a metal finish or powder coat. However, if desired, aluminum offers a wide range of finishing options, including anodizing and chromating.

Is welding aluminum different from welding steel or stainless steel?

Yes, welding aluminum is more challenging than welding steel or stainless steel due to its unique characteristics. Aluminum has high thermal conductivity and an oxide layer with a high melting point. Specialized equipment is often needed to achieve the high temperature required for welding. While it can be challenging, Approved Sheet Metal has the expertise and equipment for aluminum welding, although sometimes fasteners may be a more efficient option.

Are aluminum gauges the same as steel gauges?

No, aluminum gauges differ from steel gauges. Steel and stainless steel use the Manufacturers’ Standard Gauge, while aluminum uses the Brown & Sharpe Gauge (American Wire Gauge). For example, 10 gauge stainless steel has a thickness of 0.134″, while 10 gauge aluminum has a thickness of approximately 0.102″. To avoid confusion, it’s recommended to specify both the decimal dimension and gauge in your drawings or provide CAD-drawn 3D models with your RFQ.

What should I know about heat treating aluminum and its different alloys?

Heat treating aluminum alloys varies based on the alloy type:

• 6061-T0: Annealed state, easily formable, and can be heat treated to T4 or T6 condition.
• 6061-T4: Harder than T0, easier to form than T6 while maintaining good strength.
• 6061-T6: Excellent strength but harder to form, requiring a larger bend radius to prevent cracking.
• 7075-T0: Annealed, easily formable, and can be heat treated to T6 condition.
• 7075-T6: Excellent strength but harder to form, also requiring a larger bend radius to prevent cracking.