Aluminum Alloy Selection Guide for Sheet Metal Projects - Komacut

In this article, we’ll look at the most common aluminum alloys used in sheet metal manufacturing and how to make an informed decision in which grade of aluminum to use.

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Aluminum is a non-ferrous, lightweight and malleable metal that is widely used in sheet metal applications for its high strength-to-weight ratio, good corrosion resistance, formability, weldability and good conduction of heat and electricity. It has a lower mechanical strength than alternative metals like steel, but it is a versatile and highly useful material. Aluminum is also alloyed with other elements, including copper, magnesium, silicon, zinc and manganese, to create versions of aluminum with significantly different physical qualities.

The Aluminum Material Family

When it comes to using aluminum in sheet metal manufacturing, it’s best to think of aluminum as a family of different aluminum alloys.

All aluminum alloys have some characteristics in common:

• Light weight and good strength-to-weight ratio - Aluminum is about one-third the weight of steel, but it still maintains good strength.
• Corrosion resistance - Aluminum naturally forms a protective, surface oxide layer.
• Good thermal and electrical conductivity.
• Good formability - Easy machinability, weldability and overall formability.
• Recyclability - Fully recyclable, without losing quality.

Aluminum can also be alloyed with other metals to create variations of aluminum with different properties. Alloy materials can be used to increase strength, thermal conductivity or formability, for example. The alloy is then better suited to certain manufacturing processes and in-life uses. The various families of aluminum alloys are based upon the secondary metal the aluminum is alloyed with, so such as copper, magnesium, silicon, zinc and manganese.

In airplanes and high-performance sports equipment, for example, aluminum is alloyed with zinc to create series alloys with exceptional strength to weight ratios.

Specific Alloys of Aluminum for Sheet Metal Fabrication

In this section, we’ll look at the most popular aluminum alloys. If you have an aluminum sheet metal production project planned, it’s likely one of the alloys in this section will fit the bill.

First, we’ll explain the basics of the aluminum alloy numbering system.

Aluminum alloys are all given four numbers, and the first number refers to the material aluminum is alloyed with:

• series: Pure aluminum
• series: Copper
• series: Manganese
• series: Silicon
• series: Magnesium
• series: Magnesium and silicon
• series: Zinc

The other numbers are related to modifications to the alloy (most aren’t modified) and serialization and identification.

AL Aluminum

AL is a pure form of aluminum and actually isn’t an alloy.

AL has a lower level of mechanical strength compared to other materials in the aluminum family, but despite this, AL is a very useful manufacturing material. Where strength is not an important requirement, AL is often the right production material.

Here are the most beneficial properties of AL:

• Mechanical characteristics: Excellent corrosion resistance, high ductility, high electrical and thermal conductivity and high reflexivity.
• Processing characteristics: Good forming, welding, brazing and surface finishing
• Performance: Ideal for applications requiring light weight and high malleability.

Common Applications

Here are some common applications for AL:

• Food, pharmaceutical and liquid containers
• Low demand / cost sensitive wiring, circuit boards, and other electrical applications
• Roofing and cladding (due to its durability and corrosion resistance)
• Lighting fixtures and solar panels (due to its high reflectivity).

AL T5 Aluminum

AL T5 is also an alloy of magnesium and silicon. It is a medium-strength material (but can be heat treated to increase strength) that is known for its corrosion resistance and weldability. It is also known for being good for extrusion and is used to create complex shapes with smooth surfaces that can be anodized.

• Mechanical characteristics: Moderate strength, corrosion resistance and excellent surface finish.
• Processing characteristics: Good weldability and good for extrusion.
• Performance: Highly suitable for architectural applications and popular for decorative and structural uses.

Common Applications

• Window frames
• Door frames
• Roofs
• Sign frames
• Recreation equipment
• Storage tanks
• Vehicle and trailer structural components

Aluminum Alloy Tempering

Aluminum alloys can be tempered to alter their mechanical or physical properties. This refers to processes the alloys undergo during production. Tempering will further enhance certain properties of an aluminum alloy, such as hardness or ductility.

The main tempering processes used for aluminum are:

• Annealing
• Solution heat treatment
• Artificial aging
• Strain hardening
• Stress relieving

The following table demonstrates the benefits of each process as well as the disadvantages:

Process Benefits Disadvantages Annealing

• Softens the material
• Relieves internal stresses
• Improves machinability and workability
• Enhances uniformity

• Reduces strength
• Lowers hardness
• Potential for oxidation/scaling

Solution heat treatment

• Increases strength
• Enhances hardness and corrosion resistance

• Risk of distortion/warping
• Limited to certain alloys
• Cracking can occur

Artificial ageing

• Increases strength
• Enhances hardness
• Improves dimensional stability

• Time-consuming
• Can reduce strength
• Limited to certain alloys

Strain hardening

• Increases strength
• Enhances hardness
• Improves wear resistance
• Maintains ductility (to a degree)

• Reduces ductility and increases brittleness
• Limited to certain alloys/thicknesses
• May result in non-uniform hardening

Stress relieving

• Reduces residual stresses
• Improves dimensional stability
• Prevents cracking

• Potential for distortion if unevenly heated
• Time-consuming process
• May not eliminate all residual stresses

How to Select the Right Aluminum Alloy Material

In this section, we’ll run through the decision-making process for choosing an aluminum alloy for a sheet metal manufacturing project.

The Decision Making Process

The important factors that determine your choice of aluminum alloy are the requirements in application, the processing requirements and your budget.

• As a rule, choose an alloy that meets your requirements but which maintains as much formability as possible and comes at a low cost.
• While there may be stronger, lighter weight aluminum alloys available, there is no point increasing manufacturing difficulty and sacrificing your funds if there are no tangible benefits.

Requirements in Application

Possibly the most important consideration is how you need your aluminum alloy to perform when it’s in use.

To make this judgement properly, you need to accurately know what kind of stress your component will be put to in use. Ideally, components should be tested to ascertain minimum yield and tensile strength requirements as well as hardness. Alternatively, this can be modeled within most standard 3D software.  

This consideration will often need to be made alongside weight because weight can be a limiting factor in type selection.

Refer to our table above for guidance.

You can also refer to GB/T codes for aluminum for detailed information about alloys, including their chemical composition, mechanical properties, tempering designation, corrosion resistance and application guidance.

Processing Requirements

The next consideration is what manufacturing processes you need your alloy to be compatible with.

• CNC Bending – Aluminum alloys that are too hard are not suitable to bending. Alloys with a hardness of T6 are prone to micro-cracking during bending. AL is the primary choice for sheet metal bending.
• Stamping – High-hardness aluminum can also crack during stamping, depending on the thickness of the material and the type of stamping.
• CNC Machining – All aluminum alloys are suitable for machining, though a softer material will require less machining time.
• Welding – Aluminum alloys can be welded without issue, though they do require TIG or laser welding, as opposed to the simpler / less expensive MIG welding technology. Some types are also easier to weld.
• Extrusion – While it doesn’t apply to sheet metal parts, extrusion cannot be done with alloys with a hardness higher than T5. AL T5 is a typical choice for extruded parts.

Remember to plan your finishing processes ahead of production as well.

The following table displays the fabrication processes the different aluminum alloys are suitable for:

Aluminum Alloy Laser Cutting CNC Bending CNC Turning CNC Stamping Welding AL AL H32 AL T6 Limited AL T5 AL T6 Limited Limited

Komacut

Komacut is a subsidiary of Komaspec, a Canadian-owned contract manufacturer with more than 20 years experience of sheet metal manufacturing.

You can upload your sheet metal drawings to the Komacut platform and receive an instant manufacture quotation. You also get instant design for manufacturability feedback so you can iterate and improve designs. If you’d like to discuss the suitability of different aluminum alloys for your sheet metal project, we’d be happy to talk to you about this before you place an order as well.

If you are looking for more details, kindly visit Shangshai Wire Mesh.

Komacut can be used for anything from prototypes to high-volume (100,000 +) orders. 

Aluminum angles are a vital component in construction, manufacturing, and various industrial applications. Their strength, lightweight nature, and corrosion resistance make them a top choice for engineers and builders alike.

Here, we’ll dive deep into what aluminum angles are, their types, uses and benefits, and how to choose the right one for your project.

Table of Contents 

Key Takeaways

What Are Aluminum Angles?

Types of Aluminum Angles

How to Choose the Right Aluminum Angle for Your Project

Frequently Asked Questions (FAQs)

Make the Right Choice with FastMetals

Key Takeaways

• Aluminum angles are L-shaped metal profiles used for structural support in various applications.

• Aluminum angles are lightweight, corrosion-resistant, strong, easy to work with, and sustainable.

• Equal leg aluminum angles have uniform sides, making them ideal for balanced framing and support.

• Unequal leg aluminum angles provide extra reinforcement where one side needs more strength.

• Structural aluminum angles are designed for load-bearing applications, while decorative ones enhance aesthetics.

• Anodized aluminum angles have enhanced corrosion resistance and an attractive finish for various industries.

• Different aluminum alloys, such as and , offer varying tensile strengths for structural and decorative uses.

What Are Aluminum Angles?

Aluminum angles are metal profiles shaped into a right angle, typically with two legs of equal or unequal length. These angles are widely used in construction, manufacturing, and DIY projects due to their strength, light weight, and resistance to corrosion. The L-shaped profile of aluminum angles makes them ideal for framing, reinforcing, or adding structural support to a variety of projects.

Most aluminum angles are measured by the length of their legs and their thickness. For example, a 2” x 2” x 1/8” aluminum angle means the two legs are each 2 inches long, with a thickness of 1/8 inch.

Key Properties of Aluminum

Aluminum is an attractive material for angles because of its many beneficial properties. These qualities make it a popular choice in both industrial and commercial applications.

1. Lightweight

Aluminum is significantly lighter than other metals like steel, which makes it easier to handle, cut, and install. This lightweight feature is especially useful in projects where weight is a concern, such as automotive or aerospace industries. In construction, lightweight aluminum angles reduce the overall weight of structures, making them more cost-effective and easier to assemble.

2. Corrosion Resistant

Aluminum naturally forms a thin oxide layer when exposed to air, which protects it from rust and other forms of corrosion. This makes it ideal for outdoor and marine applications where exposure to the elements is common. Aluminum angles are often used in building facades, bridges, and railings, where their resistance to corrosion increases their longevity.

3. Strong and Durable

Despite being lightweight, aluminum has an impressive strength-to-weight ratio, which means it can handle significant stress without compromising its structural integrity. Aluminum angles are used in high-stress environments, such as in the automotive and transportation industries, where both strength and light weight are required.

4. Workable

Aluminum is easy to cut, weld, and shape. This workability allows it to be customized for a variety of purposes, making it an excellent choice for a wide range of applications. Aluminum angles can be fabricated into custom sizes and shapes to fit specific requirements in manufacturing and construction.

5. Sustainable

Aluminum is highly recyclable, which means it can be reused without losing its quality. This makes it an environmentally friendly choice for businesses that are looking to reduce their carbon footprint. Recycled aluminum angles are commonly used in the manufacturing of new products, reducing the need for virgin materials.

Types of Aluminum Angles

Aluminum angles are versatile materials that come in various types, each serving distinct functions in different industries. Understanding the different types of aluminum angles and their specific uses will help you make an informed decision when selecting the right one for your project. Below, we explore the various types of aluminum angles and where they are best applied.

1. Equal Leg Aluminum Angles

Equal leg aluminum angles feature two legs that are of equal length and are typically in an L-shape. This type is the most common and widely used due to its balanced structure. The uniformity of the legs makes it easy to use in numerous applications, from simple home projects to complex industrial constructions.

Where They’re Used

Equal leg aluminum angles are highly versatile and are often used in various industries due to their ability to provide balanced support. They are commonly used for:

• Framing: Equal leg angles are perfect for creating strong, stable frames for structures like shelving, partitions, and more.

• Supports: They are ideal for providing even support in applications such as electrical panels, sign frames, and more.

• Bracketing: The symmetrical shape offers effective reinforcement for a variety of bracketing purposes, from construction to vehicle parts.

2. Unequal Leg Aluminum Angles

Unequal leg aluminum angles, as the name suggests, have one leg longer than the other. This design allows for more flexibility in applications that require one side to carry more weight or provide additional support. The unequal dimensions offer specific advantages in situations where a custom support structure is needed.

Where They’re Used

Unequal leg aluminum angles are often chosen when structural integrity is required, but one side of the angle needs more reinforcement than the other. They are typically used in:

• Structural Frames: Ideal for creating frames that require different lengths on each side to meet specific design or load-bearing needs.

• Heavy-Duty Supports: These angles are commonly used in applications like vehicle chassis, machinery, and large-scale equipment where one side needs extra strength or support.

• Braces and Reinforcements: In constructions where specific bracing is required for uneven loads or to enhance structural stability.

3. Structural vs. Decorative Aluminum Angles

There are two main categories of aluminum angles based on their intended purpose: structural and decorative.

• Structural Aluminum Angles: Made for heavy-duty applications, typically thicker and stronger. These angles are designed to bear significant loads and withstand harsh environments.

• Decorative Aluminum Angles: Focus more on appearance, providing a lightweight and aesthetically pleasing finish. They are often used in areas where the angle is visible and must complement the overall design of the space.

Where They’re Used

• Structural Aluminum Angles: Used primarily in construction, manufacturing, and engineering, structural angles are found in applications that demand strength and stability, such as:

• Building frames in commercial and industrial settings.
• Support beams in large structures like bridges or warehouses.
• Heavy-duty brackets in machinery, equipment, or even railings.

• Decorative Aluminum Angles: These are perfect for environments where the aesthetic value of aluminum angles is crucial. They are often found in:

• Interior design applications, such as wall trim, decorative furniture, or shelving units.
• Furniture accents, where the lightness and shine of aluminum angles enhance the overall visual appeal.
• Architectural elements, like window frames, door trims, and facades in modern buildings.

4. Anodized Aluminum Angles

Anodized aluminum angles have undergone a specialized electrochemical process that enhances the natural oxide layer on aluminum’s surface. This process not only increases the material’s resistance to corrosion but also improves its appearance by adding color options or a shiny finish.

Where They’re Used

Anodized aluminum angles are commonly used in industries where both function and form are important. The anodized coating provides durability and an attractive finish that resists wear and tear. These angles are perfect for:

• Automotive Industry: Anodized angles are used in car parts, trim pieces, and external accessories where corrosion resistance and an appealing finish are crucial.

• Architectural Applications: These angles are used for window frames, building facades, and other exposed components in commercial or residential construction, offering both durability and a clean, modern look.

• Electronics and Appliances: The anodizing process makes aluminum angles more resistant to scratches, ensuring long-term use in gadgets and household appliances.

5. Tensile Strength Variations

Aluminum alloys come in different grades, each offering specific tensile strength characteristics. Tensile strength refers to the maximum amount of tensile (pulling) stress that the aluminum can withstand before breaking. Common alloys such as and offer different levels of strength, making them suitable for distinct applications.

• Aluminum: Known for its high strength, aluminum is commonly used in structural applications, providing excellent durability and performance under stress. It is widely used in construction, aerospace, and marine industries.

• Aluminum: This alloy is softer than and is often used in decorative applications, including anodized aluminum angles, due to its malleability and ability to take on a refined finish.

Where They’re Used

Selecting the right alloy with the appropriate tensile strength is critical to ensuring the angle will meet the demands of the application. Here’s where these alloys are typically used:

• Aluminum Angles: Ideal for structural components, including:

• Building frames and support beams in heavy-duty constructions.
• Aerospace components, like wing braces or structural parts in aircraft.
• Marine applications, such as boat frames and dock supports, where high strength is needed to withstand harsh environments.

• Aluminum Angles: Perfect for more lightweight, decorative applications, such as:

• Window and door frames in residential or commercial buildings.
• Furniture design and fixtures, like display racks or decorative trim.
• Interior designs where the focus is on aesthetics over heavy-duty strength.

How to Choose the Right Aluminum Angle for Your Project

Choosing the right aluminum angle is essential for the success of your project. Whether you are constructing a heavy-duty support structure, or crafting decorative elements, selecting the correct aluminum angle ensures that your project is durable, functional, and aesthetically pleasing. Below are the key factors to consider when choosing the right aluminum angle for your needs:

1. Consider the Application

The first step in selecting an aluminum angle is to determine the primary purpose of the material. Different applications require different types of aluminum angles based on strength, appearance, and functionality. This decision will guide your choice in terms of size, strength, finish, and design.

• Structural Support: If the aluminum angle is intended for load-bearing or structural purposes, you’ll need to prioritize strength and durability. Structural aluminum angles are commonly used in the construction of frames, beams, and supports in industries like architecture, engineering, and manufacturing.

• Decorative Use: For applications where aesthetics matter, such as interior design, furniture, or architectural details, focus on decorative aluminum angles that offer a refined finish. These angles are typically lighter and may have a more polished or anodized surface.

• Mechanical Purposes: When aluminum angles are used for mechanical or functional purposes (e.g., in machinery or equipment), the focus is typically on durability, resistance to wear and tear, and the ability to withstand stress over time.

2. Size and Dimensions

Once you have an idea of the angle’s application, the next step is to consider the size and dimensions. The aluminum angle must fit within the designated space and handle the load requirements effectively.

• Leg Length: Measure the area where the angle will be installed to ensure the legs of the aluminum angle will fit properly. Equal leg aluminum angles are typically used for symmetrical frames, while unequal leg angles may be required if one side of the angle needs to carry more weight or cover a larger area.

• Thickness: The thickness of the aluminum angle is directly related to its strength. Thicker angles provide more support and can handle heavier loads, making them suitable for structural or heavy-duty applications. On the other hand, thinner angles may be suitable for lighter applications like decoration or framing.

• Fit and Placement: Ensure the angle is sized appropriately to fit within your design. For example, if you’re using aluminum angles for window frames, make sure they are sized to accommodate the dimensions of the window. For construction or support frames, consider both the vertical and horizontal dimensions of the angle to ensure it will provide the needed support.

3. Strength Requirements

Strength is one of the most crucial factors when selecting an aluminum angle, especially if it will be used in structural applications. Different aluminum alloys offer varying levels of tensile strength, which affects their ability to bear loads and perform under stress.

• Stronger Alloys for Structural Projects: If your project requires high strength and load-bearing capabilities, opt for aluminum angles made from strong alloys like aluminum. This alloy is known for its excellent tensile strength, making it ideal for heavy-duty applications like construction frames, bridges, and aerospace components.

• Softer Alloys for Lighter Applications: For decorative purposes or situations where weight isn’t a significant concern, a softer aluminum alloy like aluminum may be sufficient. This alloy is more malleable and easier to work with, making it perfect for architectural designs and furniture.

• Weight Considerations: Consider how much weight the aluminum angle needs to support. If you are working with lighter materials or small structures, a lower-strength alloy may be enough. For larger, more complex designs, a stronger alloy will ensure the angle holds up over time.

4. Finish and Coating

The finish and coating on aluminum angles play a significant role in both their appearance and durability. Depending on your project’s exposure to the elements or aesthetic requirements, you may need to choose a specific type of finish or coating.

• Anodizing: If the aluminum angle will be exposed to harsh environments, such as outdoor construction or marine applications, consider anodizing the angle. The anodizing process creates a durable oxide coating that improves corrosion resistance and extends the material’s lifespan. 

• Powder Coating: For additional protection, especially in exterior settings, powder coating is an excellent option. It provides a durable, high-quality finish that helps prevent rust and corrosion, making it suitable for outdoor applications like framing, railings, and outdoor furniture.

• Polished or Brushed Finishes: If aesthetics are important and the aluminum angle will be visible, consider a polished or brushed finish. These finishes enhance the angle’s appearance and provide a clean, modern look. Polished finishes reflect light, while brushed finishes offer a textured, non-reflective appearance.

5. Cost vs. Benefit

Cost is always an important consideration when selecting materials for any project. However, it’s essential to weigh the cost of aluminum angles against their benefits to ensure that you’re making a sound investment in the long run.

• Budget Considerations: Aluminum is generally more affordable than other metals like steel, but costs can vary depending on the alloy, finish, and size. Evaluate your project budget and determine how much you are willing to invest in the material.

• Performance vs. Price: Higher-strength alloys and specialty finishes often come at a higher price. If you are working on a structural project where strength and durability are critical, investing in a stronger, more durable alloy may be worth the additional cost. For decorative purposes or less demanding applications, you can often opt for more cost-effective alloys or finishes.

• Long-Term Durability: While the upfront cost of a high-quality aluminum angle may be higher, consider how the material will perform over time. Aluminum angles with corrosion resistance or a longer lifespan may save you money in maintenance and replacements in the future.

Frequently Asked Questions (FAQs)

Make the Right Choice with FastMetals

When it comes to choosing the right aluminum angle for your project, attention to detail is essential. If you’re ready to purchase aluminum angles and other high-quality metal products, look no further than FastMetals. Offering a wide variety of aluminum angles and custom cuts, FastMetals is dedicated to providing fast, reliable service. Most orders ship within 1 to 2 business days, ensuring that you get the products you need.

For more information, please visit Aluminum Alloy Frame.