7 Things to Consider When Choosing an Aluminum Grade

Aluminum comes in many different shapes and grades. The type of aluminum grade you choose ultimately depends on how you intend to use the metal. Your intended use allows you to rank the characteristics of each grade from most important to least important. This will help you narrow down the list of suitable aluminum grades and uses. For example, if weldability is most important to your project but strength is not, it may make sense to choose Alloy 1100, as this aluminum grade has excellent weldability but is not typically used for high-strength or high-pressure applications.

Use the quick aluminum grades chart at the end of this article to quickly and easily find the aluminum grade that is right for you.

When choosing an aluminum grade, consider if the following are important factors:

• Formability or Workability
• Weldability
• Machining
• Corrosion Resistance
• Heat Treating
• Strength
• Typical end-use applications

Is Formability or Workability (the Fashioning Parts Through Mechanical Deformation) an Important Factor?

Formability and workability determine how well a material can endure mechanical deformation processes like bending, shaping, or drawing. Aluminum grades with high workability simplify manufacturing, reduce production costs, and minimize the chances of defects during processing.

• Alloy 1100 – Excellent Formability / Workability
• Alloy 2011 – Good Formability / Workability
• Alloy 2024 – Good Formability / Workability
• Alloy 3003 – Excellent Formability / Workability
• Alloy 5052 – Good Formability / Workability
• Alloy 6061 – Good Formability / Workability
• Alloy 6063 – Good Formability / Workability
• Alloy 7075 – Poor Formability / Workability

Is the Weldability of the Aluminum an Important Factor?

The ability to weld aluminum efficiently and effectively without compromising its strength, durability, or appearance plays a significant role in various industries. Different aluminum grades exhibit varying levels of weldability, influenced by their alloy compositions and physical properties. Opting for aluminum grades with excellent weldability ensures strong, defect-free joints and reduces the likelihood of issues such as cracking or warping during the welding process.

• Alloy 1100 – Excellent Weldability
• Alloy 2011 – Poor Weldability
• Alloy 2024 – Poor Weldability
• Alloy 3003 – Excellent Weldability
• Alloy 5052 – Good Weldability
• Alloy 6061 – Good Weldability
• Alloy 6063 – Good Weldability
• Alloy 7075 – Poor Weldability

Is the Machining of the Aluminum an Important Factor?

Aluminum’s machinability refers to how easily it can be cut, drilled, or milled without excessive wear on tools or compromising the material’s properties. Aluminum grades with good machinability can reduce production time, enhance cost-effectiveness, and improve the quality of the finished product.

• Alloy 1100 – Good Machinability (Best if Hard Temper)
• Alloy 2011 – Excellent Machinability
• Alloy 2024 – Fair Machinability (Best in Annealed Condition)
• Alloy 3003 – Good Machinability
• Alloy 5052 – Fair Machinability (Better if Hard Temper)
• Alloy 6061 – Good Machinability (T4 and T6 Tempers only)
• Alloy 6063 – Fair Machinability
• Alloy 7075 – Fair Machinability (Best in Annealed Condition)

Is the Corrosion Resistance of the Aluminum an Important Factor?

Aluminum naturally forms a protective oxide layer, which enhances its resistance to corrosion, making it an ideal choice for industries such as marine, automotive, and construction. However, the level of corrosion resistance varies among aluminum grades, with some offering superior performance in challenging conditions. Choosing an appropriate grade ensures longevity, reduces maintenance costs, and prevents structural degradation caused by environmental factors.

• Alloy 1100 – Excellent Corrosion Resistance
• Alloy 2011 – Poor Corrosion Resistance
• Alloy 2024 – Poor Corrosion Resistance
• Alloy 3003 – Good Corrosion Resistance
• Alloy 5052 – Excellent Corrosion Resistance (Preferred in marine applications)
• Alloy 6061 – Excellent Corrosion Resistance
• Alloy 6063 – Good Corrosion Resistance
• Alloy 7075 – Average Corrosion Resistance

Is Heat Treating of the Aluminum an Important Factor?

Heat treating directly impacts the material’s strength, hardness, and overall performance. This process alters the microstructure of aluminum alloys, enhancing their mechanical properties to meet specific application requirements.

• Alloy 1100 – Does not respond to Heat Treatment
• Alloy 2011 – Can be Heat Treated
• Alloy 2024 – Can be Heat Treated
• Alloy 3003 – Does not respond to Heat Treatment
• Alloy 5052 – Does not respond to Heat Treatment
• Alloy 6061 – Can be Heat Treated
• Alloy 6063 – Can be Heat Treated
• Alloy 7075 – Can be Heat Treated

Is the Strength of the Aluminum an Important Factor?

Strength directly influences the material’s ability to withstand applied forces without deforming or failing, and different applications demand varying levels of strength to ensure safety, durability, and performance. Aluminum grades offer a wide range of strength levels, often determined by their alloy composition and heat treatment.

• Alloy 1100 – Not used for high-strength or high-pressure applications
• Alloy 2011 – A high mechanical strength alloy
• Alloy 2024 – A high-strength aluminum alloy
• Alloy 3003 – Medium strength
• Alloy 5052 – Medium- to high-strength alloy
• Alloy 6061 – Medium- to high-strength alloy
• Alloy 6063 – Medium strength
• Alloy 7075 – A high-strength aluminum alloy

Typical End-use Applications of Aluminum Grades:

Different aluminum grades offer unique properties suited to particular uses, from high-strength aerospace components to corrosion-resistant marine fittings. By exploring aluminum grades and uses, manufacturers can ensure optimal functionality and cost-efficiency in their projects.

• Alloy 1100 – Metal Spinning and General Fabrication
• Alloy 2011 – General Machining
• Alloy 2024 – Aerospace Applications
• Alloy 3003 – Food & Chemical Equipment – General Fabrication
• Alloy 5052 – Marine Applications – General Fabrication
• Alloy 6061 – Structural Applications – General Fabrication
• Alloy 6063 – Architectural Applications
• Alloy 7075 – Aerospace Applications

Aluminum Grades Chart – Choosing an Aluminum Grade