How To Choose The Correct Aluminum Alloy

1000 Series

1000 series alloys are chemically pure (99%+ aluminum) and are commonly available in wire and thin sheets.  This series has excellent corrosion resistance, workability, and high thermal and electrical conductivity.  1350, for example, is the go-to choice for high voltage transmission lines and other large-scale electrical products. 

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2000 Series

2000 series alloys are alloyed with copper, which allows the material to be precipitation hardened to strengths near those of steel.  This is, however, at the expense of corrosion resistance.  2024 was once one of the most common high-strength aerospace alloys, but has been increasingly replaced by 7000 series materials which aren’t as susceptible to stress-corrosion cracking.

3000 Series

Manganese is the alloying element in 3000 series aluminums.  This alloy has good corrosion resistance and strength, and also performs notably well in stamping applications.  This makes it the material of choice for beverage cans, grating, and many types of tubing.

4000 Series

Silicon is used as the main alloying element in 4000 series alloys.  Silicon improves the fluidity of the material in its molten state which is helpful in products like welding wire and brazing rod. 

5000 Series

5000 series aluminum is alloyed mainly with magnesium and silicon, giving it superb corrosion resistance.  This is helpful in marine applications where the material is subjected to constant harsh conditions.  5052 aluminum is widely known for being one of the easiest alloys to weld.  Combine that with the alloy’s excellent corrosion resistance and you have a perfect material for pressure vessels and ship hulls.

6000 Series

The 6000 series materials are alloyed with magnesium and silicon.  They are easily machined, weldable, and heat treatable (though not to the same strengths as 2000 and 7000 series).  6000 series alloys like 6061 and 6063 are extremely common in machining and architectural applications.  6061, for example, is available in almost any shape and size you could imagine including bar, plate, sheet, tube, channel and more. 

7000 Series

Zinc is the primary alloying element in 7000 series alloys, but magnesium and copper are usually present as well.  These materials possess the highest strengths of any of the aluminum alloys.  7075 is commonly used in aircraft landing gears and other parts requiring high strength to weight ratios.  7050 is another common 7000 series alloy and is also heavily used in aerospace applications requiring stress-corrosion resistance. 

Temper and Age Conditions

Temper designations tell the material producer and consumer how an alloy has been mechanically and/or thermally modified to achieve certain properties.  The first letter designates the class of treatment, while the succeeding number(s) designate specific processes that have been applied to an alloy.

• F – as fabricated.  These are semi-finished products that have not yet been thermally modified. 

• O – annealed.  Materials with the O designations have been annealed, usually to maximize workability.

• H – strain hardened.  This is for non-heat-treatable alloys that have had their strength increased by strain hardening.  This process, of course, usually does not involve heat as is performed at room temperature.

• T – thermally treated.  This designation represents products that have gone through the entire tempering process.  These materials have been given a solution heat treatment followed by quenching and artificial aging.

• W – solution heat treated.  This designation usually represents an unfinished product.  Solution heat treating is the process by which a material is heated up and held at a certain temperature for a specified amount of time, and then rapidly cooled to “lock in” the properties of the heated material.  This process is usually followed by tempering and quenching.

Key Takeaways

For an engineer or part designer, series numbers are the most important topic to understand.  Temper and age conditions are somewhat set-in stone, and engineers typically don’t specify these in the design stage, except in very specific circumstances.  For example, if you would like a part to made from 6061 aluminum, it is likely going to be of the 6061-T6511 designation. Engineers should also understand the shapes and sizes alloys are available in. McMaster Carr is a good source for this information.

Choosing the correct alloy can have major impacts not only on the performance of your parts, but also on the cost.  If you need help selecting the right material for your parts, contact us or get a quote!

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Aluminum is an excellent choice for machining because it is easy to shape. It’s a better choice for many projects because it is more machinable than other metals like steel. Because aluminum is readily available, and easy on equipment as well as cost-effective, manufacturers choose aluminum for machining projects. But how do you know what aluminum alloy is the one for your specific project or application?

Choosing an Aluminum Alloy

The first step is understanding the common characteristics of the different aluminum alloys available. Aluminum is soft, lightweight, and abundant. It can be used to make aluminum sheeting, aluminum plates, or aluminum bars. There are numerous alloys that may lend themselves well to your project. But how to do you know the aluminum alloy to choose? Understanding the different series of aluminum alloys as well as their strengths can help you make the right choice. Our team can also advise you. Read about each series below and let us know if you have questions.

Series 1xxx

Consisting of 99% pure aluminum, this series contains silicon and iron as well. It can easily be drawn out into a thin wire and therefore is used frequently in electrical projects or for chemical applications. Two other factors that may be appealing (or necessary!) are the fact that series 1xxx alloys are resistant to corrosion with low mechanical properties. This alloy is easy to form, and very workable. 

Series 2xxx

The primary element in the Series 2xxx alloys is copper. You’ll hear them referred to as copper alloys. Their “trait” that is most appealing and what they are most well known for is their excellent machinability. It is less reliable in the areas of corrosion resistance and weldability. Because of the strength of these alloys, however, they are used frequently in aerospace/aircraft. 

Series 3xxx and Series 4xxx

Frequently used in building and architecture, the Series 3xxx alloys are primarily manganese and are well known for formability and medium-grade strength. The Series 4xxx alloys are primarily silicon and have a lower melting point so they are less brittle than other alloys. They are also frequently used in the architecture industry. 

Series 5xxx

The primary two elements for Series 5xxx are magnesium and manganese. They hit the trifecta of being strong, formable, and corrosion-resistant. You’ll find these alloys in bridges and other transportation projects. They are also commonly used in the marine industry. 

Series 6xxx

Versatility makes the Series 6xxx alloys very popular. Silicon and magnesium are the main alloy elements for this Series. They fall in a mid-strength range but are highly formable and offer great corrosion resistance which makes them popular in numerous segments of industry including pipes, electrical components, and even some consumer products. 

Series 7xxx

Strength is the name of the game for Series 7xxx. The alloying elements include zinc, copper, chromium, and magnesium. This Series offers a very high level of strength but is not known for easy machinability. Because of its uses for making molds , it is commonly used by our team. Because of the high level of strength, this Series is found in almost all industries including, but not limited to, automotive, aerospace, marine, and machinery manufacturing.

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