Fabrication of Aluminum

Grades, Tempers & Formability

Choosing the right grade and temper of aluminum is crucial when considering both the fabrication process and the durability of the material in service. While the formability of an aluminum alloy is tied to its type, the temper can also impact how easily it can be fabricated. For example, the same alloy may be perfect for one application in a specific temper but unsuitable in another.

• Non-Heat Treatable Alloys: Strength is imparted through work hardening, which can be modified by annealing.
• Heat Treatable Alloys: These alloys gain strength through heat treatment, quenching, and aging processes.

Here is an overview of the properties of the main aluminum alloy series:

Cutting Aluminum

Aluminum can be cut using various methods, depending on the shape and form:

• Plate Cutting: Done with saws, lasers, plasma, or water jets. Water jet cutting avoids altering aluminum’s properties since no heat is involved.
• Extrusion and Tube Cutting: Carbon-tipped circular saws are commonly used, and lubrication (e.g., wax) can enhance blade performance. Bandsaws and guillotines are also employed.

Filing & Grinding Aluminum

Special tools are required for filing and grinding aluminum as standard tools may become clogged with filings. Proper tools include files with deeply cut curved teeth and grinding wheels covered in emery or corundum abrasive, which should be lubricated with paraffin.