Originally published on fastradius.com on December 9,
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CNC machining is a traditional manufacturing process that uses drills and turning tools to create a part by removing material from a solid block of material. This process is fast, highly repeatable, and ideal for creating parts with tight tolerances. CNC machining can be done with any material that&#;s rigid enough to machine &#; from plastic to metal to fiberglass &#; and aluminum is a popular choice among product teams.
Broadly speaking, aluminum is a strong, non-magnetic, cost-effective material that is highly corrosion-resistant.
Here&#;s everything engineers and designers should know about the most common types of aluminum used for CNC machining, plus how to choose which type is best for their next project.-T6 is one of the most popular aluminum alloys on the market and most manufacturing companies offer it as the standard grade for CNC machining. It&#;s versatile, easy to machine, and can even have different heat treatments.
-T6 is an excellent all-purpose material applicable to a wide variety of use-cases. Even though this material has a good strength-to-weight ratio, it&#;s ill-suited for high-stress applications. Common applications include automotive parts like chassis, bicycle frames, valves, computer parts, and much more.
Mechanical specifications:
For high-stress or high-performance applications, engineers should consider -T6. This grade of aluminum is well known for its excellent strength-to-weight ratio and its hardness can even be comparable to that of some softer steels.
Widely used for high-stress applications in the aerospace and military industries, common applications include aircraft fittings, missile parts, and fuse parts. Certain high-performance bikes and sporting goods also include parts made from aluminum -T6.
Despite its high strength and excellent mechanical properties, -T6 does have its drawbacks. This material is less ductile and less resistant to corrosion than other grades. What&#;s more, aluminum -T6 can be prohibitively expensive for some product teams.
Mechanical specifications:
Aluminum -T4 is a moderate- to high-strength alloy that offers good fatigue resistance and fracture toughness. Aluminum -T4 isn&#;t as strong as -T6, but it&#;s still suitable for aerospace applications.
Common applications for aluminum -T4 include aircraft fuselage, transport vehicle parts, and wing tension members. However, product teams should note that this grade of aluminum has poor corrosion resistance and is highly sensitive to thermal shock.
Mechanical specifications:
Aluminum MIC 6 is unique because of its specific combination of alloy and casting method that was developed for producing stable, high-tolerance plates. MIC 6 has impressive stress-relieving properties, excellent accuracy, and high machinability. Aluminum MIC 6 is also contaminant- and porosity-free. This smooth, lightweight option can be found in machining components, electronics, and even laser technology.
One drawback is that MIC 6 threads aren&#;t as strong as threads made from , and particularly fine threads can lead to early thread failure. Product designers should keep this limitation in mind during the material selection phase.
Mechanical specifications:
Aluminum has similar properties to aluminum ; however, has a slightly higher tensile strength. Further, this type of aluminum has the highest strength out of all of the series alloys and it&#;s exceptionally corrosion-resistant. is a good option for engineers who want more strength than what offers, but don&#;t want to invest in the series.
Aluminum is well-suited for general purpose applications that need an added degree of strength and toughness. This material is popular in the construction industry and can be found in many bridges, towers, and trusses. However, product designers should keep in mind that it&#;s difficult to produce thin walls using aluminum .
Mechanical specifications:
If product teams choose to machine a part using aluminum, they can trust they&#;re choosing a strong, conductive, and corrosion-resistant material. Aluminum alloys -T4, -T6, and are best for high-performance applications, while and MIC 6 can be used in most cases in which an all-purpose aluminum will suffice.
Since CNC machining is so versatile, it can be challenging for engineers to narrow down their list of well-suited materials for a given project. With decades of technical experience, the SyBridge team of expert designers and engineers can help make material selection much easier for every product team. We are committed to helping every customer innovate and achieve their desired results throughout the entire manufacturing process &#; and with our expert advisory services, teams can rest assured that their material choice will fulfill all critical requirements. Contact us today &#; let&#;s make new things possible, together.
Aluminum is often used in custom component creation using subtractive, or CNC machining that makes use of cutting tools guided by Computer Numerical Control (CNC) to cut away at a solid.
This type of manufacturing method is extremely accurate and precise, offering different surface finishes and often using special tooling to handle metals like aluminum.
But, considering there are many different types of aluminum, what is the best aluminum for machining?
Like most questions with many variables, the answer depends on what you need to create using this versatile metal.
Aluminum is one of the most versatile materials to use for machined parts. It has a high strength-to-weight ratio and is lightweight, making it economical for production use. It is also easy to recycle: According to the Aluminum Association almost 75% of all aluminum previously produced is still in use today.
Pure aluminum can be further optimized by mixing it with other elements to create an alloy. Commonly used aluminum alloys often include:
Silicon
Magnesium
Copper
Iron
Zinc
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Alloys of aluminum are classified into a wide variety of grades. The grading system helps classify a particular aluminum alloy according to its characteristics. This classification helps engineers and machine shops to determine which alloy is best, based on end-use.
In addition to considering the grade of the alloys of aluminum, engineers may also look at whether or not a particular alloy is heat-treatable.
Heat treating is a process in which aluminum is able to be strengthened by increasing its temperature for a set amount of time, essentially baking the metal. There are several kind of heat treatments available including:
Annealing
Homogenizing
Solution heat treatment
Precipitation hardening (artificial aging)
Heat-treatable alloys in the annealed condition are especially strong: after heating, the parts are rapidly cooled, which freezes the metal&#;s atoms in place. An alloy&#;s aluminum grade and further processes like those listed above, give aluminum specialized advantages for various utilizations.
Aluminum makes for an excellent machining metal partly due to its ability to be easily shaped and cut. Tooling tends to last longer, which translates to cost savings for manufacturers. One of the best tool coatings for machining aluminum is diamond since it performs well at high speeds, although there is significant cost up-front.
It is necessary to have a system of organization for aluminum since so many different alloys exist. Each has unique physical properties like corrosion resistance, strength and ductility. Aluminum grades are classified into seven groups in numerical order, ranging from the 1XXX series to the strongest alloys in the 7XXX series.
Determining the best grade of aluminum for machining depends highly on what it will be used for. Although not always the case, the following types of aluminum are often paired with the usages below.
2XXX Group
The 2XXX group is used in the world&#;s largest automotive, aerospace and transportation industries. The most apparent element used in these alloys is copper, and they are very resistant to fatigue.
Sometimes called &#;duralumin,&#; this group has a high strength-to-weight ratio but, due to the copper, is susceptible to corrosion. A commonly used alloy from the 2XXX series is aluminum .
Aluminum
Aluminum is nearly pure but does contain the mineral manganese. It is a non-heat treatable alloy, ideal for making items used in the kitchen like cooking equipment and utensils, as well as chemical equipment, roofing and siding.
Its heat resistance also makes it ideal for secondary treatments and is a great choice if you want the best coating for machining aluminum.
Aluminum
Aluminum is strong, workable and corrosion-resistant. Its main elements are magnesium and chromium.
This alloy is resistant to saltwater which makes it perfect for the marine industry and bridges. Aluminum is the strongest non-heat-treatable alloy. It is also found in aircraft parts, household appliances and commercial, heavy-duty cooking equipment.
6XXX Group
The major alloys in this group are magnesium and silicon. One of the most versatile of all machinable alloys is aluminum , which is available in sheet, plate and extrusions.
In its sheet metal form, aluminum is one of the best-stamped aluminum alloys for machining. It is often used in metal fabrication including aerospace applications.
7XXX Group
The 7XXX group is often used for highly&#;stressed functions and is heat-treatable, ductile and tough. Its major element is zinc but alloys may contain copper, chromium, and magnesium.
In addition to the sporting goods industry, aluminum from the high-strength 7XXX series is used for marine applications, aerospace, defense and transportation. These alloys are so strong, they can become brittle over time. One of the most popularly used alloys in this series is aluminum .
Although the adaptability of the 6XXX group makes it a top runner for the best aluminum grade for machining, it truly depends on the mechanical properties of the alloy, the end application and the machining processes used. Regardless, aluminum is offered in such a range of options, it will continue to be used as one of the most flexible, economical and strong metals in engineering.
At Moseys Production Machinists, we have almost half a century of experience creating highly precise, ready for assembly parts that speed up your supply chain management and reliably reduce inventory issues.
If you require large, or even small volumes of CNC, Swiss precision parts made of aluminum, or any material for that matter, talk to us today and get a free quote.
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