CNC Machining of Aluminum: Properties and Applications by RapidCalib

Aluminum: The Ideal Choice for CNC Machining

Aluminum, with its unique combination of physical and mechanical properties, has become a preferred material in CNC machining across various industries. As a professional prototype and custom part manufacturer, RapidCalib leverages the advantages of aluminum in CNC machining to deliver high-precision, high-quality components for clients worldwide. This article explores the key properties of aluminum that make it suitable for CNC machining and the diverse applications of aluminum CNC machined parts, highlighting RapidCalib's expertise in this field.

Aluminum is one of the commonly used materials in current machining. In fact, the CNC machining process for aluminum materials is second only to steel in terms of frequency of use.

In its high-purity form, the chemical element aluminum is soft, ductile, non-magnetic, and has a silvery-white appearance. However, this element is not used solely in its pure aluminum state. Aluminum is usually alloyed with various elements such as manganese, copper, and magnesium to form a variety of aluminum alloys with significantly improved properties. Common machining aluminum alloys and their designations under different standards can be found here.

Advantages of Using Aluminum for CNC Machined Parts

Although there are countless aluminum alloys with varying properties, all aluminum alloys share some basic characteristics:

• Machinability
  Aluminum can be easily and rapidly cut by machine tools due to its soft texture and low cost. It is less prone to deformation during processing and allows for higher tolerance, resulting in precise components.
• Specific Strength
  Despite its light weight, aluminum has very high strength, making it suitable for applications in industries such as automotive and aerospace.
• Corrosion Resistance
  Aluminum is highly resistant to corrosion, and its resistance can be further enhanced through anodization. This property varies depending on the alloy grade.
• Low-Temperature Performance
  Unlike carbon steel or rubber, aluminum maintains its softness, ductility, and strength at low temperatures.
• Electrical Conductivity
  While aluminum alloys have lower electrical conductivity than pure aluminum, they still meet the requirements for many electronic components.
• Recyclability
  Aluminum is highly recyclable, requiring little energy for recycling, making it an environmentally friendly choice for CNC machining.
• Anodization Potential
  Aluminum's anodization process improves wear resistance, corrosion resistance, and offers the ability to color parts easily.

Popular Aluminum Alloys in CNC Machining

Based on our experience at Xometry, the following seven aluminum grades are commonly used in CNC machining:

1. EN AW-2007 / 3.1645 / AlCuMgPb

• Other designations: 3.1645; EN 573-3; AlCu4PbMgMn
• This aluminum alloy is an aluminum-copper alloy, with copper as its main alloying element (accounting for 4%-5%). It is a short-chipping alloy that is durable, lightweight, and functional, with high mechanical properties similar to AW 2030.
• Suitable for: Tapping, heat treatment, and high-speed machining. These characteristics make it widely used in the production of mechanical parts, bolts, rivet nuts, screws, and deformed steel bars.
• Note: This grade has poor weldability and corrosion resistance, so it is recommended to perform anodization after part processing for protection.

2. EN AW-5083 / 3.3547 / Al-Mg4.5Mn

• Other designations: 3.3547; Alloy 5083; EN 573-3; UNS A95083; ASTM B209; AlMg4.5Mn0.7
• Alloy AW 5083 is known for its excellent performance in extreme environments. It contains magnesium and small amounts of chromium and manganese. This grade exhibits very high corrosion resistance in chemical and marine environments.
• Among all non-heat-treatable aluminum alloys, it has higher strength, which can be maintained even after welding.
• Note: It is not suitable for use in environments with temperatures above 65°C, but performs excellently at low temperatures.
• Application scenarios: Low-temperature equipment, marine applications, pressure vessels, chemical applications, welded structures, and vehicle bodies.

3. EN AW 5754 / 3.3535 / Al-Mg3

• Other designations: 3.3535; Alloy 5754; EN 573-3; UNS A95754; ASTM B 209; Al-Mg3
• AW 5754 is an aluminum-magnesium alloy with very high aluminum content, suitable for rolling, forging, and extrusion. It is a non-heat-treatable aluminum alloy that can be strengthened through cold working but has relatively low ductility.
• This alloy has excellent corrosion resistance and high strength, making it one of the most popular aluminum materials for CNC machining.
• Application scenarios: Welded structures, floor coverings, fishing gear, vehicle bodies, food processing, and rivets.

4. EN AW-6060 / 3.3206 / Al-MgSi

• Other designations: 3.3206; ISO 6361; UNS A96060; ASTM B 221; AlMgSi0.5
• This aluminum alloy contains magnesium and silicon. It is heat-treatable, with medium strength, good weldability, and formability. It is also highly corrosion-resistant, and this property can be further improved through anodization.
• Application scenarios: Construction, food processing, medical equipment, and automotive engineering.

5. EN AW-7075 / 3.4365 / Al-Zn6MgCu

• Other designations: 3.4365; UNS A96082; H30; Al-Zn6MgCu
• Zinc is the main alloying element in this grade. Although EN AW 7075 has average machinability, poor cold forming properties, and is not suitable for welding and brazing, it has high specific strength, excellent tolerance in atmospheric and marine environments, and higher strength than some steel alloys.
• Application scenarios: Hang gliders and bicycle frames, climbing equipment, weapons, and mold manufacturing.

6. EN AW-6061 / 3.3211 / Al-Mg1SiCu

• Other designations: 3.3211; UNS A96061; A6061; Al-Mg1SiCu
• The main alloying elements are magnesium and silicon, with a small amount of copper. It is a high-strength alloy with a tensile strength of up to 180 megapascals, making it very suitable for high-load-bearing structures such as scaffolding, railway carriages, machinery, and aerospace parts.

7. EN AW-6082 / 3.2315 / Al-Si1Mg

• Other designations: 3.2315; UNS A96082; A-SGM0.7; Al-Si1Mg
• This alloy is usually produced by rolling and extrusion, with medium strength, excellent weldability, and thermal conductivity. It has high resistance to stress corrosion cracking. The tensile strength ranges from 140 to 330 megapascals.
• Application scenarios: Widely used in marine construction and containers.

Industrial Applications of CNC Machined Aluminum Parts

CNC machined aluminum parts are indispensable across multiple industries due to their versatile properties:

• Aerospace
  Aluminum alloys’ high specific strength makes them ideal for many aircraft components.
• Automotive Manufacturing
  Parts such as drive shafts and other components are often made of aluminum for its strength-to-weight ratio.
• Electrical
  Aluminum is used for electronic components in household appliances due to its electrical conductivity.
• Food/Pharmaceutical
  Aluminum parts do not react with most organic substances, making them essential in these industries.
• Sports
  Aluminum is frequently used to manufacture sports equipment like baseball bats and sports whistles.
• Low-Temperature Applications
  Aluminum maintains its properties below zero degrees Celsius, making it ideal for cold applications.

In summary, the exceptional properties of aluminum make it a versatile choice for CNC machining, catering to the diverse needs of multiple key industries. TOP Prototype, with its profound expertise in CNC machining technology and in-depth understanding of aluminum materials, is well-equipped to provide customized, high-precision aluminum machined parts. Whether for aerospace, automotive, electrical, or other specialized applications, TOP Prototype is committed to delivering reliable, high-quality solutions that meet and exceed client expectations, driving innovation and efficiency across various industrial sectors.