When planning a new project, picking the fabrication process might be just as crucial as deciding on the raw materials. There are a number of ways to fabricate aluminium, as you may have noticed if you've chosen to work with it. Its physical properties and the amount you spend on production can be influenced by the method of fabrication.
The process of fabricating aluminium, which involves cutting, bending, and joining metal parts, is today useful in many different industries. Following extrusion, the majority of parts undergo additional processing, including fabrication, machining, and surface treatment. Extrusions made of aluminium are ideal for practically any kind of fabrication due to the material's characteristics.
Aluminium is among the most common metals used for fabrication, although any metal can be used. Consequently, aluminium fabrication services are in high demand globally. Aluminium is ubiquitous; just take a look around your house or place of business. Aluminium door, window, and shower frames, as well as aluminium gates, are among the most common architectural elements.
Here we take a look at the ways that aluminium is typically worked. Getting to know these will help you determine which one is best suited to your needs.
Table of Contents
What is Aluminum Fabrication?
Whatever technique is used to shape aluminium into a desired form is considered an aluminium fabrication process. The physical properties of aluminium can be altered through a variety of physical and chemical processes, which can be employed in these techniques.
There is a wide variety of aluminium fabrication techniques. So, the physical characteristics of the finished products are highly process dependent. So, it's important to know how these fabrication methods differ, because some of those differences will determine which process is best.
For instance, there are some components that require a particular manufacturing process in order to achieve the required properties, such as shape or strength. Another possibility is that a part can be successfully manufactured using two processes, but the surface finish produced by one of them is subpar. When choosing a process, it's vital to consider not only the benefits, but also the cost and production rate.
Aluminium Fabrication Techniques
Just like other metals, aluminium can be shaped and transformed into anything you want by using a variety of fabrication techniques. Nevertheless, there are methods that produce better outcomes when dealing with this adaptable material.
Here we'll take a look at some helpful hints for fabricating aluminium using some of the most common and efficient methods. Although we have already covered the basics of metal fabrication in a different article, this one is going to be all about aluminium fabrication and the methods that make it shine.
Cutting
Metal cutting, in which large sheets of metal are divided into smaller ones, is one of the most typical metal fabrication processes. Typically, the metal being cut is still in its raw, unformed state, having just been produced. Bars and measured panels are examples of pre-shaped metals that are sent for cutting in other applications. A variety of cutting tools are utilised, including plasma torches, lasers, and more complex, high-tech machinery.
Extrusion
Extrusion places the least amount of stress on aluminium compared to the other methods. The process entails applying pressure to an open or closed die in order to force aluminium through or around it. This process shapes the metal to fit the die precisely. Both hot and cold states, in which the metal is heated or left at room temperature, are possible during extrusions.
Drawing
To draw, one must stretch metal by drawing it through a tapered die. When drawing something, "deep drawing" means to make sure its depth is at least as big as its width. The exceptional ductility of aluminium makes it a popular material for drawing into wire and using in products such as cans. Particularly well-suited to this process are the aluminium alloys 3003, 5005, and 5052.
Forming
Because of its malleability and relative softness, aluminium lends itself nicely to forming operations like stamping, rolling, and bending. When it comes to this, the 3003 alloy really shines, but the 5052 and 6061 varieties are also great. It is also possible to successfully form the majority of alloys in the 1000, 2000, 4000, and 5000 families. Forming is the process of shaping a sheet or plate by applying pressure to either the surface or both in order to achieve the desired shape.
Castings
Metal is poured into a mould or die to form a casting. Using 4000 and 5000 alloys, which are well-known for their durability and resistance to wear, yields the best results.Metal is poured into the mould until the entire cavity is filled, and then it solidifies, producing an exact aluminium replica of the mold's inside shape.
Many various kinds of moulds, such as sand moulds, clay moulds, permanent moulds, and dies, can be used for casting. Parts made by casting usually don't need much more machining. Using steel dies allows you to repeat the process multiple times before needing to replace the die.
Die casting's ability to create intricate components is a major plus. There are virtually no size restrictions, and you can choose from a variety of textures thanks to this complexity, which is unmatched by other aluminium forming processes.
Forging
Metal can be bent or shaped by applying pressure or hammering during the forging process. When it comes to stress-bearing components in particular, this technique shines for uses necessitating extraordinary durability.
Folding
Folding, the manipulation of a metal surface to form at an angle, is one of the more intricate processes in metal fabrication. It is sometimes desired to have the metal surface fold at a sharp angle, or at least at a 90-degree angle, for specific folding applications. Because folding is such a complex process, it can only be done in facilities with specialised, high-tech equipment. The more practical alternative would be to join two metal panels at specific angles in many cases where a fold is required.
Machining
Milling and turning are both part of machining, and the two types of aluminium that work best for this process are 7075 and 6061. Machining is a manner of shaping metal by removing material, a process known as subtractive cutting. Because of its unusual thermal properties, working with aluminium requires specialised tools and lubricants that aren't always available when using standard equipment.
Machining is the process of cutting metal using a machine to remove specific shapes and sizes. The metal is usually turned on a lathe, which uses rotating tools to cut the edges and corners to the required size and shape. On the other hand, there are machining tasks that involve cutting holes into the metal. Therefore, the metal drill may be considered a tool for machining.
Waterjet Cutting
Instead of using heat, waterjet cutting uses a high-pressure spray of water mixed with abrasives to make the cut. Unlike laser cutting, this process does not compromise the aluminum's original characteristics. On the other hand, plasma cutting and laser cutting are two alternate techniques that can be used to cut aluminium.
Welding
When working with 1000 and 3000-6000 aluminium alloys, MIG and TIG welding techniques—which include melting a metal thread to join two pieces of aluminum—are at their most effective. When joining metals, friction welding can be useful for joining aluminium.When working with metal, cutting and welding are two of the most common techniques used by hobbyists. Two metal components are joined during the welding process.
Metal sheets, panels, bars, or shapes will do for a welding application; the specific shape is less important than the type of metal. It is possible to weld using a wide variety of techniques and equipment. The application of heat along the joining points of two pieces is a common method for producing welds. Many people who work with metal initially get into the field because they want to do welding jobs.
Adhesive Bonding
Because some adhesives stick well to the oxide layer on aluminium, adhesive bonding is a popular technique for assembling aluminium.
Applications Of Aluminum Alloys
A few of the most typical uses for aluminium alloys are these.
Aerospace Industry
Strong yet lightweight aluminium alloys are frequently needed in the aircraft industry. These alloys need to be lightweight and strong, all within the specified price range. Similarly, aircraft made of certain aluminium grades are less likely to sustain premature damage from exposure to harsh weather.
Healthcare Sector
Because of aluminium products, the healthcare industry has been able to keep its standards of cleanliness and biocompatibility high. Surgical and orthopaedic tools, among others, are constructed from a variety of aluminium alloys. Aluminium is also used to make trays and containers, which are multipurpose pieces of machinery.
Automotive Industry
Aluminium grades are used by vehicle manufacturers to create ideal vehicles that are lightweight, eco-friendly, and long-lasting. The lightweight and extremely durable properties of aluminium alloys are used by manufacturers to create a variety of die-cast parts that contribute to the agile and rugged nature of automobiles.
Electrical and Electronics Engineering
Due to their high heat conductivity, various types of aluminium alloys are consistently used in the production of consumer electronics. Cooling components for graphics processing units and heat sinks are made possible by the high heat conductivity of aluminium.
Conclusion
Aluminium fabrication is a crucial process in various industries, involving cutting, bending, and joining metal parts. The physical properties of aluminium can be altered through various physical and chemical processes. The process is highly process-dependent, and the choice of process depends on factors such as cost, production rate, and desired properties.
Common aluminium fabrication techniques include cutting, extrusion, drawing, and forming. Cutting involves dividing large sheets of metal into smaller ones, while extrusion uses pressure to shape the metal to fit a die. Drawing involves stretching metal through a tapered die, and forming is a process that shapes a sheet or plate by applying pressure to achieve the desired shape.
Aluminum alloys are used in various industries, including casting, forging, folding, machining, waterjet cutting, welding, and adhesive bonding. Castings use 4000 and 5000 alloys for durability and resistance to wear, while forging involves applying pressure or hammering for stress-bearing components. Folding involves manipulating a metal surface to form at an angle, but requires specialized equipment.
Machining uses 7075 and 6061 alloys, while waterjet cutting uses a high-pressure spray of water mixed with abrasives. Welding techniques like MIG and TIG are most effective for 1000 and 3000-6000 alloys. Adhesive bonding is a popular technique for assembling aluminium. Aluminum alloys are used in the aerospace industry, healthcare sector, automotive industry, and electronics engineering due to their high heat conductivity.
Content Summary:
• Aluminium fabrication involves cutting, bending, and joining metal parts.
• The process is used in various industries and is highly sought after globally.
• Aluminium is a common metal used for fabrication, with its properties influencing the cost and production cost.
• Aluminium door, window, shower frames, and gates are common architectural elements.
• The process of aluminium fabrication alters the physical properties of aluminium through physical and chemical processes.
• Different fabrication methods can affect the physical characteristics of the finished products.
• The choice of a process should consider benefits, cost, and production rate.
• Cutting: This involves dividing large sheets of metal into smaller ones.
• Extrusion: This process uses pressure to force aluminium through or around a die, shaping the metal to fit the die precisely.
• Drawing: This involves stretching metal through a tapered die, with the depth of the drawing being at least as big as its width.
• Forming: Aluminium is well-suited for forming operations like stamping, rolling, and bending due to its malleability and relative softness.
• Metal is poured into a mould or die to form a casting, using 4000 and 5000 alloys for durability and resistance to wear.
• Various moulds like sand moulds, clay moulds, permanent moulds, and dies can be used for casting.
• Die casting allows for intricate components with virtually no size restrictions and a variety of textures.
• Metal can be bent or shaped by applying pressure or hammering during the forging process.
• This technique is particularly useful for stress-bearing components.
• The manipulation of a metal surface to form at an angle is a complex process in metal fabrication.
• Folding can be done in facilities with specialized, high-tech equipment.
• Milling and turning are part of machining, with 7075 and 6061 being the best for this process.
• Machining involves shaping metal by removing material, a process known as subtractive cutting.
• Waterjet cutting uses a high-pressure spray of water mixed with abrasives to make the cut.
• Plasma cutting and laser cutting are alternate techniques that can be used to cut aluminium.
• MIG and TIG welding techniques are most effective for 1000 and 3000-6000 aluminium alloys.
• Friction welding can be useful for joining aluminium.
• Adhesive bonding is a popular technique for assembling aluminium.
• The aerospace industry uses aluminium alloys for their lightweight, strong, and durable properties.
• The healthcare sector uses aluminium products for their high standards of cleanliness and biocompatibility.
• The automotive industry uses aluminium grades to create lightweight, eco-friendly, and long-lasting vehicles.
• The electrical and electronics engineering industry uses aluminium alloys for cooling components for graphics processing units and heat sinks.
Frequently Asked Questions
The most prevalent techniques in aluminum fabrication include cutting (like laser cutting and waterjet cutting), bending, welding, CNC machining, and forming. Each technique has its unique applications and is chosen based on the specific requirements of the project.
The choice of fabrication technique directly impacts the product's quality, strength, precision, and suitability for its intended use. For instance, CNC machining is known for its precision, making it ideal for complex components, while welding is crucial for creating strong joints in structural applications.
Not all welding techniques are suitable for aluminum due to its unique properties like high thermal conductivity and susceptibility to warping. Techniques like TIG (Tungsten Inert Gas) welding and MIG (Metal Inert Gas) welding are commonly used for aluminum, as they provide better control and result in stronger, cleaner welds.
CNC machining is widely used in aluminum fabrication for creating intricate and precise components. Its applications range from aerospace parts, automotive components, and intricate machinery parts to custom-designed consumer products. The precision of CNC machining makes it ideal for components that require tight tolerances and complex geometries.
Different aluminum grades have varying properties like strength, ductility, corrosion resistance, and ease of fabrication. The choice of grade influences the fabrication process; for example, some grades are more suitable for bending or welding. It also determines the product's suitability for specific applications, such as high-strength requirements in aerospace or corrosion resistance in marine environments. Choosing the right aluminum grade is essential for ensuring that the final product performs as expected in its specific application.