Aluminium fabrication is a crucial manufacturing process that can be utilised to create a wide variety of parts. You will utilise efficient and cost-effective methods to fabricate aluminium, whether it's for profiles, inclosures, or automotive parts.
Welding, stamping, bending, extruding, and shearing are among the many processes used in the fabrication of aluminium.The refining of the extraction process for aluminium in 1886 led to its widespread use in production. Before that, aluminium had the same status as gold as a precious metal. With the help of custom metal fabrication services, the procedure has been further optimised.
The engineering of structures for many different types of industries relies heavily on aluminium fabrication. Custom aluminium fabrication has numerous uses, including medical and automotive parts. Anyone new to the process of aluminium fabrication can benefit from reading this primer on the subject.
Table of Contents
What Does Aluminium Fabrication Mean?
You can't expect control panels and handrails made of aluminium to magically appear. A specialist is required to cut that shape, along with countless others, from aluminium.However, trees also do not produce aluminium. Aluminium has to be mined from bauxite before it can be used in manufacturing.
Bauxite is a red, clay-like rock that is mostly found in Australia, China, and Brazil, but there is a lot of it in many other places around the world as well. Professionals can turn raw bauxite into alumina, which is then quickly refined even more to make aluminium oxide.
Next, the aluminium is carefully mixed with molten cryolite to get it ready for electrolysis.
To do electrolysis, an electric current is sent through a mixture of molten aluminium oxide and cryolite. Once the electrolysis is done, the aluminium that is left can be shaped into useful materials that we'll talk about in more detail later in this guide.
After learning about where aluminium comes from, let's go back to how to make this useful metal. Professionals in aluminium fabrication bend, weld, or cut the metal to fit specific sizes and shapes. Don't worry—"specific designs" is a general term, but we'll talk more about what it means later. First, let's talk about what it means to bend, weld, and cut. These are three of the most common ways to work with metal, but they're not the only ones.
Many different processes are involved in aluminium metal fabrication, such as:
Forming
Forming a new shape out of aluminium requires applying force through rolling, stamping, or bending. Press braking is the standard procedure for shaping aluminium.
Welding
To join metal parts, welders use a welding torch to heat the metal until it melts. Aluminium can be joined using any of several popular welding techniques, including TIG, MIG, and stick. Aluminium alloys from the 2XXX and 7XXX series aren't the best choice for welding. Metals from the 1XXX, 3XXX, 4XXX, 5XXX, and 6XXX series of alloys work wonderfully when it comes to welding components together.
Cutting
Cutting aluminium into a desired shape is what this process is all about, as the name implies.
Plasma nozzles, water jets, and shears are typical tools for metal fabricators. Using these cutting methods, aluminium can be fabricated with remarkable precision.
Types of Aluminum Materials to Fabricate
Aluminium is available in a variety of forms:
- Sheets of aluminium or plates made of aluminium
- Stainless steel tubes
- Tubing made of aluminium
- Bars of aluminium alloy
One of the best things about metal fabrication is the limitless potential it has for transforming various types of aluminium into practical goods.
Fabricate Aluminum Sheet Metal
Flat sections of aluminium sheet metal are available in a range of thicknesses and gauges. Electrical inclosures, cylindrical sections, and other shapes can be created using aluminium sheet metal fabrication.
Fabricating Aluminum Rods
Metal rods made of aluminium can have a variety of cross-sectional shapes. Shapes such as round, square, rectangular, and so on are available. In fact, you can find metal bars that are quite similar to aluminium.
You can make an endless number of structures if you focus on fabricating aluminium rods or bars. Aluminium rods and bars are used to construct numerous machine sections and bridges.
Fabricating Aluminum Tubes
A hollow section is an aluminium tube. Typically, their shape is cylindrical.
Once again, a variety of structures can be created using aluminium tubes or pipes. Aluminium has many uses, including in the construction of heat exchanger tubes, buildings, and pipelines.
To put it simply, any type of aluminium can be formed into a product. A good method, the correct grade of aluminium alloy, and some metalworking tools are all that's needed.
Keeping that in mind, let's take it a step further and assess different aluminium alloys that are good for metalworking.
Properties of Aluminum
Because it is both soft and lightweight, aluminium is often a fabrication material that is easy to work with and takes little time to shape. However, when mixed with other metals to form alloys, its properties can undergo changes. Our comprehensive rundown of general aluminium types and their properties, as well as our guide on particular, commonly used alloys, provide more specific information.
Advantages of Aluminum in Fabrication
A lot of people like aluminium because of its special set of qualities. Lighter than stainless steel and having a higher strength-to-weight ratio, it weighs only one third as much.
In addition to being a recyclable, relatively soft, and corrosion-resistant metal, aluminium is also a breeze to work with. Due to its lack of toxicity, it is commonly used in food processing equipment. Additionally, its reflective and non-combustive qualities have solidified its position in lighting.
Aluminium, a very light metal, weighs just one-third as much as stainless steel. Its pliability and resistance to corrosion make it a pleasure to work with. Its non-toxicity has contributed to its rise in popularity among food preparation appliances. Adding it to other metals makes it easy to make alloys with a wide range of characteristics.
Drawbacks of Aluminum in Fabrication
However, final goods may be less robust due to this material's suppleness and weakness in comparison to stainless steel. Many types of aluminium are notoriously difficult for novice welders to handle due to their high thermal conductivity, which makes them easily melted through. Because of its brittle nature, aluminium can also crack under specific pressures.
Although aluminum's malleability has its uses, it often results in inferior finished goods due to its ease of shaping. In addition, its high conductivity makes it challenging for unskilled aluminium welding services welders to work with without causing permanent damage.
Aluminium Fabrication Methods
It is possible to shape aluminium in the same ways that you would shape any other common metal, but some ways work better than others. We talked about some of the most basic ways to work with metal in a different article. Here, we'll talk about how to work with aluminium using some of the most common methods:
- Extrusions: Aluminium is not stressed as much when it is extruded. A piece of aluminium is forced through or around an open or closed die during extrusion. Making the metal fit the shape and size of the die is what this does. When the metal is hot, the extrusion process can be done. When the metal is cold, the process can be done.
- Drawing is the process of forcing metal through a tapered die to make it longer. A product that is drawn deeply has a depth that is greater or equal to its width. Because it is flexible, aluminium is often used to make wire and things like cans. This helps a lot with the 3003, 5005, and 5052 alloys.
- Forming: Because aluminium is soft and flexible, it can be shaped by bending, stamping, and rolling. It's best to use the 3003 alloy, but the 5052 and 6061 alloys also work well. You can also make most alloys from the 1xxx, 2xxx, 4xxx, 5xxx, and 8xxx families. When you form something, you press on part or all of the sheet or plate to make it into the shape you want.
- Castings: Metal is poured into a mould or die to make a casting. The best alloys for making them are 4xxx and 5xxx, which are strong and don't wear down easily.
- Forging: Forging is the process of beating or compressing metal into shape. It works best when the end result needs to be very durable, like for stress-bearing parts.
- Machining: Aluminium types 1110, 2011, 3001, and 6061 are the best for machining, such as turning and milling. Machining is a type of subtractive cutting that shapes by taking away metal. It's important to use particular instruments and lubricant on aluminium because it has unique thermal characteristics that make it hard to work with regular tools.
- Waterjet Cutting: Cutting with a waterjet, which sprays water with abrasives at high pressure, doesn't use heat. This way, it doesn't change the properties of the aluminium like laser cutting could. It can still be cut with a saw blade, a laser, or plasma, though.
- MIG and TIG: The best aluminium alloys for MIG and TIG welding are 1xxx and 3xxx-6xxx. These alloys melt a metal thread to join two pieces of aluminium together. When putting aluminium together with another metal, friction welding can also be helpful.
- Adhesive Bonding: Another common way to put aluminium together is with adhesive bonding, where certain adhesives stick to the oxide layer on the outside.
Industry Applications
Next, we'll finally talk about the "specific designs" we talked about in the beginning of this guide. Aluminium is a flexible metal that has many industrial uses, which you will learn about below.
Aerospace
Because aluminium is both strong and light, it is perfect for making parts for aeroplanes. As an example, this metal is often used to make fuselages, wings, aircraft cowls, skins, and other parts. 2024, 5052, 6061, 7050, and 7075 are some of the most common aluminium alloys used in aerospace.
The alloy 5052 is very good at resisting corrosion, which makes it useful in marine settings. While 6061 and 2024 are alloys that are more likely to be found in aeroplane wings and fuselages, to be exact.
Automotive
Just like the aerospace sector loves aluminium for the same reasons, the auto industry does too. There are many areas of making cars that benefit greatly from being able to use lightweight materials to make parts that are still strong. Fabricated aluminium is used in many different ways in the auto industry, such as for car structures, engine components, hoods, bumpers, transmissions, and cooling parts.
One of the nicest things about metal fabrication is working with a specialist to create components that are tailor-made for your requirements. If you're in the auto repair business and your clients require very specific replacement parts, for instance, expert metal fabrication can streamline the process of obtaining those parts.
Construction
Roofing material, siding, gutters, window frames, metal beams, and extra structural support are all common uses for aluminium in the building industry. In fact, aluminium has been an important part of building skyscrapers since the 1930s. Because aluminium can be recycled, it is a long-lasting and eco-friendly building material.
Medical
A lot of the time, aluminium structural frames are used to make bases for ventilators, stethoscopes, and other specialised medical equipment and parts. But this metal can be used in a number of medical facilities.
Frames made of aluminium can be used to make hospital beds, tents, curtains, cabinets, boxes, trays, guardrails, and more. Aluminium can be very helpful whether you're making a complicated medical machine or some chairs for patients.
Conclusion
Aluminium fabrication is a crucial manufacturing process used to create various parts, including profiles, inclosures, and automotive parts. It involves various processes such as welding, stamping, bending, extruding, and shearing. The process began in 1886 and has been further optimized with custom metal fabrication services.
Aluminium is mined from bauxite, a red, clay-like rock found in Australia, China, and Brazil. It is then mixed with molten cryolite for electrolysis. Professionals in aluminium fabrication bend, weld, or cut the metal to fit specific sizes and shapes.
Aluminum is available in various forms, such as sheets, plates, tubes, tubing, and bars. Its properties include being lightweight, recyclable, and corrosion-resistant. It is commonly used in food processing equipment and lighting due to its non-toxicity and elasticity. The process requires the correct grade of aluminium alloy and metalworking tools.
Aluminum is a flexible metal with various applications in various industries. It is used in aerospace for its strength and lightness, making it ideal for parts like fuselages, wings, and aircraft cowls. It is also used in the auto industry for car structures, engine components, and cooling parts.
In construction, aluminium is used for roofing, siding, gutters, window frames, and structural support. It is also used in medical facilities for its structural frames for ventilators and stethoscopes. However, aluminium's suppleness and weakness make it difficult for novice welders to handle due to its high thermal conductivity.
Aluminium welding services welders may struggle to work with aluminium without causing permanent damage. The best alloys for aluminium are 3003, 5005, and 5052. However, aluminium welding services welders must use specific instruments and lubricants due to its unique thermal characteristics.
Content Summary
- Aluminium fabrication is a crucial manufacturing process that can be utilised to create a wide variety of parts.
- You will utilise efficient and cost-effective methods to fabricate aluminium, whether it's for profiles, inclosures, or automotive parts.
- Welding, stamping, bending, extruding, and shearing are among the many processes used in the fabrication of aluminium.
- With the help of custom metal fabrication services, the procedure has been further optimised.
- The engineering of structures for many different types of industries relies heavily on aluminium fabrication.
- Custom aluminium fabrication has numerous uses, including medical and automotive parts.
- Anyone new to the process of aluminium fabrication can benefit from reading this primer on the subject.
- Aluminium has to be mined from bauxite before it can be used in manufacturing.
- After learning about where aluminium comes from, let's go back to how to make this useful metal.
- Professionals in aluminium fabrication bend, weld, or cut the metal to fit specific sizes and shapes.
- Don't worry—"specific designs" is a general term, but we'll talk more about what it means later.
- Forming a new shape out of aluminium requires applying force through rolling, stamping, or bending.
- Press braking is the standard procedure for shaping aluminium.
- To join metal parts, welders use a welding torch to heat the metal until it melts.
- Cutting aluminium into a desired shape is what this process is all about, as the name implies.
- Plasma nozzles, water jets, and shears are typical tools for metal fabricators.
- Using these cutting methods, aluminium can be fabricated with remarkable precision.
- You can make an endless number of structures if you focus on fabricating aluminium rods or bars.
- Aluminium rods and bars are used to construct numerous machine sections and bridges.
- Once again, a variety of structures can be created using aluminium tubes or pipes.
- Aluminium has many uses, including in the construction of heat exchanger tubes, buildings, and pipelines.
- Because it is both soft and lightweight, aluminium is often a fabrication material that is easy to work with and takes little time to shape.
- However, when mixed with other metals to form alloys, its properties can undergo changes.
- Our comprehensive rundown of general aluminium types and their properties, as well as our guide on particular, commonly used alloys, provide more specific information.
- A lot of people like aluminium because of its special set of qualities.
- In addition to being a recyclable, relatively soft, and corrosion-resistant metal, aluminium is also a breeze to work with.
- Aluminium, a very light metal, weighs just one-third as much as stainless steel.
- Its pliability and resistance to corrosion make it a pleasure to work with.
- Adding it to other metals makes it easy to make alloys with a wide range of characteristics.
- Many types of aluminium are notoriously difficult for novice welders to handle due to their high thermal conductivity, which makes them easily melted through.
- It is possible to shape aluminium in the same ways that you would shape any other common metal, but some ways work better than others.
- We talked about some of the most basic ways to work with metal in a different article.
- Here, we'll talk about how to work with aluminium using some of the most common methods:
- A piece of aluminium is forced through or around an open or closed die during extrusion.
- Making the metal fit the shape and size of the die is what this does.
- When the metal is hot, the extrusion process can be done.
- Drawing is the process of forcing metal through a tapered die to make it longer.
- Forging: Forging is the process of beating or compressing metal into shape.
- Machining is a type of subtractive cutting that shapes by taking away metal.
- This way, it doesn't change the properties of the aluminium like laser cutting could.
Frequently Asked Questions
Aluminum fabrication is the process of shaping and manipulating aluminum into various forms and products. It involves several techniques like cutting, bending, welding, and finishing to create parts and structures used in numerous industries.
Aluminum is favored due to its lightweight nature, high strength-to-weight ratio, corrosion resistance, and flexibility in fabrication. These properties make it ideal for applications in aerospace, automotive, construction, and consumer goods.
Key techniques include cutting (laser, waterjet), bending, welding (TIG, MIG), machining (CNC milling and turning), and finishing processes like anodizing and powder coating. Each technique is chosen based on the specific requirements of the product being fabricated.
Aluminum can be welded, but it requires specific techniques like TIG or MIG welding due to its lower melting point and higher thermal conductivity compared to other metals. Challenges include avoiding warping, managing heat input, and preventing the formation of oxides.
Quality control in aluminum fabrication involves regular inspections at each stage of the process, from material selection to final finishing. Testing for mechanical and chemical properties is also conducted to ensure the final product meets the required specifications and standards.