Aluminum CNC Machining: Alloy Selection Guide (6061/7075/2024…)

CNC (Computer Numerical Control) machining is a vital process in modern manufacturing approaches. It enhances precision and cost-effective manufacturing processes. Aluminum is a key common type of CNC. An essential characteristic of aluminum is its light-weight and suitability for specific products. It is also famous for its durability, strength, and excellent machinability. These traits make it a material that applies to various industries. They form part of the factors that determine the materials selection.

Top 9 Aluminum Alloys for CNC Machining (Applications Compared)

 Aluminum alloys are applicable in different areas. Their role is its combination high strength-to-weight ratio and corrosion resistance. These traits make aluminum a unique and vital material, especially in CNC. The CNC process uses alloys like aluminum to achieve specific outcomes.

1. 6061 Aluminum

Characteristics

6061 aluminum is a common and versatile alloy. Its role in CNC Machining offers ripple benefits. It provides proper strength, resistance, and high machinability. It can also blend to aid in resistance and corrosion.

Applications

6061 aluminum is used to produce structural components. Its roles extend to the marine, automotive, and aerospace industries. It is commonly used to make truck wheels, bicycle frames, marine hardware, and bicycle frames.

Machining Considerations

The 6061 is easy to machine. However, this trait sometimes makes it difficult to attain surface finishes. It demands adequate lubrication and cooling. Lubrication is essential to prevent overheating and extend the tool’s life. The process can add surface finishing in additional specifications to the process.

When to Choose 6061 Aluminum 

The alloy represents a compelling choice of parts that need proper balance, ease of machining, and corrosion resistance. 6061 Aluminum is effective for prototypes and vital for light-weights and structural parts.

2. 7075 aluminum

Characteristics

7075 aluminum is one of the strongest aluminum alloys available. It is recognized for its strength and resistance level. Nevertheless, it has less corrosion resistance than aluminum 6061. The material also has a lower machinability rate, which is advocated by its high strength.

Applications

7075 aluminum is essential in the aerospace industry, incorporating military and tooling. It is used for products such as aircraft wings, sports equipment such as mountain bike frames and golf clubs, and fuselage structures. Strength and weight are among the determinants of its application.

Machining Considerations

Machining 7075 aluminum requires more focus. The high strength can cause wear and tear. The wear which increases immensely and achieves good results. Wear and tear are necessary for high-quality cutting tools. 

When to Choose 7075 Aluminium

Choosing 7075 Aluminium depends on many factors. Wear and tear is a major focus in the CNC. Nevertheless, this factor is vital for applications that require its inclusion in the process.

3. 2024 Aluminum

Characteristics

The 2024 aluminum is famous for its high strength-to-weight ratio. , which makes it superior to other types of alloy. It is famously applicable in aerospace applications.

Applications

2024 aluminum is mainly used in the manufacture of aircraft. The common parts in its construction are the fuselage, the wings, and the essential load-bearing parts. It is also used in the manufacture of military vehicles. The precision of military vehicles lies in the quality and ability to create protective coatings. The products require materials with strength and less fatigue resistance.

Machining Considerations

2024 aluminum machining can present numerous challenges due to various factors. The materials occasionally undergo work hardening in the machining process. Proper lubrication and cooling are also crucial for overcoming overheating. Using sharp tools and managing cutting speed is vital to overcome tool wear.

When to Choose 2024 Aluminium

 The 2023 aluminum choice suits parts that demand high strength and fatigue resistance. Aerospace parts is a major consumer of 2024 aluminum products.   It is also effective for products that undergo significant stress.

4. 5052 Aluminum

Characteristics

The 5052 aluminum alloy is used to manufacture tools that experience less resistance. It is most applicable in the marine environment. It provides moderate strength. It is also formable but not as strong as the 6061 and 7075.

Applications

It applies to the manufacture of fuel tanks in the aerospace and automotive industries. It is a key material in manufacturing marine components such as deck plates and boat hulls. It is also key in the construction of pressure vessels. The product’s standard pressure levels are in tanks and containers. The resistance characteristic of the product is essential in an environment with moisture and salt. It is also vital in the construction of architectural products. The roofing panels and the exterior panel product in coastal areas have 5052 aluminum.

Machine Considerations

The 5052 aluminum is relatively straightforward and easy to machine. However, it can portray rough surface finishes when there is inadequate lubrication. The 5052 effectively exhibits corrosion resistance, making it suitable for use in areas where products exist in harsh environments.

When to choose 5052 aluminum

5052 aluminum is suitable for corrosion-resistant products. Are the coating products that need it applicable in chemical and marine environments? It offers moderate strength, and corrosion resistance is of great need.

5. 6082 Aluminum

Characteristics

The 6082 is a high-strength alloy vital for structural applications. It provides excellent machining, resistance to corrosion, and high strength. It is stronger than the 6061 aluminum but less than the 7075.

Applications

The 6082 is commonly used as a coating in constructing different parts. It is essential to manufacture structural parts such as beams and frames. It supports the strength of construction and machinery. In the transport industry, it is vital to manufacture bridges, rails, and heavy-duty parts. The automotive components parts are key, with moderate strength and effective resistance to corrosion.

Considerations

The maching process focuses on the strength and ease of machining. The 6082 aluminum has moderately easy machining characteristics and offers effective surface finishing.

When to Choose 6082 Aluminum:

6082 Aluminum is suitable for products that are key to machinability. Like other metals, it is also the best choice for parts that undergo high-volume manufacturing and tight tolerances. It’s ideal for intricate and small parts that demand fabrication in the shortest time.

6. 2011 Aluminum

Characteristics

2011 aluminum was an alloy commonly used for effective machinability. It is among the most straightforward aluminum alloys for machining and the best choice for intricate designs. Nevertheless, it is less corrosion-resistant. However, it is weak in comparison to other alloys. It is a primary material for machinability in most parts.

Applications

The 2011 aluminum is vital in the manufacture of precision components. Some products are bearings, intricate parts, and gears. Due to its high precision and details, it applies to manufacturing machine parts. The final element is high-precision tools that require high-level machinability and tight tolerances.

Machining considerations

The 2011 aluminum coating alloy is highly machinable. It is suitable for products that demand high-precision machining. Nevertheless, it offers lower corrosion resistance. It is not ideal for products applicable in harsh environments.

When to Choose 2011 Aluminum

2011 aluminum is suitable for products that are key to machinability. It is also the best choice for parts that undergo high-volume manufacturing and tight tolerances. It’s the best choice for intricate and small parts that require fabrication in the shortest time.

7. MIC6

Characteristics

The MIC 6 is a cast aluminum alloy used in products with high stability and machinability. It is common for parts to require tight tolerances, and manufacturers desire stability over time.

Applications

The MIC6 is commonly used to produce precision molds, such as casting and molding injection. It is also suitable for tooling components, including jigs and fixtures. Finally, in aerospace parts, the MIC6 is applicable for products that require high dimensional stability.

Machining considerations

The MIC6 is ideal for parts that demand the highest level of accuracy. It is common and instrumental in areas where parts have to uphold high tolerances. The tooling, molds, and components of aerospace products are key to precision accuracy. This demands that CNC machining focus on specification and any emerging new requirements of the parts.

8. A380 Aluminium

Characteristics

The A380 aluminum is suitable for the production of automotive parts. Typical products from the alloy are transmission cases, engine blocks, and other strong automotive elements. It is also ideal for the production of computer parts. Common computer parts with the A380 are phones, computers, and consumer electronics. The A380 aluminum is also suitable for aerospace products. Noncritical components, including brackets and housing, rely on the A380.

Machining Considerations

Considerations for the A380 are limited due to its ineffective characteristics. The A380 aluminum can exhibit limitations in producing the parts due to the casting process and composition. Sharp tools are crucial to prevent tearing, and cutting speeds need to be controlled to attain optimal results.

When to Choose A380 Aluminum

A380 aluminum is an essential tool in high-strength cast parts. The objective is to attain good machinability and less focus on corrosion resistance.

9. 1100 Aluminum

Characteristics

1100 aluminum is commercial-based. It is applicable in the manufacture of products that require corrosion resistance. It is also crucial for good formability. Although 1100 aluminum has lower strength than other alloys, it is effective for products that require strength.

Applications

1100 aluminum is vital in manufacturing architectural components, including facades, roofing, and siding. It is also critical in the manufacture of heat exchangers. Standard products are HVAC and different refrigeration systems. The final component with the 1100 aluminum is food processing equipment. The alloys are common on kitchen utensils and other essential products for corrosion resistance.

Machining considerations

1100 aluminum is suitable for machining. It provides crucial excellent surfaces. Nevertheless, it provides low-level strength and is less effective in high-stress applications.

When to Choose 1100 Aluminium

The choice of 1100 aluminum is for products that require effective corrosion resistance. It is also common for formability. However, it is less critical in applications where strength is less important.

Comparison of Aluminum Alloys in CNC Machining

Common properties include corrosion resistance, machinability, and strength. Aluminum alloys are common for CNC machining due to their desirable properties. However, this process requires more advanced equipment, such as precision measurement and tool cutting.

Comparison of the Strength of Aluminum Alloys

• The 7075 and 2024 aluminum:  The alloy is suitable and preferred for its unique strength. It has zinc as the main component and is effective in military and aerospace products. The 7075 aluminum matches the characteristics of the 2024 aluminum, which also has excellent and high strength. The 2024 aluminum has copper as the primary alloy, enabling it to have a high havele strength. The 2024 and 7075 aluminum manufacturers of aircraft and other structural components. However, the 2024 aluminum possesses lower corrosion resistance than the 7075 aluminum. It requires the addition of other materials to improve the resistance level.
• 6061 aluminum: Unlike the 7075 and 2024 aluminum, the 6061 offers moderate strength. In the CNC manufacturing process, it is one of the versatile alloys. However, it has an impressive strength-to-weight ratio. Aluminum is instrumental in manufacturing structural components, marine environments, and automotive parts. It effectively balances other properties and strengths; hence, a key allows for parts applicable for general purposes.
• 1100 aluminum: The 1100 aluminum is the weakest aluminum alloy in CNC machining. It is weak but effective in environments with low corrosion resistance and workability. Unlike the 7075 and the 2400 aluminum, its production does not need corrosion resistance and workability. However, it is also vital in areas with high formability. 
• 5052 Aluminum: The 5052 Aluminum is instrumental in providing adequate resistance to corrosion in CNC machining. However, its strength is low compared to the 7075 and the 6061. It still effectively provides strength for different applications, such as marine and chemical tanks.

Machinability Comparison

It refers to the ease of cutting, processing, and shaping the material in CNC machines. It is crucial in material selection due to the ease of machining. It directly affects time, cost, wear, and production.

• 2011 aluminum: The 2011 is one of the suitable alloys for machinability. It has a high level of copper and offers excellent cutting properties. It is ideal for products with intricate designs and high tolerances. It has w tool wear and can produce effective cuts, hence high-speed machining. It is also suitable for precision and efficiency.
• 6061 aluminum: 6061 Aluminum is effective for ease of machining. It takes a short process time, hence good dimensional accuracy and smooth finishing. It balances machinability and strength, hence effective for various parts in different industries. Nevertheless, it requires other parts in different applications.
• 6082 aluminum: The alloy has the same machinability qualities as 6061. However, provides a high level of strength. It undergoes ease of machinability. Increasing the 6082 can require more potent tools and precision to help prevent damaging tools. It is easy in comparison to 7075.
• MIC 6 Aluminum: The MIC 6 is a cast aluminum alloy applicable due to its superior machinability and dimensional abilities. Smooth finishing and precision are typically key. Common products are molds and plates for the automotive industries. The MIC 6 provides effective surface finishing and is effective for easier machining.
• 7075 and 2024 Aluminum: The 7075 and 2024 Aluminum offer high strength and toughness in the machine compared to the toughness of the 2011 and 6061 aluminum. The high strength is sometimes responsible for increased wear and tear. Manufacturers need to control the cutting parameters effectively. Nevertheless, they can be effective in machining but less forgiving than lower-strength alloys.

Corrosion Resistance Comparison

Corrosion resistance is an essential trait for parts that encounter harsh environments. More parts must be applicable in marine, outdoor, and chemical settings. The composition impacts the level of corrosion and resistance. It is in comparison to the various types of resistance than others.

• 1100 aluminum: The 1100 aluminum offers high levels of corrosion resistance among most alloys. It has lower strength levels and limited use in areas where strength is a lesser primary concern. It is common for products to be processed, handled, and stored in the food process. It is also common in decorative purposes.
• 6061 Aluminum:  6061 Aluminum offers effective resistance to corrosion. However, it is less effective than the 1100 and 5052 aluminum alloys. It is effective in products applicable in outdoor applications such as marine environments, bridges, and buildings. The 6061 is highly corrosive in seawater environments, demanding coating and anodizing to boost the resistance.
• 7075 and 2024 Aluminium: The two alloys possess poor resistance rates compared to 6061 and 7075 products. The 2024 and 7075 aluminum have high resistance to corrosion properties. The harsh environment may not be effective until there is coating and treatment. Key coating approaches are painting and anodizing, which are key for overcoming degradation.

CNC Machining Process Flow for Aluminum

 The CNC machining process follows a series of steps. The objective is to ensure adherence to all design specifications.

• Material Selection: The initial step is to choose an appropriate aluminum alloy. The choice has to match the expected properties, including resistance, machinability, and corrosion.
• Design and Programming: The second step is creating a CAD model. This step also entails converting the design to the CAM Program, which is vital in determining machining operations and the path tools to develop the part.
• Toot setup: The third step is tool setup. It entails using the necessary drilling, tapping, cutting, and finishing tools. The material undergoes operations precisely. The objective is to adhere to the dimensional expectations.
• Machine Operations: The CNC undertakes different operations, such as drilling, cutting, finishing, and tapping, based on the instructions in the programming phase. The process includes the speed, tool selection, and feed rates.
• Inspection: After machining, there is an inspection. The objective is to meet the specific tolerances and the surface finish.
• Post-Processing: The final phase is post-processing, which entails coating, anodizing, and polishing.

Aluminum vs. Other Metals in CNC Machining

Aluminium has more advantages than machining than brass, steel, and titanium in CNC match.

• Weight: One of aluminum’s advantages is light. It is lighter than titanium and steel. Therefore, it is crucial to use in scenarios where weight is a significant consideration.
• Machinability: Aluminium alloys are more straightforward to machine than metals such as steel and titanium. This property allows them to minimize wear on cutting and shorten production times, making them essential for mass production.
• Corrosion Resistance: Aluminium is more effective at resisting corrosion than other metals. When it undergoes anodizing, it becomes ideal for areas with chemicals, saltwater, and moisture.

It is also clear that the strength of titanium and steel alloys sometimes outperforms aluminum. This trait is common in areas with high-stress levels. For products and parts that require durability or unique tensile strength, titanium and steel become more suitable.

CNC Machining Tolerances of Aluminum Profiles

Aluminum profiles undergo machining to exhibit tight tolerances. Therefore, the parts must fit the assemblies with precision. The capability to shape the aluminum properties is vital in upholding the performance and integrity of complex systems. Any interference with the integrity and complexity implies compromising the quality of the product in the long term. CNC machining tolerances for aluminum alloys: ±0.001in (aerospace) to ±0.010in (general)

Nevertheless, industries that require precision include aerospace, electronics, and automotive products. The objective is to ensure safety, optimal performance, and reliability. Tolerance for such parts is as tight as ±0.001 inches. Success in acceptable tolerances requires improved machining approaches like CNC machining. High-precision processes such as laser cutting and EDM Electrical Discharge Machining are also necessary for ultra-fine results.

Additionally, practical inspection and testing approaches are crucial to the manufacturing process. The objective is to enhance profiles that adhere to the set specifications. The long-term objective is to attain corrosion resistance, machinability, or strengths.

Conclusion

The advanced CNC machine offers superior quality and precision in manufacturing. It also requires more advanced equipment, such as precision measurement and tool cutting. The alloys have unique traits that make them practical for various environments. A key focus in alloy manufacturing is corrosion resistance, strength, and durability of the final product. The decisions must ensure the final product meets economic and functional requirements. The selection of the appropriate alloy leads to optimizing the machining process. The manufacturers need to focus on the production of high-quality aluminum components. The products have excellent performance and precision. Therefore, the 6061 is excellent for versatility, and the 5052 is the most effective for effective corrosion resistance.