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.

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.

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.

Pure aluminum can be further optimized by mixing it with other elements to create an alloy. Commonly used aluminum alloys often include:

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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.

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Its heat resistance also makes it ideal for secondary treatments and is a great choice if you want the best coating for machining aluminum.

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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:

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.

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.

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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.

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This alloy is resistant to saltwater which makes it perfect for the marine industry and bridges. Aluminum 5052 is the strongest non-heat-treatable alloy. It is also found in aircraft parts, household appliances and commercial, heavy-duty cooking equipment.

This type of manufacturing method is extremely accurate and precise, offering different surface finishes and often using special tooling to handle metals like aluminum.

The major alloys in this group are magnesium and silicon. One of the most versatile of all machinable alloys is aluminum 6061, which is available in sheet, plate and extrusions.

Aluminum 3003 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.

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.

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.

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 2024.

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In its sheet metal form, aluminum 6061 is one of the best-stamped aluminum alloys for machining. It is often used in metal fabrication including aerospace applications.

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 7075.

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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.

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