Aluminum Fabrication Services

Aluminum is the most common non-ferrous metal on the market and is praised for its low density, high strength-to-weight ratio, durability, natural corrosion resistance, thermal properties, and more. Xometry offers high-quality aluminum fabrication services for multiple industries — from automotive and aerospace to construction and electronics. Our aluminum fabrication services include: custom aluminum fabrication, CNC machining, sheet metal fabrication, precision laser cutting, finishing, and more. Our industry experience and deep understanding of manufacturing processes ensure that aluminum parts are made to customers’ specific requirements. Couple that with our vast manufacturing network and you can rest assured that your aluminum parts will meet both your schedule and the highest standards of quality. 

This aluminum alloy uses magnesium as its primary alloying element. It has excellent corrosion resistance due to the lack of copper in its composition. Though 5052 cannot be heat treated, it has the highest strength of the non-heatable alloys. This alloy also has better formability than series 3 alloys. It is typically used for fuel tanks and highway and road signs.

This is among the most “general-purpose” aluminum alloys. The primary alloying elements are magnesium and silicon and it will accept heat treatment. Bending aluminum 6061 is not recommended after it reaches high tempering levels because at that point it is likely to crack. This aluminum alloy can be used for sheet metal parts but requires some care and preparation.

Lightweight Nature

Aluminum has a density of 2.71 g/cm3, about one-third the density of steel. This makes aluminum cheaper, less massive, and easier to transport. Additionally, its minimal weight makes it great for places like the aerospace or automotive industries where mass is a limiting factor.

Corrosion Resistance

Aluminum naturally resists corrosion by generating a protective oxide layer on its surface. Aluminum is very reactive to oxygen. Therefore when it contacts air, a thin oxide layer about 4-5 nm thick forms on the part. Unlike iron, which oxidizes into rust, aluminum’s oxide layer protects the surface from corrosion. While aluminum is naturally resilient, surface treatments like painting or anodizing can further improve the metal’s corrosion resistance. Aluminum’s properties make it an excellent choice for applications in corrosion-inducing environments.

High Strength-to-Weight Ratio

Aluminum has a high strength-to-weight ratio, so it fits in well wherever weight is a major concern. Aircraft and automobiles make heavy use of aluminum for that reason. Aluminum has a density of 2.71 g/cm3, but its yield strength varies between 24-483 MPa, depending on the type of aluminum alloy. In comparison, steel is almost three times denser at 7.8 g/cm3. While steel is stronger (yield strength between 220-1570 MPa), its weight makes it untenable for lightweight construction. Aluminum shines when it comes to applications that require low weight and load-bearing capability.

Recyclability

Aluminum is highly recyclable; none of the metal is lost in the recycling process. Manufacturers can thus reduce their environmental impact and carbon footprint while also minimizing costs. Some purchase recycled aluminum for manufacturing, recycle aluminum for internal use, or sell scrap aluminum. 

Lower Melting Point

Aluminum melts at 660 °C — far cooler than most engineering metals. It’s also difficult to weld since it has a tendency to burn before melting. Moreover, its low melting temperature means aluminum becomes softer and has reduced mechanical strength once temperatures exceed 200-250 °C. Combined, these facts make aluminum unsuitable for high-temperature operations. 

Susceptibility to Galvanic Corrosion

Although aluminum resists most ordinary corrosive effects, it is susceptible to galvanic corrosion. When two dissimilar metals are in indirect or direct contact via an electrolytic fluid, galvanic corrosion occurs. The electrolyte facilitates the transfer of electrons between dissimilar metals. Aluminum will lose electrons to a more noble metal and thus will corrode. Aluminum is one of the least noble metals in the galvanic series table that describes the nobility of different metals. As such, it is highly susceptible to galvanic corrosion. To reduce the likelihood of galvanic corrosion in aluminum parts, place it only near metals that occupy similar positions on the galvanic scale.

Higher Cost Than Other Metals

Aluminum is more expensive than some other metals. Its cost can be attributed to the expensive and lengthy process of refining pure aluminum from bauxite and other aluminum-rich ores for the creation of different alloys. These processes are more energy-intensive than those used to extract other pure metals and use them for alloys. Aluminum’s relatively high price is why many companies opt to use Xometry for their aluminum fabrication needs.

Construction

Buildings and infrastructure projects often involve aluminum in the form of external facades, walls, roofs, staircases, railings, shelves, and more. The metal is valued for its minimal mass and high strength-to-weight ratio. Additionally, aluminum’s durability and acceptance of lacquer or other finishes make it great for construction applications.

Aerospace

Many different aluminum alloys make their way into aerospace applications. 2024 aluminum alloy sheets, for example, get turned into fuselage and wing components while 2014 aluminum alloy is often used in interior framing components. Low density, high strength-to-weight ratio, durability, and natural corrosion resistance are the primary driving factors in the industry’s material selection. Aluminum fabrication techniques like CNC machining, die casting, forming, and laser cutting are all used to produce high-quality aerospace components.

Automotive

Aluminum is often used in automotive settings for its minimal weight, high strength-to-weight ratio, and natural corrosion resistance. Its low mass improves the efficiency of automobiles, while its high strength and corrosion resistance makes it great for load-bearing applications in outdoor environments. CNC machining, die casting, forming, and laser cutting are all common aluminum fabrication methods for automotive parts. From engine blocks and transmissions to brake components, frames, and electrical parts, aluminum is very common in the automotive industry.

Marine

The marine industry is another that commonly utilizes aluminum alloys. Aluminum silicon and aluminum-magnesium alloys are two of the most common alloys in marine products. They are valued for their corrosion resistance, strength, and low density. Corrosion resistance can be further improved by processes like anodizing or painting — important because salt water can accelerate galvanic effects. Aluminum is commonly employed in ladders, railings, and ship hulls.

Electronics

Aluminum has great electrical and thermal conductivity. These properties, as well as the low density, make aluminum great for electronics. From automotive and aerospace subsystems to consumer electronics, aluminum is used in numerous different electronic applications. Aluminum is often used for electrical wiring and electrical components like capacitors, antennas, heat sinks, and more.

Steel Fabrication

Steel and aluminum often get compared head-to-head. Steel is better when exposed to extreme loads or high temperatures. Additionally, you may prefer steel if there’s little risk of corrosion or when you simply need cheap metal. Steel has higher yield strengths (220-1570 MPa) compared to aluminum (24-483 MPa). Steel also has a higher melting temperature (1,205-1,370 °C) than aluminum (660 °C). Moreover, basic steel is cheaper than aluminum. However, steel is much heavier than aluminum and is almost three times as dense. For applications that require high strength but where low weight and corrosion resistance aren’t major factors, steel is often preferred. 

Titanium Fabrication

Titanium is another viable alternative to fabricated aluminum parts. Titanium has a density of 4.506 g/cm3 — denser than aluminum, but still minimal compared to most metals. Additionally, titanium has a high strength-to-weight ratio and a yield strength of 170-480 MPa, depending on the alloy. While it is slightly heavier and weaker than aluminum, titanium is harder and has a higher melting point (1649-1671 °C). This means titanium can be used in highly abrasive environments. Additionally, its higher melting point and temperature tolerance mean titanium’s properties won’t begin to change until it hits much higher temperatures than aluminum could dream of. Moreover, titanium is biocompatible, so it can be used in medical applications like implants and pacemakers. It’s not a perfect replacement, though; titanium is significantly more expensive than aluminum to process and alloy. Compared to aluminum, titanium is preferred for applications that require higher strength, abrasion resistance, or biocompatibility.