8 Questions Abuot Aluminum for Metal Stamping

aluminum alloys precision metal stamping

This article introduces the common questions of aluminum and aluminum alloys using in the metal stamping process for your reference:

1. What are aluminum and aluminum alloys?

Aluminum is a metal with low strength and good plasticity. In addition to the application of part of pure aluminum, in order to improve the strength or comprehensive performance, it is formulated into an alloy. The addition of an alloying element to aluminum can change its organization and performance, making it suitable for various processing materials or casting parts. The alloying elements often added are copper, magnesium, zinc, silicon. With the rapid development of industrial economy, there is an increasing demand for aluminum alloy stamping parts, which have been applied in large quantities in aviation, aerospace, automobile, machinery manufacturing, shipbuilding and chemical industries.

2. What are the advantages of Aluminum in Metal Stamping?

1) Light weight

Aluminum density is very small, only 2.7 g/cm, which can be made into various aluminum alloys, such as hard aluminum, super hard aluminum, rust-proof aluminum, cast aluminum and so on. These aluminum alloys are widely used in the manufacturing industries of aircraft, automobiles, trains and ships.

aluminum automotive

2) Strong electrical and termal conductivity

Aluminum with strong electrical conductivity feature, second only to silver, copper, although its conductivity is only 2/3 of copper, but only 1/3 of the weight of copper, so the same amount of electricity transmission, the quality of aluminum wire is only half of the copper wire. Aluminum surface oxide film has the ability to resist corrosion, and has a certain degree of insulation, so aluminum in the electrical manufacturing industry, wire and cable industry and radio industry has a wide range of uses.

As it strong termal conductivity, aluminum also can be used in industry to manufacture a variety of heat exchangers, heat dissipation materials and cookware, etc.

3) Good ductility

It’s ductility is second only to gold and silver, in 100 ℃ ~ 150 ℃ can be made of thin than 0.01 mm aluminum foil. These aluminum foils are widely used for packaging cigarettes, candy, etc., can also be made of aluminum wire, aluminum bars, and can be rolled into a variety of aluminum products.

4) Surface protection film

Aluminum with dense oxide protective film, it is not easy to be corroded and is often used to manufacture chemical reactors, medical devices, refrigeration devices, petroleum refining devices, oil and gas pipelines, etc.

5) Attractive Apperance

Aluminum powder color with silver-white luster, often used to make coatings, commonly known as silver powder, silver paint, to protect iron products from corrosion, and beautiful.

aluminum alloys metal stamping

3. What are the classifications of aluminum alloys?

Aluminum Alloy Material Types

Features

Applications

Stamped Aluminum 1100

One of the softest aluminum alloys, high ductility and material flexibility.

Spun parts, chemical equipment and anodized parts, tableware or decorative parts.

Stamped Aluminum 2024

Heat treatable aluminum alloy with copper as the main alloy element, high strength and fatigue resistance.

Aircraft structures parts, rivets, components, truck wheels, propeller elements and other various structural parts.

Stamped Aluminum 3003

Good corrosion resistance and medium strength, machinability.

Cooking instruments, kitchen equipment and chemical processing products.

Stamped Aluminum 5052

Weldability and corrosion resistance, easy to bend and shape without cracking, good machinability and finishing characteristics.

Aircraft parts, household appliances and heavy cooking appliances, transportation vehicles, sheet metal parts of ships.

Stamped Aluminum 6061

Corrosion resistance, formability and weldability, high versatility.

Manufacture of automotive bodies, frames, marine hardware, architectural structures and aerospace components.

4. Why are aluminum alloys often used in automotive?

1)Lightweighting.

For every 1% reduction in vehicle mass, fuel consumption can be saved by 0.6%~1.0%; for every 100 kg of vehicle weight reduction, CO2 emissions can be reduced by about 5 g/km, and for every 1 kg of aluminum used in a car, tailpipe emissions can be reduced by 20 kg during its service life; vehicle tailpipe emissions are positively correlated with fuel consumption; existing cars are becoming more and more advanced and additional devices are becoming available. The same makes the use of lightweight aluminum inevitable.

2)The main object of automotive lightweighting:

Engine, chassis, body and interior and exterior accounted for a large proportion of the total mass of the car, weight reduction potential is also large. Car body is the car weight of the larger components, accounting for about 30% of the total weight of the car, so the body of the aluminum is pivotal.

lightweight main object

3)Highly recyclable

Aluminum is good for the environment because it is highly recyclable, and producing aluminum from scrap consumes less energy than producing aluminum from raw materials.

5. What are the products of aluminum alloy in the automotive industry?

6. How to calculate the strength of steel plate and aluminum alloy plate?

After the aluminum alloy plate replaces the steel plate, in order to meet the performance of the stamped parts, it is necessary to make the equal strength calculation. Bending stiffness and strength are important indicators of the plate. In order to achieve the product performance to meet the use requirements after aluminum replaces steel, this paper is realized by changing the thickness of aluminum alloy plate, and the thickness calculation process is as follows.

(1)When judging the performance of automotive structural parts by bending stiffness, the thickness ratio of aluminum alloy plate and steel plate is calculated according to the following formula: (DX54D is chosen for steel plate and 5754 for aluminum alloy plate)

tAl /tS = (ES /EAl)1/3

tAl – thickness of the aluminum plate, mm.

tS – thickness of the steel plate, mm.

ES – modulus of elasticity of steel, MPa.

EAl – modulus of elasticity of aluminum, Mpa.

ES=210Gpa , Eal=61Gpa 

tAl/tS = (ES/EAl)1/3=1.5

 

aluminum

(2)When the bending strength is used as a criterion, the thickness ratio of aluminum alloy plate and steel plate is calculated according to the formula (4-2). 

tAl /tS = (σS / σAl)1/2 

where: σS – the yield strength of the steel plate, MPa.

σAl – yield strength of aluminum plate, MPa.

σs = 184.4 MPa, σAl = 116.9 MPa. (The material of the original steel plate is DX54D.

The aluminum alloy plate is selected as 5754)

From the formula (4-2): tAl / tS = (σS / σAl) 1/2 = 1.26

Then the thickness of the aluminum alloy plate is

tAl =1.26tS =1.26×0.7 = 0.88mm

Take tAl =max{1.05, 0.88}=1.05mm. According to the specification thickness of the plate in production, tAl is 1mm, that is, the thickness of aluminum alloy plate increases from 0.7mm to 0.88mm after replacing the steel plate.

The thickness increases from 0.7mm to 1mm.

7. What are the common surface treatments for aluminum stamping parts?

Aluminum alloy is widely used because of its low density, high strength, good plasticity, high electrical conductivity and good mechanical properties. In order to make the workpiece more beautiful and improve other properties, surface treatment is usually done.

(1) Sandblasting

It makes the surface flatter, makes the aluminum parts more beautiful and precise, and also improves the performance of the workpiece to increase the adhesion between the aluminum alloy punching parts and the coating.

(2) Aluminum anodizing treatment

Improve the abrasion resistance and hardness of the surface of aluminum parts, through anodic oxidation can also obtain a variety of surface colors.

(3) Brushing treatment 

The effect of decoration, the common types of drawing are: straight drawing, messy drawing, rotary drawing, thread drawing.

aluminum secondary operation

8. What are the general industrial applications of aluminum stamping?

  • Transportation – aircraft, automobiles, ships, trucks, bicycles, railroad cars.
  • Construction – walls, windows and doors, building wires
  • Cookware – pots, pans, disks, mixers, blender parts, mixing bowls, everyday items
  • Packaging – jars, aluminum foil
  • Electronics-CPU and transistor heat sinks

To learn more about our metal stamping capabilities, materials we used, and how we can benefit your metal stamping project, contact us or request a quote today.

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