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Why choose aluminum alloy?
Industries like aerospace, automotive, construction, and electronics widely use aluminum alloys for their light weight, corrosion resistance, and conductivity. These alloys are essential materials for everything from cell phone casings to aircraft parts. Understanding the machining methods of aluminum alloys is crucial for selecting the appropriate process that meets both the functional and manufacturing requirements of different products.

1. Basic concepts of aluminum alloys
Aluminum alloys are aluminum-based materials with adjustable properties, influenced by alloying elements like copper, silicon, and magnesium.
These alloys have a low density but strength that matches or surpasses some high-quality steels. They also offer good plasticity for shaping.
Its excellent electrical and thermal conductivity and corrosion resistance make aluminum alloy widely used in industry, especially in aviation, construction, and electronics.
2. Three major classifications of aluminum alloy processing methods
There are three primary categories of aluminum alloy processing methods: casting, deformation processing, and surface treatment. Each method comes with its own set of applicable scenarios, advantages, and technical requirements. In the following sections, we will explore the characteristics and applications of each of these methods in detail.
Deformed Aluminum Alloy Processing Methods
1. What is deformed aluminum alloy?
Deformed aluminum alloys withstand pressure processing and, through forging, rolling, and other methods, become the desired material. Manufacturers shape these alloys into various specifications and shapes, making them ideal for aerospace equipment and architectural doors and windows.
2. Classification of deformed aluminum alloys
Non-heat-treated reinforced aluminum alloys can’t be heat-treated for strength. They rely on cold work for strengthening. Examples include industrial pure aluminum and rust-proof aluminum, which are used for rust resistance and electrical conductivity.
Heat-treated reinforced aluminum alloys can undergo processes like quenching and aging to improve their mechanical properties. Common types include duralumin, wrought aluminum, super duralumin, and specialty alloys. These high-strength alloys are often used in aerospace and automotive manufacturing, where durability and light weight are critical.
3. Deformation Aluminum Alloy Processing
Deformation machining is the process of obtaining the desired shape of an aluminum alloy billet by causing it to undergo plastic deformation in the solid state through an external force. Common deformation processing methods include extrusion, rolling, drawing, and forging.
(1) Extrusion
Extrusion is a processing method that passes aluminum alloy billets through die orifices to produce aluminum profiles with different cross-sectional shapes, such as window frames and pipes. The extrusion process is highly flexible and can produce long profiles with various complex cross-sections.
(2) Rolling
Rolling is the use of a pair of rotating rolls to press aluminum alloy into thin plates or strips, suitable for large areas, and uniform thickness of the plate production. Based on thickness, we divide it into cold rolling and hot rolling. Cold rolling makes thin, smooth products, while hot rolling is for thicker aluminum plates.
(3) Drawing
Drawing process by pulling the aluminum into a thin wire or tube, suitable for the manufacture of smaller diameter aluminum alloy wire and long thin tubes. The process delivers high precision and manufacturers widely use it to produce cables and wires.
(4) Forging
Forging is the process of forming aluminum alloy in a die by applying impact force to it. Forged aluminum parts have good mechanical properties and denseness, and are suitable for parts requiring high strength, such as aircraft and automobile engine parts.

Deformed aluminum alloy processing methods are flexible and capable of processing a wide range of shapes and sizes.
Casting Aluminum Alloy Processing Methods
1. What is cast aluminum alloy?
Manufacturers create casting aluminum alloy by injecting liquid aluminum into a mold and cooling it to form. These alloys are ideal for producing complex parts with high strength and corrosion resistance. We categorize cast aluminum alloys based on their alloy composition.
2. Classification of cast aluminum alloy
You can classify casting aluminum alloy into the following types based on its chemical composition:
Aluminum-silicon alloy: with good fluidity and corrosion resistance, it is suitable for complex castings.
Aluminum-copper alloy: high hardness and strength, suitable for high-strength parts.
Aluminum-magnesium alloy: high corrosion resistance, suitable for marine equipment and chemical equipment.
Aluminum-zinc alloy: high hardness but weak corrosion resistance, mainly used for industrial machinery parts.
Aluminum rare earth alloys: with unique physical properties and heat resistance, suitable for special equipment.
3. Common processes for casting aluminum alloys
Casting is the process of injecting liquid aluminum alloy into a mold and forming it into the desired part by cooling. We can further divide casting methods based on the mold and process, as follows:
(1) Sand casting
Sand casting utilizes sand as the mold material and is suitable for large, complex-shaped aluminum alloy parts. Its advantage is high flexibility and low cost, but lower precision and rougher surface, suitable for workpieces that require subsequent processing.
(2) Die Casting
Die casting through the pressure of aluminum alloy liquid into the mold, cooling molding, suitable for mass production of high precision parts. Die-casting products surface smooth, dense structures, commonly used in automobile parts, electronic shells, and other requirements of high precision and beautiful parts.
(3) centrifugal casting
Centrifugal casting through high-speed rotation of the mold, so that the liquid aluminum in the centrifugal force under the action of uniform distribution, for the manufacture of cylindrical, ring-shaped parts, such as pipe fittings and bearings. Centrifugal casting reduces porosity in castings and improves material strength.
(4) Continuous Casting
Manufacturers use continuous casting to produce long or plate-shaped aluminum alloy products. They rapidly cool liquid aluminum in a mold to form a continuous strip or sheet, then cut it to the desired size. It is suitable for mass production of aluminum alloy strips and plates.
Casting aluminum alloys can obtain good mechanical properties and corrosion resistance after appropriate heat treatment, making them ideal for scenarios requiring strength and corrosion resistance, such as aerospace, automotive, and electronic products.
Aluminum Alloy Surface Treatment Process
Surface treatment improves the corrosion resistance, aesthetics, and other properties of aluminum alloys. Common surface treatment methods include oxidizing, painting, and plating.
1. Anodizing
Anodizing is a method of forming an oxide film on the surface of aluminum alloys by electrolytic reaction to improve corrosion resistance and hardness. You can dye anodizing to achieve various colors for decoration. Manufacturers commonly use it for architectural aluminum and electronic housings.
2. Spraying
Spraying is to evenly spray powder coatings or paints onto the surface of aluminum alloys, which is suitable for products that require diverse colors. The spraying process offers flexibility, meeting various color and texture needs. People commonly use it for surface treatment in architecture and home decoration.
3. Electroplating
Electroplating is a method of covering the surface of aluminum alloy with a layer of metal or alloy coating to increase corrosion resistance and decorative properties. Nickel plating and galvanizing electroplating processes enhance conductivity and wear resistance in electrical parts.

Comparison of Aluminum Alloy Processing Methods and Suggestions for Selection
When choosing aluminum alloy machining methods, we usually start with the productivity, cost, precision, and specific performance requirements of the product.
Aluminum Alloy Machining Methods Comparison and Selection Recommendation Table

In practical applications, it is important to choose the right aluminum alloy machining method. Considering material properties, productivity, and end use can help manufacturers improve product quality and reduce production costs.
Summary: How to choose the right aluminum alloy machining method
Aluminum alloy processing methods vary by application. For door and window materials in the construction industry, extruded, deformed aluminum alloys are available, while for high-strength applications such as automotive and aerospace, die-cast aluminum alloys are a better choice. With a comprehensive understanding of the classification and characteristics of aluminum alloy processing methods, companies can make more effective process choices in the production process to meet product quality and performance needs.
Frequently Asked Questions (FAQ)
Q: What is the main difference between deformed and cast aluminum alloys?
A: Pressure processing forms deformed aluminum alloys, making them suitable for various aluminum shapes. Liquid casting forms cast aluminum alloys, ideal for complex castings.
Q: What is the difference between heat-treated reinforced and non-heat-treated reinforced types?
A: Heat-treated reinforced aluminum alloys increase strength through heat treatment, while non-heat-treated alloys rely on cold-working. Both suit different performance needs.