Forging Aluminium

Material Description

Aluminium, with its chemical symbol Al and atomic number 13, is a lightweight, silvery-white, and malleable metal known for its exceptional combination of physical and mechanical properties. It boasts a density of approximately 2.7 g/cm³, making it one of the lightest commercially available metals. This low density, along with its high corrosion resistance due to a naturally forming oxide layer on its surface, makes aluminium a popular choice in various technical applications. The metal exhibits good thermal and electrical conductivity, enabling its use in electrical wiring, heat sinks, and other heat transfer applications. Furthermore, aluminium is highly recyclable, which not only reduces environmental impact but also conserves energy as it takes only a fraction of the energy to recycle aluminium compared to extracting it from bauxite ore, its primary source.

In addition to its lightweight nature, aluminium possesses excellent strength-to-weight ratio, making it a favored material in the aerospace and automotive industries. It is commonly alloyed with other elements like copper, magnesium, and silicon to enhance its mechanical properties. These alloys can be tailored to suit specific engineering requirements, balancing strength, corrosion resistance, and formability. Aluminium’s versatility extends to various forms, including sheets, plates, extrusions, and castings, making it suitable for a wide range of technical applications, from aircraft construction to automotive components, architectural structures, and consumer electronics. Its non-toxic nature and non-magnetic properties further enhance its utility in sectors such as food packaging and medical equipment, underlining aluminium’s significance in modern technical and industrial contexts.

Industry Applications

Widely used in automotive components, aircraft structures, beverage cans, electrical wiring, building facades, and general engineering for its lightweight, corrosion resistance, and electrical conductivity.

Finishing Options

Anodizing, Powder Coating, Paint

DensityTensile Yield
Strength (MPa)
Conductivity (W/m-K)
Coeff. of
(micro Ohm-cm)
2.795-1257030-70205-23522.22.82 x 10^-8

Design Recommendation

When forging aluminum components, it’s advisable to design parts with simple shapes and uniform cross-sections to minimize material waste. Consider incorporating thicker sections where necessary for added strength and structural integrity. Avoid sharp corners in your design, as these can create stress concentrations that might lead to cracking during forging. Moreover, aim for smooth transitions and gradual changes in geometry to facilitate the flow of material in the die, which can enhance the overall efficiency of the forging process.

Cost Saving Tip

When forging aluminum, consider using recycled aluminum to reduce material costs. In addition, employ energy-efficient heating and forging processes to minimize energy expenses. Careful design and planning of the forging process can help reduce scrap and material wastage. Multi-cavity dies can increase production efficiency, and implementing lean manufacturing practices can reduce waste and save costs.