Aluminum Machining Services

Aluminum CNC machining is one of the most versatile and cost-effective manufacturing techniques available today. With its exceptional machinability, lightweight properties, and excellent strength-to-weight ratio, aluminum has become the material of choice for countless precision components across industries.

Various Options

Functionality

Cost-effectiveness

Specification	Capability	Notes
Dimensional Tolerance	±0.001 in (0.025 mm)	Tighter tolerances possible for specific applications
Surface Roughness	Ra 0.8–3.2 μm	Smoother finishes achievable with polishing
Maximum Part Size	60″ x 40″ x 20″	Varies by equipment capabilities
Minimum Wall Thickness	0.020″ (0.5 mm)	Depends on part geometry and alloy
Minimum Hole Diameter	0.020″ (0.5 mm)	Aspect ratio considerations apply
Thread Size Range	M1.6 to M36	Standard and custom threading available

CNC Machining of Aluminum

Aluminum is highly machinable and can be processed three to four times faster than steel or titanium. This efficiency, combined with aluminum's natural properties, makes it ideal for applications requiring lightweight yet durable components with complex geometries.
CNC machining centers used for aluminum processing range from 3-axis to 5-axis configurations, with the latter enabling complex geometries and undercuts in a single setup. This multi-axis capability is particularly valuable for aerospace and automotive components where intricate features and weight reduction are critical.

CNC milling – using rotating cutting tools to remove material
CNC turning – rotating the workpiece against stationary cutting tools
Drilling – creating precise holes in aluminum components
Tapping – cutting threads into holes for fasteners
Surface finishing – achieving desired texture and appearance

Excellent machinability – Cuts 3-4 times faster than steel
Lightweight – 2.7 g/cm³ (about 1/3 the weight of steel)
High strength-to-weight ratio – Ideal for aerospace and automotive
Corrosion resistance – Natural oxide layer provides protection
Thermal conductivity – Excellent heat dissipation properties
Electrical conductivity – Good for electrical components
100% recyclable – Environmentally friendly material
Cost-effective – Lower machining costs than many metals

Lower hardness – Less wear-resistant than steel
Heat sensitivity – Can melt and stick to cutting tools
Chip management – Long chips can tangle and cause issues
Galling tendency – Can stick to cutting tools without proper lubrication
Lower fatigue strength – Compared to steel and titanium
Welding challenges – Some alloys are difficult to weld
Thermal expansion – Higher than steel, affecting precision

Aluminum
1000 Series
(Pure Aluminum)

Core Characteristics: ≥99% aluminum content; excellent corrosion resistance, high thermal/electrical conductivity, good ductility; low strength (no heat treatability).
Common Applications: Electrical conductors, heat exchangers, chemical tanks, food packaging (foils), decorative trim.

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

1050

70–90

30–50

~35

15–20

20–30

2.71

120

1060

70–95

30–55

~35

15–22

20–35

2.71

120

1100

75–100

35–60

~40

18–23

15–30

2.71

120

Aluminum
2000 Series
(Al-Cu Alloys)

Core Characteristics: Copper as main alloying element; high strength (heat-treatable, peak strength in T6 temper); poor corrosion resistance (needs surface treatment like anodizing).
Common Applications: Aerospace components (fuselages, wings), high-strength structural parts, truck frames.

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

2011

290–370 (T6)

170–260 (T6)

~100 (T6)

80–100 (T6)

20–30

2.80

150

2024

470–520 (T6)

325–380 (T6)

~145 (T6)

120–140 (T6)

20–35

2.78

150

2017

380–420 (T6)

275–310 (T6)

~120 (T6)

100–115 (T6)

15–30

2.79

150

Aluminum
3000 Series
(Al-Mn Alloys)

Core Characteristics: Manganese as main alloying element; moderate strength (non-heat-treatable, strengthened by cold working); good corrosion resistance and formability.
Common Applications: Cookware, beverage cans (sidewalls), heat sinks, architectural trim.

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

3003

110–160 (H14)

40–110 (H14)

~50 (H14)

30–45 (H14)

12–20 (H14)

2.73

120

3004

140–210 (H16)

65–140 (H16)

~65 (H16)

40–60 (H16)

8–15 (H16)

2.73

120

3105

120–170 (H14)

50–120 (H14)

~55 (H14)

35–50 (H14)

15–25 (H14)

2.73

120

Aluminum
4000 Series
(Al-Si Alloys)

Core Characteristics: Low melting point (ideal for brazing/welding); medium strength (non-heat-treatable); good fluidity in molten state; moderate corrosion resistance; primarily used as filler metals (welding rods/wires).
Common Applications: Welding consumables (for joining aluminum alloys), heat exchangers, automotive cylinder heads.

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

4043

170–210 (T6)

100–130 (T6)

~65 (T6)

45–55 (T6)

12–20 (T6)

2.69

160

4047

150–190 (T6)

90–120 (T6)

~60 (T6)

40–50 (T6)

10–18 (T6)

2.68

160

4A01

180–220 (T6)

110–140 (T6)

~70 (T6)

50–60 (T6)

10–15 (T6)

2.70

160

Aluminum
5000 Series
(Al-Mg Alloys)

Core Characteristics: Magnesium as main alloying element; high strength-to-weight ratio (non-heat-treatable); excellent corrosion resistance (especially in marine environments) and weldability.
Common Applications: Marine structures (hulls, decks), automotive body panels, pressure vessels, offshore components.

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

5052

210–290 (H34)

100–210 (H34)

~90 (H34)

60–80 (H34)

10–18 (H34)

2.68

150

5083

310–380 (H116)

190–270 (H116)

~125 (H116)

85–105 (H116)

15–25 (H116)

2.66

120

5754

180–250 (H24)

80–160 (H24)

~80 (H24)

50–70 (H24)

15–25 (H24)

2.68

150

Aluminum
6000 Series
(Al-Mg-Si Alloys)

Core Characteristics: Mg-Si as main alloying elements; balanced strength/formability (heat-treatable); good corrosion resistance and weldability.
Common Applications: Architectural extrusions (window frames, doors), automotive parts (wheels, bumpers), structural frames.

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

6061

310–380 (T6)

275–310 (T6)

~110 (T6)

95–110 (T6)

10–15 (T6)

2.7

150

6063

170–240 (T5)

110–200 (T5)

~70 (T5)

50–70 (T5)

15–25 (T5)

2.7

150

6082

180–250 (H24)

250–300 (T6)

~120 (T6)

90–110 (T6)

8–12 (T6)

2.7

150

Aluminum
7000 Series
(Al-Zn-Mg Alloys)

Core Characteristics: Zinc as main alloying element (often with Mg/Cu); highest strength among aluminum alloys (heat-treatable); good fatigue resistance; moderate corrosion resistance (needs surface protection).
Common Applications: Aerospace (landing gear, aircraft spars), high-performance sports equipment (bike frames, ski poles), military components.

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

7075

570–650 (T6)

500–570 (T6)

~160 (T6)

150–170 (T6)

5–8 (T6)

2.81

120

7050

510–580 (T7451)

450–530 (T7451)

~150 (T7451)

135–155 (T7451)

7–11 (T7451)

2.80

150

7005

350–400 (T6)

290–340 (T6)

~130 (T6)

100–120 (T6)

10–15 (T6)

2.79

120

Aluminum
8000 Series
(Specialty Alloys)

Core Characteristics: Specialized properties (varies by alloying elementl like lithium, iron, tin, etc.): e.g., lithium reduces density; iron improves wear resistance; customized for niche industries; limited commercial availability.
Common Applications: High-performance aerospace parts (lithium-containing alloys), food packaging foils, battery tabs.

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

8011

190–220 (H18)

150–180 (H18)

~160 (T6)

55–65 (H18)

3–8 (H18)

2.71

130

8090

450–510 (T6)

380–450 (T6)

~140 (T6)

120–140 (T6)

5–9 (T6)

2.55

150

8176

280–330 (T6)

200–250 (T6)

~95 (T6)

75–90 (T6)

8–12 (T6)

2.7

140

Mechanical Finishes

These processes alter the surface texture through physical means:

Polishing – Creates a mirror-like reflective surface
Bead Blasting – Produces a uniform matte finish
Brushing – Creates a directional, lined appearance
Tumbling – Smooths edges and creates a consistent finish

Mechanical finishes can be applied before other treatments like anodizing for enhanced results.

Chemical Finishes

Chemical processes that modify the aluminum surface:

Chemical Film (Alodine/Chromate) – Thin conversion coating for corrosion protection
Passivation – Removes free iron from the surface
Etching – Creates a matte finish by controlled chemical attack

Chemical finishes are often used as pre-treatments before painting or as standalone protective layers.

Applied Coatings

Additional materials applied to the aluminum surface:

Powder Coating – Durable, thick coating available in many colors
Wet Painting – Versatile finish with unlimited color options
Clear Coating – Transparent protection that preserves appearance
PTFE/Teflon Coating – Low friction surface for moving parts

Applied coatings offer the widest range of appearance options and specialized properties.

Anodizing

Create a durable, corrosion-resistant oxide layer on the aluminum surface:

Type I (Chromic Acid) – Thin coating (0.00005″-0.0001″), excellent corrosion resistance
Type II (Sulfuric Acid) – Medium coating (0.0002″-0.001″), decorative and functional
Type III (Hard Anodizing) – Thick coating (0.001″-0.004″), excellent wear resistance

It can be done in various colors, popular for both functional and aesthetic applications.

Aerospace

Structural components and brackets
Instrument housings and panels
Fuel system components
Wing and fuselage parts
Satellite and space vehicle components

Automotive

Engine components and blocks
Transmission housings
Suspension components
Heat sinks and cooling systems
Interior trim and structural elements

Medical

Surgical instrument components
Medical device housings
Diagnostic equipment parts
Laboratory equipment frames
Prosthetic components

Electronics

Heat sinks and thermal management
Enclosures and housings
Mounting brackets and frames
LED lighting components
Computer and server chassis parts

Robotics & Automation

Actuator housings and mounts
Robotic arm components
Sensor mounts and enclosures
Structural frames and joints
End-effector tooling

Consumer Products

Camera bodies and mounts
Sporting equipment components
High-end audio equipment
Decorative hardware and fixtures
Smartphone and laptop chassis

Aluminum Machining FAQs

Why is aluminum good for CNC machining?

Aluminum is excellent for CNC machining because of its high machinability rating, allowing for faster cutting speeds and longer tool life compared to harder metals. It's lightweight yet strong, with good thermal conductivity that helps dissipate heat during machining. Additionally, aluminum is cost-effective, readily available in various alloys, and can achieve excellent surface finishes. These properties make it ideal for prototyping and production runs across numerous industries.

What is the best aluminum alloy for structural parts?

For structural applications requiring strength and durability, 6061-T6 and 7075-T6 are typically the best aluminum alloys. 6061-T6 offers a good balance of strength, corrosion resistance, and machinability, making it suitable for most structural applications. For higher-stress applications where maximum strength is required, 7075-T6 provides superior mechanical properties with nearly twice the yield strength of 6061-T6, though at a higher cost and with slightly reduced machinability. The choice between these alloys depends on specific strength requirements, weight constraints, and budget considerations.

How does aluminum machining compare to steel machining?

Aluminum machining differs significantly from steel machining in several ways. Aluminum can be machined 3-4 times faster than steel due to its lower hardness, resulting in shorter cycle times and reduced tool wear. However, aluminum's lower melting point means it can gall or stick to cutting tools if not properly cooled. Steel is harder and more wear-resistant but requires slower cutting speeds and more robust tooling. While steel provides greater strength and durability, aluminum offers better weight reduction, corrosion resistance, and typically lower overall machining costs. The choice between these materials depends on application requirements for strength, weight, and environmental conditions.

What surface finishes are available for aluminum machined parts?

Aluminum machined parts can receive various surface treatments to enhance appearance and functionality. Common options include anodizing (Type I, II, or III) for corrosion resistance and color options; chemical film treatments like Alodine for electrical conductivity; mechanical finishes such as bead blasting, polishing, or brushing for aesthetic effects; and applied coatings like powder coating or wet painting for color and additional protection. Each finish offers different benefits in terms of durability, appearance, and functional properties, allowing for customization based on specific application requirements.

What tolerances can be achieved with aluminum CNC machining?

CNC machining of aluminum can achieve tight tolerances, typically ±0.001" (0.025mm) for standard precision machining. For high-precision applications, tolerances as tight as ±0.0005" (0.0127mm) are possible with proper setup and environmental controls. Factors affecting achievable tolerances include the specific aluminum alloy used, part geometry, machine capability, tooling quality, and temperature stability during machining. Complex parts with deep pockets or thin walls may require wider tolerances due to material deflection during machining. Always specify the critical dimensions where tight tolerances are functionally necessary to optimize manufacturing costs.

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Advantages of Aluminum Machining

Aluminum vs. Steel

Limitations of Aluminum Machining

Popular Aluminum Alloys for CNC Machining

Aluminum 1000 Series (Pure Aluminum)

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

Aluminum 2000 Series (Al-Cu Alloys)

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

Aluminum 3000 Series (Al-Mn Alloys)

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

Aluminum 4000 Series (Al-Si Alloys)

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

Aluminum 5000 Series (Al-Mg Alloys)

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

Aluminum 6000 Series (Al-Mg-Si Alloys)

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

Aluminum 7000 Series (Al-Zn-Mg Alloys)

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Maximum Temp (°C)

Aluminum 8000 Series (Specialty Alloys)

Grade

Tensile Strength (MPa)

Yield Strength (MPa)

Fatigue Strength (MPa)

Hardness (Brinell)

Elongation at Break (%)

Density (g/cm³)

Aluminum
1000 Series
(Pure Aluminum)

Aluminum
2000 Series
(Al-Cu Alloys)

Aluminum
3000 Series
(Al-Mn Alloys)

Aluminum
4000 Series
(Al-Si Alloys)

Aluminum
5000 Series
(Al-Mg Alloys)

Aluminum
6000 Series
(Al-Mg-Si Alloys)

Aluminum
7000 Series
(Al-Zn-Mg Alloys)

Aluminum
8000 Series
(Specialty Alloys)