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Aluminum

High cutting speeds and feed rates possible; demanding for thin wall thicknesses and distortion.

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Suitable machines
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Brief definition

Aluminum

Lightweight, easily machinable, corrosion-resistant — standard material for structural components.
AW-6061
AW-7075
Approved
Properties
Density

2.7 g/cm³

approx. 35% of steel

Tensile strength

Up to 570 MPa

Highly alloy-dependent, e.g., AW-7075

Thermal conductivity

High

approx. 130–170 W/(m·K), promotes high cutting speeds

Corrosion resistance

Good

Protective oxide layer, sensitive to certain media

Machinability

Good

High cutting speeds and feed rates possible

Machining

Challenge and solution

  • Challenge

    Distortion in thin wall thicknesses

    Residual stresses and clamping forces easily deform thin-walled aluminum components during and after machining.

    Our Solution

    Defined clamping strategy

    Fixturing and machining sequences are selected to minimize distortion and include in-process inspection of critical dimensions.

  • Challenge

    Built-up edge formation

    Incorrect cutting speeds or dull tools cause aluminum to adhere to the cutting edge, degrading surface quality.

    Our Solution

    Sharp cutting edges, optimized cutting parameters

    Positive cutting geometries and high cutting speeds prevent material adhesion on the cutting edge.

  • Challenge

    Chip evacuation and heat dissipation at high feed rates

    High material removal rates generate significant heat and large chip volumes in a short time.

    Our Solution

    High-performance coolant lubrication

    Adequate coolant flow reliably dissipates heat, clears chips, and protects surface integrity.

  • Challenge

    Dimensional accuracy in thin-walled structural components

    Aerospace aluminum structural components require tight tolerances with minimal material thickness.

    Our Solution

    In-process measurement

    Critical dimensions are inspected during machining to eliminate rework.
Machining

How we machine this material

We machine aluminum at high cutting speeds and feed rates, relying on rigid clamping setups to prevent distortion in thin-walled components. Sharp, positive cutting geometries and sufficient coolant lubrication prevent built-up edges and ensure superior surface quality.

  • High cutting speeds and feed rates
  • Clamping strategy to prevent distortion of thin walls
  • Sharp cutting edges to prevent built-up edge formation
  • Sufficient coolant lubrication for superior surfaces

Manufacturing

Suitable processes

CNC Milling

CNC milling at FORMA Maschinenbau: Milled parts up to 24 m length, 5-axis simultaneous machining, and 5-axis milling for single parts and series from the Münsterland region.
  • Up to 24,000 mm component length
  • 5-axis simultaneous
  • More About This Service

Machine allocation

Approved Aluminum for

DMG MORI

DMG DMC160U

X-axis travel
1,600 mm
Axes
5 axes simultaneous
Size Class
Up to 2 m
Technical Data →

Applications

Where Aluminum it is used

For us, quality is not just a word, but measurable reality. Through state-of-the-art testing equipment such as laser interferometers and 3D measurement technology, we ensure that every component precisely meets specifications.

Aerospace

Aerospace

Structural components, housings

Frequently asked questions

FAQ Aluminum

Which aluminum alloys do you machine?

We manufacture components from alloys including AW-6061, AW-7075, and AW-2024, depending on your specific requirements for strength, toughness, or corrosion resistance.

Why is aluminum more cost-effective to machine than titanium?

Aluminum allows for significantly higher cutting speeds and feed rates, resulting in shorter cycle times and reduced tool wear.

How do you prevent distortion in thin-walled components?

By implementing a predefined clamping concept, an optimized machining sequence, and intermediate measurements of critical dimensions.

Do you provide material test reports for aluminum?

Yes, upon request we provide material test certificates and inspection reports with full heat/batch traceability.

Inquiry

Request a component made of this material

Please specify the alloy, wall thicknesses, and tolerances. We provide realistic estimates for machining time and tooling costs.
Inquire about material
+49 2862 58787-0

Your contact person

Norbert Groß-Onnebrink

Executive Management
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