Is Your 7075 Bar Just a Shape, or a High-Integrity Solution?

You order 7075 aluminum¹ bar for its high strength, but your complex machined parts fail during testing or in the field. You’ve paid a premium for the alloy, but its performance is undermined by hidden internal flaws.

A bar is a shape; a forged blank is a solution. We don’t just supply 7075—we deliver its full potential. Our process ensures a refined, uniform grain structure, eliminating the internal risks that turn high-value machined parts into scrap.

I remember a client who manufactures high-performance automotive components. They were machining parts from standard 7075 extruded bar stock and experiencing unexpected failures under torsional load. The problem wasn’t the alloy; it was the form. The unidirectional grain flow of the extruded bar created a weak point when stress was applied from the side. They came to us for a solution. We supplied them with custom-forged 7075 blanks. Our forging process created a fine, uniform grain structure that provided superior strength in all directions. Their parts not only passed testing but exceeded expectations. They learned that for critical components, the manufacturing process of the raw material is just as important as the alloy itself.

Can 7075 aluminum be forged?

You know 7075 is one of the strongest aluminum alloys. But you’re unsure if it can be forged to create the near-net shapes you need for complex parts.

Yes, 7075 aluminum is an excellent candidate for forging. The forging process is actually key to unlocking its maximum strength and performance by refining its grain structure and eliminating internal defects.

Not only can 7075 be forged, but it should be forged for any critical application. The 7075 alloy gets its incredible strength from its chemical composition (primarily zinc) and a specific heat treatment process (T6 temper). However, the forging process adds another layer of performance enhancement that you cannot get from a standard extruded bar. When we forge a 7075 billet, the immense pressure forces the internal grains of the metal to align and refine, creating a dense, homogenous structure. This process closes up any microscopic voids or porosity that might exist in the raw cast material. The result is a forged blank with superior fatigue resistance, impact strength, and overall reliability. It transforms a strong alloy into a high-integrity engineering material, which is why we specialize in creating forged 7075 rings and discs for our clients’ most demanding applications.

Is 7075 aluminum stronger than 6061?

You’re trying to choose between 7075 and 6061 for a part that requires high strength. Making the wrong choice could lead to over-engineering and unnecessary cost, or worse, component failure.

Yes, 7075-T6 aluminum is significantly stronger than 6061-T6. It has nearly double the tensile and yield strength, making it the superior choice for high-stress, performance-critical applications.

There’s no contest when it comes to pure strength. 6061-T6 is a fantastic general-purpose structural alloy, offering a great balance of strength, weldability, and corrosion resistance. It’s a true workhorse. However, 7075-T6 is in a different league. Think of 6061 as strong and reliable for everyday structures, while 7075 is the high-performance specialist reserved for the most demanding jobs. This dramatic difference in strength comes from its primary alloying agent, zinc, compared to the magnesium and silicon in 6061. This makes 7075 the standard for applications where strength-to-weight ratio² is the most important factor, such as in aerospace structural components, high-performance racing parts, and military-grade equipment. At SWA Forging, when a client specifies a part must withstand extreme loads without fail, we almost always start with a 7075 forged blank.

Strength Comparison: 7075-T6 vs. 6061-T6

What are the disadvantages of 7075 aluminum?

You know 7075 offers incredible strength, but you’re concerned about potential trade-offs. Understanding its limitations is crucial for successful design and application.

The main disadvantages of 7075 aluminum are its higher cost, lower corrosion resistance compared to other alloys like 6061, and poor weldability. It requires careful consideration of the operating environment.

While 7075’s strength is legendary, it’s not the perfect alloy for every situation. Its high zinc content, which gives it its strength, also makes it more susceptible to stress corrosion cracking (SCC), especially in certain tempers and environments. This is why surface protection, such as anodizing or painting, is often required. For this reason, it’s generally not recommended for applications involving constant exposure to corrosive elements like saltwater without proper treatment. Another significant limitation is its poor weldability. The alloy chemistry that makes it so strong also makes it prone to cracking during welding. Therefore, it’s almost always joined using mechanical fasteners rather than welding. For machining customers, these factors are critical. They must account for the need for protective coatings and design for bolted or riveted assembly. At SWA Forging, we always consult with our clients to ensure 7075 is the right choice for their specific application and environment.

Is aluminium 7075 expensive?

You need the strength of 7075, but you’re concerned about the high material cost impacting your project budget and your ability to be competitive.

Yes, 7075 aluminum is one of the more expensive common aluminum alloys. The cost is driven by its complex alloying elements, more demanding manufacturing processes, and the precision heat treatment required.

The premium price of 7075 aluminum is a direct result of the value it delivers. The raw materials, particularly the high-purity zinc used as the primary alloying agent, are more expensive. The manufacturing process to create a consistent, high-quality billet is more complex and requires tighter controls than for a general-purpose alloy like 6061. Finally, the multi-stage heat treatment process (solution heat treating, quenching, and artificial aging) required to achieve the T6 temper is energy-intensive and time-consuming, adding to the final cost. This is why using this material efficiently is so important for our customers. Machining a complex part from a large, solid bar of 7075 results in a huge amount of expensive scrap. By providing a near-net shape forged blank, like a custom ring or disc, we help our clients minimize this waste. They start closer to the final shape, reducing material cost and saving countless hours of machining time, making the use of this premium alloy much more economical.

Conclusion

Don’t let the shape of a standard bar dictate the integrity of your component. Partner with SWA Forging to transform 7075 alloy into a certified, high-performance³ solution for your most critical parts.