Aluminum Round Bar vs. SWA Forged Components: Choosing the Right Material for Peak Performance

Are you settling for standard aluminum round bars¹ when your application demands superior material integrity and performance? SWA Forging crafts precision-forged components that redefine strength and reliability.

When the inherent limitations of aluminum round bars, such as grain flow misalignment and potential internal defects, hinder peak performance in critical applications, SWA Forging's custom-forged components offer a superior, monolithic solution with optimized material properties for enhanced strength and reliability.

Many engineers and procurement specialists start their material selection journey with aluminum round bars. These bars are widely available in various alloys, like the common 6061 or the corrosion-resistant 5052, and are a staple for many machining operations. Their ease of machining and availability make them a go-to for a vast range of parts, from simple fasteners to more complex shafts. However, when we look at high-stress applications in aerospace, defense, or heavy industry, simply machining a part from a standard bar can introduce significant risks. The grain structure within a bar might not be aligned with the stresses the final component will experience, leading to potential failure points. Internal voids or imperfections, sometimes present in bar stock, can also compromise structural integrity. At SWA Forging, we address these limitations directly through our custom forging process. We take high-performance aluminum alloys and shape them under immense pressure, which refines the grain structure, aligns it with the component's geometry, and virtually eliminates internal defects. This results in components with superior strength, fatigue life, and reliability compared to anything machined from a standard aluminum round bar.

Is forged aluminum better than aluminum?

Forged aluminum is not inherently "better" than all aluminum in every situation, but it offers superior mechanical properties, making it the better choice for demanding applications.

Forged aluminum is superior to standard aluminum in terms of strength, toughness, fatigue resistance, and grain structure. The forging process refines the metal's internal grain flow, aligning it with the component's shape to withstand higher stresses and resist failure, making it ideal for critical aerospace and industrial parts.

The question of whether forged aluminum is "better" than aluminum is nuanced, as aluminum itself is a broad category of metals. However, when comparing forged aluminum to aluminum in its more common forms, like cast or simply machined bar stock, forged aluminum generally offers superior performance. The key difference lies in the manufacturing process. Forging involves shaping metal using compressive forces, often at elevated temperatures. This process manipulates the metal's grain structure, creating a refined and continuous grain flow that follows the contour of the part. This optimized grain structure significantly enhances strength, toughness, ductility, and resistance to fatigue and impact. Standard aluminum bars, on the other hand, are typically produced through extrusion or rolling, where the grain structure might not be as uniformly aligned for specific stress patterns. Cast aluminum can have porosity and a coarser grain structure. Therefore, for applications where reliability and strength under significant stress are paramount—think aircraft landing gear, high-performance engine components, or critical structural elements—forged aluminum is the demonstrably superior choice. At SWA Forging, our expertise is in leveraging these advantages for our clients.

Forged vs. Other Aluminum Forms:

• Forged Aluminum: Optimized grain structure, superior strength, toughness, fatigue resistance.
• Machined Bar Stock: Standard grain structure, good machinability, but grain flow may not align with stress.
• Cast Aluminum: Can have porosity and coarser grain, generally lower mechanical properties.

Forging elevates aluminum's mechanical performance for demanding roles.

What is the best grade of aluminum for extrusion?

The "best" grade of aluminum for extrusion depends heavily on the desired properties of the final product, but 6061 and 6063 are among the most common and versatile.

For general-purpose extrusion with a good balance of strength, corrosion resistance², and workability, 6061 is an excellent choice. For applications prioritizing smooth surfaces, clean finishes, and good anodizing characteristics, such as window frames and architectural elements, 6063 is often preferred.

When clients at SWA Forging inquire about the extrusion process, understanding alloy selection is crucial. Aluminum alloys are categorized into series based on their primary alloying elements. For extrusion, the 6000 series alloys, which contain magnesium and silicon, are particularly well-suited. Alloy 6061 is a medium-strength alloy that offers a good combination of properties: it's strong, weldable, machinable, and has decent corrosion resistance. This makes it a workhorse for many structural applications, including various extruded shapes and tubing used in aerospace, automotive, and general manufacturing. Alloy 6063, while slightly less strong than 6061, is renowned for its excellent extrudability, resulting in smooth surfaces and sharp details. It also has superior corrosion resistance and takes anodized finishes very well, making it the preferred choice for architectural applications like window frames, doors, and decorative trim where aesthetics are as important as structural integrity. For very high-strength applications, some 7000 series alloys can also be extruded, but they can be more challenging to work with. At SWA Forging, we primarily focus on achieving the highest mechanical properties through forging, often using alloys like 6061 and 7075, to surpass the performance ceiling of extruded forms.

Common extrusion alloys:

• 6061: Good all-around strength, corrosion resistance, weldability.
• 6063: Excellent extrudability, superior surface finish, good anodizing.
• Series: 6000 series (Mg-Si) is most common for extrusion.
• Considerations: Strength, formability, surface finish, corrosion resistance.

The choice of alloy depends on the specific performance and aesthetic requirements of the extruded part.

What are the benefits of forged aluminum?

The benefits of forged aluminum are numerous and significant, particularly for applications requiring high performance and reliability.

The benefits of forged aluminum include superior mechanical strength, excellent fatigue resistance, increased toughness and ductility, refined grain structure aligned with the component's shape, and the elimination of internal voids, leading to greater reliability and safety in critical applications.

At SWA Forging, our focus is on delivering components that offer distinct advantages over conventionally machined parts. The benefits of forging aluminum stem directly from the process itself. By shaping the metal under controlled pressure, we refine its internal grain structure. Instead of the potentially random or misaligned grains found in a standard bar or extruded product, forging creates a continuous grain flow that follows the contours of the component. This optimized grain structure means the material is inherently stronger and more resistant to stresses, especially under cyclic loading, which is crucial for fatigue life. Forging also consolidates the metal, eliminating internal porosity, micro-voids, and inclusions that can act as stress concentrators and lead to premature failure. This results in a more homogeneous and robust material. Consequently, forged aluminum parts exhibit higher tensile strength, yield strength, and toughness. They are also more ductile, meaning they can deform significantly before fracturing. These combined benefits translate into enhanced safety margins, longer service life, and improved reliability for critical components in aerospace, automotive, and heavy machinery.

Key benefits of forged aluminum:

• Enhanced Strength: Higher tensile and yield strength.
• Improved Toughness: Greater resistance to impact and fracture.
• Superior Fatigue Life: Withstands repeated stress cycles better.
• Optimized Grain Flow: Grains align with component shape for maximum strength.
• Reduced Defects: Minimizes porosity and internal voids.
• Reliability: Higher confidence in performance under load.

Forging delivers a fundamentally more robust and reliable aluminum component.

What is the difference between 7068 and 7075 aluminum?

While both are high-strength 7000 series aluminum alloys, 7068 is generally considered stronger and tougher than 7075, though it may have slightly different processing characteristics.

7068 aluminum alloy is a newer, advanced alloy designed to offer higher strength and toughness than the widely used 7075 alloy. It is often specified for applications requiring the absolute maximum performance, such as high-stress aerospace components and premium sporting goods, while 7075 remains a robust, standard choice for many demanding applications.

When clients at SWA Forging are looking for the absolute pinnacle of aluminum performance, we often discuss advanced alloys like 7068 in comparison to established standards like 7075. Both alloys belong to the 7000 series, characterized by their high zinc content and excellent strength when properly heat-treated. Alloy 7075 has been a cornerstone in aerospace and high-performance industries for decades, offering a fantastic balance of strength, stiffness, and relatively good fracture toughness for its strength class. Alloy 7068, however, was developed to push these boundaries further. It typically exhibits even higher tensile strength and yield strength compared to 7075. Furthermore, 7068 often possesses improved toughness and ductility, making it more resilient to impact and stress. This makes it an excellent candidate for highly critical components or applications where weight savings are extremely important, and every ounce of strength counts. The trade-offs can sometimes include cost and specific processing considerations, but for applications where ultimate performance is the driving factor, 7068 is often specified over 7075. Our forging expertise allows us to fully realize the potential of both these high-strength alloys.

Alloy comparison:

• 7075: High strength, good toughness, widely used in aerospace, established standard.
• 7068: Very high strength, superior toughness, designed for extreme performance, newer alloy.
• Series: Both are high-strength 7000 series alloys (zinc-based).
• Application Focus: 7068 for highest stress/performance, 7075 for strong, reliable performance.

7068 represents an advancement in high-strength aluminum alloys.

What is the difference between 6061 and 5083 aluminum?

The primary differences between 6061 and 5083 aluminum lie in their alloy composition, heat treatability, and resulting mechanical properties, making them suitable for different applications.

6061 is a heat-treatable alloy known for its good strength, weldability, and corrosion resistance, making it versatile for structural applications. 5083 is a non-heat-treatable alloy with excellent corrosion resistance, particularly in marine environments, and good formability, but lower strength than 6061.

When clients at SWA Forging consider different aluminum alloys, understanding the distinctions between series like the 6000s and 5000s is essential. Alloy 6061 belongs to the 6000 series, which are magnesium-silicon alloys and are heat-treatable. This means 6061 can be significantly strengthened by specific heat treatment processes, such as the T6 temper, which gives it a good combination of strength, hardness, and moderate corrosion resistance. It’s very common for structural components, frames, and machined parts. Alloy 5083, on the other hand, is part of the 5000 series, which are primarily magnesium alloys and are non-heat-treatable. This means its strength comes from alloying and cold working, rather than heat treatment. 5083 is renowned for its exceptional corrosion resistance, especially in saline or marine environments, and also offers good ductility and formability, making it ideal for applications like boat hulls, shipbuilding, and cryogenic storage tanks. However, its ultimate tensile strength is typically lower than that of a heat-treated 6061. So, if the priority is strength and the ability to harden further, 6061 is often preferred. If the priority is extreme corrosion resistance and formability, 5083 is a stronger contender.

Alloy comparison summary:

• 6061: Heat-treatable, good strength, versatile for structures, moderate corrosion resistance.
• 5083: Non-heat-treatable, excellent marine corrosion resistance, good formability, lower strength than heat-treated 6061.
• Series: 6000 (Mg-Si) vs. 5000 (Mg).
• Primary Use: 6061 for general structures, 5083 for marine and corrosion-critical applications.

The choice depends on whether heat-treatable strength or superior corrosion resistance is the main requirement.

Conclusion

For applications demanding the highest levels of strength, reliability, and performance, moving beyond standard aluminum round bars¹ to SWA Forging's precision-forged components provides a significant advantage through optimized material properties and superior structural integrity.