Is aluminum tubing bendable?

Planning a project with aluminum tubing but worried it might crack or kink when you try to shape it? Choosing the wrong bending technique or alloy can ruin your material. Yes, aluminum tubing is very often bendable, but success depends on key factors.

Yes, aluminum tubing is generally bendable, especially common alloys like 6061 and 6063 in appropriate tempers. Success depends on the alloy, temper, tube wall thickness, bend radius, and using the correct bending tools and techniques to prevent kinking or cracking.

At SWA Forging, while our primary focus is on creating robust forged rings and discs, we understand the properties of aluminum inside and out, including how it behaves under different forming processes. Many of our clients work with various aluminum forms, including tubing, often in conjunction with the forged components we supply. Knowing how to correctly manipulate aluminum, whether it's forging or bending, is crucial for achieving the desired outcome. Let's delve into the specifics of bending aluminum tubing.

What is the difference between regular aluminum and extruded aluminum?

Confused by terms like "regular aluminum" versus "extruded aluminum¹" when sourcing materials? This uncertainty can lead to selecting an unsuitable form for your application. "Regular aluminum" is a broad term, while "extruded aluminum" refers to a specific manufacturing process.

"Regular aluminum" isn't a technical term but often refers to aluminum in generic forms like cast billets, rolled sheets, or plates. Extruded aluminum, however, is specifically aluminum alloy that has been forced through a die to create a specific cross-sectional profile, like tubing or complex shapes.

The term "regular aluminum" can be a bit vague, as aluminum comes in many forms. It could refer to:

• Cast aluminum: Molten aluminum poured into a mold. The grain structure is typically equiaxed and can be coarser. We at SWA Forging often start with large cast billets for our forging process.
• Wrought aluminum (sheet/plate): Aluminum that has been worked mechanically, often by rolling, to reduce its thickness and refine its grain structure.
  In contrast, extruded aluminum has a very distinct manufacturing process and characteristics:
• Process: A heated aluminum billet (often a round log) is pushed (extruded) through a specially shaped die opening using a powerful hydraulic press. This is how most aluminum tubing, angles, channels, and custom profiles are made.
• Grain Structure: Extrusion imparts a directional grain structure aligned with the extrusion direction. This can influence its mechanical properties.
• Dimensional Accuracy & Surface Finish: Extrusion can produce profiles with tight dimensional tolerances and good surface finishes.
• Complexity of Shapes: Extrusion allows for very complex cross-sectional shapes that would be difficult or impossible to produce efficiently by other methods.
  So, when someone mentions "extruded aluminum tubing," they are referring to tubing made by this specific process, which generally offers consistency and specific profiles suitable for bending.

Can 6061 aluminum be extruded?

Thinking of using 6061 aluminum² for a custom profile or tube and wondering if it's suitable for extrusion? Using an alloy not well-suited for extrusion could lead to poor results. Yes, 6061 is excellent for extrusion.

Yes, 6061 aluminum is one of the most widely used and suitable alloys for the extrusion process. Its favorable combination of mechanical properties, good formability, and response to heat treatment makes it ideal for creating a vast range of extruded profiles, including tubing.

At SWA Forging, while we forge 6061 aluminum into solid components, we recognize its immense popularity in extruded forms, which are often complementary to our products. Many of our clients who purchase our forged 6061 rings and discs might also use 6061 extruded tubes or structural members in their larger assemblies.
The reasons 6061 is so well-suited for extrusion include:

• Good Extrudability: It flows well through extrusion dies, allowing for complex shapes and consistent dimensions.
• Strength and Versatility: After extrusion, 6061 can be heat-treated (typically to a T6 temper) to achieve good strength, making it suitable for structural applications. This includes tubing that needs to withstand pressure or mechanical loads.
• Corrosion Resistance: 6061 offers excellent resistance to corrosion, which is beneficial for extruded products used in various environments.
• Weldability and Machinability: Extruded 6061 profiles can be easily welded and machined, further expanding their applicability.
  Common extruded 6061 products include round, square, and rectangular tubing, pipes, angles, channels, I-beams, and custom-designed profiles for everything from architectural applications to automotive components and machine frames. This makes 6061 extruded tubing a very common candidate for bending operations.

How do I know if my aluminum is 6061 or 7075?

Have a piece of aluminum and need to identify if it's 6061 or the much stronger 7075? Mistaking one for the other can have serious consequences for your project's performance. Identification without documentation can be tricky.

Without material certifications or markings, visually distinguishing between 6061 and 7075 aluminum is nearly impossible. Professional methods like X-Ray Fluorescence (XRF) analysis or checking hardness against known specifications are reliable ways to identify them.

This is a common challenge, especially with unlabelled stock material. As a supplier providing product quality certificates with every order, we at SWA Forging stress the importance of material traceability. Here’s what you can consider:

• Markings: Check for any stenciled or stamped markings on the material. Manufacturers often mark the alloy and temper.
• Material Test Reports (MTRs): If the material was sourced properly, it should have come with an MTR detailing its chemical composition and mechanical properties. This is the most reliable way.
• Hardness Testing: 6061-T6 typically has a Brinell hardness around 95 HB, while 7075-T6 is significantly harder, around 150 HB. A portable hardness tester could give a good indication if you have reference values.
• Chemical Analysis: Portable X-Ray Fluorescence (XRF) analyzers can quickly determine the elemental composition, distinguishing between the magnesium/silicon based 6061 and the zinc-based 7075. This is a common method for material verification in industry.
• Machinability & Chip Formation: Experienced machinists might notice differences. 7075 often produces smaller, more broken chips and feels "crisper" to machine than 6061. This is subjective and not a definitive test.
• Density: While there's a slight difference (7075 is ~4% denser), it's usually not practical to measure accurately enough for identification.
  Relying on guesswork is risky. If positive identification is critical, especially for structural or high-stress applications, investing in a professional analysis or ensuring traceable sourcing is essential.

What grade of aluminium is used for extrusion?

Curious about which aluminum alloys are best suited for making those intricate extruded shapes like tubing? Choosing an alloy with poor extrudability can lead to manufacturing problems. Specific grades are favored for their excellent extrusion characteristics.

The most common aluminum grades used for extrusion are from the 6xxx series, notably 6063 and 6061. Others like 6005A and 6082 are also used. These alloys offer a good balance of extrudability, strength, surface finish, and corrosion resistance.

Not all aluminum alloys are created equal when it comes to the extrusion process. Some flow through the die much more easily and produce better results than others. The 6xxx series, which primarily uses magnesium and silicon as alloying elements, dominates the extrusion market.
Here's why these grades are preferred:

• 6063: Often called the "architectural alloy," it's valued for its excellent extrudability, allowing for complex shapes and very smooth surface finishes suitable for anodizing. It has moderate strength, often used for window frames, door frames, and decorative trim. Aluminum tubing for general purposes is often 6063.
• 6061: Offers higher strength than 6063, especially after T6 heat treatment. It's used for more structural applications, including load-bearing tubing, machine parts, and transportation components. While slightly less extrudable than 6063, it's still very good.
• 6005A: Provides a strength profile between 6063 and 6061, with good extrudability and surface finish. Often used in automotive and rail applications.
• 6082: A medium-strength structural alloy, common in Europe, with excellent corrosion resistance. It's often used for more demanding structural applications than 6061.
  The choice of grade depends on the required strength, desired surface finish, complexity of the profile, and end-use application. For bending aluminum tubing, knowing the specific grade and its temper is key to predicting its behavior.

Conclusion

Aluminum tubing is indeed bendable, with alloys like 6061 and 6063 being common. Understanding extrusion and material identification helps ensure you select and work with the right aluminum effectively.