From raw material to high-tech component: the art of aluminum processing
Aluminum is an indispensable material in many industries – from aerospace to mechanical engineering. However, processing this versatile material requires precise know-how and state-of-the-art technologies. In this article, you will learn how to master the challenges of aluminum processing and which production techniques are now standard.
Aluminum: Light, strong and unique
Aluminum is a versatile material. It is light and strong at the same time, which makes it indispensable in many industries – especially in aerospace, vehicle construction and mechanical engineering, where the perfect balance between weight and strength is essential. Aluminum is easy to machine and offers an attractive surface.
But aluminum also has its own characteristics. One of these is its low density, which ensures that heat is distributed quickly during machining. This can be problematic: Heat builds up quickly when cutting or milling, which can cause tools to overheat or change material properties. It is therefore crucial to maintain the correct cutting conditions.
Another feature is the natural oxide layer that protects aluminum from corrosion. This is good, but when welding or soldering, this layer must be removed or controlled as it can affect adhesion.
Aluminum also has a low melting temperature. This means that more heat is quickly generated during machining than the material can tolerate. Precise work is required here to avoid overheating and material distortion.
The anodizing of aluminium is particularly interesting. The natural oxide layer is not removed, but rather reinforced. This creates a hard, protective surface that protects against corrosion and looks good at the same time – in matt silver or bright colors. Anodized aluminium is not only lightweight and durable, but also a real eye-catcher, ideal for applications that require both design and technology.
Aluminum processing: From craftsmanship to high-tech
Machining aluminum requires precise know-how. Everything has to fit exactly, especially with classic processes such as CNC milling or turning. The cutting speed must be right and the tools need special coatings to protect them from wearing out too quickly. If you don’t work cleanly here, you will see this in the surface later on.
Drilling and grinding aluminum is also not as easy as it sounds. Chips can get caught in the tools and impair the surface quality. Clever cooling strategies are therefore necessary to achieve clean results.
Welding aluminum is, as already mentioned, another topic in itself. The oxide layer must be controlled so that the joint remains stable. With the right technique and many years of experience, welding also works without any problems. Modern welding techniques such as TIG welding also make it possible to remove the oxide layer in a targeted manner so that the joint remains stable.
In recent years, aluminum processing has changed significantly thanks to additive manufacturing – i.e. 3D printing. Today, many complex components can be built up layer by layer from aluminum. This reduces material waste and enables flexible production, ideal for individual pieces or small batches. This is particularly important in specialized areas such as aviation, prototype construction or medical technology, as these industries are increasingly benefiting from the possibilities of additive manufacturing.
Regardless of whether classic machining or state-of-the-art production techniques are used, aluminum shows what it is capable of in every discipline. You just have to know how to tackle it properly.
The right aluminum grade: more than just metal
With aluminum, it is not just a matter of processing, but also of choosing the right grade. Depending on the application, the right material is crucial. HSM® has gained this experience over the last few decades, which is why we are now experts in the field of aluminum and its processing.
One of our classics is EN AW 6061, which is characterized by good machinability and high strength and is often used in fixture construction or for other applications.
EN AW 7075 is often used for particularly high strength in vehicle construction. This material has also proven itself in racing. A project at RWTH Aachen University, in which students from the EcurieAix form student team worked with EN AW 7075, demonstrates the versatility of this alloy. HSM® supplied the raw material and they used it to manufacture various components, including the wheel carrier for the racing car.
If you need something even more robust, you can rely on EN AW 2024, an aluminum alloy that is valued in the aerospace industry for its toughness and machinability and has even made it into space. Why do we know this so well? As an audited supplier for Ariane Group, we have already been able to procure the material several times.
Whether for the road, the workbench or outer space: there is a suitable aluminum grade for every project. In our material finder you will find the right solution for your next project.
Our service for your aluminum processing
Machining aluminum is demanding. It requires precision and experience. But you don’t have to master it alone. Our HSM® Technik team will help you select the right manufacturing process, carry out the implementation precisely and complete the post-processing perfectly.
Our aim is to make your life easier and save you time. We take care of the details while you concentrate on your core business. From the first step to the finished component, we are at your side and ensure that your projects are successfully implemented. And so that you know who is behind this service, we would like to introduce you to our team:
Our experts in the technology team are not only specialists, but also problem solvers and creative minds. There are no run-of-the-mill solutions – we develop individual strategies that are tailored precisely to your requirements. Because at the end of the day, it’s not just about aluminum or machining – it’s about getting you exactly the result you need.
