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Aluminum

Aluminum is one of the most abundant elements on Earth. In its pure form, aluminum is highly reactive, easily bonding with the oxygen in the air. However, when combined with other metals to form an alloy, aluminum becomes a highly versatile and practical material used across a wide range of industries. In its raw state, aluminum is soft and pliable, and while it can sometimes be directly processed into products, it is more commonly alloyed with other materials to enhance its properties. Aluminum alloys are widely used in fields such as construction, aerospace, food services, sporting goods, and many others.

Aluminum’s popularity comes from its excellent strength-to-weight ratio. Even a small amount of aluminum can support a significant amount of weight compared to other metals. The specific alloy chosen depends on the particular application, as each alloy mixture offers distinct advantages and disadvantages tailored to different needs.

History of Aluminum

Ancient Roman texts describe a material that resembled silver but was much lighter, which we now know was an early form of an aluminum alloy. During this time, aluminum oxide clays were also utilized for various purposes, including hide-tanning, first aid, and fireproofing.

Over the years, curiosity surrounding this material grew, leading to Hans Christian Oersted's successful creation of the first aluminum alloy. While aluminum quickly gained popularity, it remained scarce due to the high cost of production. The versatility and potential of aluminum sparked a race to find more cost-effective methods of production.

In 1887, Karl Josef Bayer developed a process that allowed aluminum to be extracted from a common, naturally occurring aluminum ore. This method is still used today to produce most of the world’s aluminum.

Bayer’s breakthrough revolutionized the industry, making aluminum affordable and accessible for a wide range of applications. It became widely used in the manufacturing of aircraft, automotive parts, electrical wiring, and any other application requiring a high-strength, low-weight metal.

After World War II, aluminum became a staple in household products, with aluminum washers and dryers becoming standard in American homes.

In the late 1950s, aluminum reached a new milestone with the introduction of the first two-piece aluminum beverage cans with a pop-top.

As the decades passed, aluminum continued to be one of the most essential materials on Earth. It played a key role in launching spacecraft and was instrumental in the personal computer revolution.

Aluminum's Many Uses

Aluminum and Building Construction
In the early 20th century, aluminum was primarily used for roofing, wall panels, and flashing. As time went on, its use expanded to more structural purposes. One of the most notable early examples of aluminum's role in building construction is New York's Empire State Building, which featured extensive use of aluminum in its spire, structure, entrances, elevator doors, decorative trim, and window panels.

Looking ahead, aging concrete and steel structures will need to be reinforced or replaced, and aluminum's durability and cost-effectiveness make it an ideal solution for replacing or reinforcing these decaying materials.

Aluminum in the Aerospace Industry
Aluminum has been essential to the aerospace industry from its inception. It was a critical material for America's efforts during World War II, with most of the country's fighter planes being constructed from this lightweight, affordable, and corrosion-resistant material.

Aluminum's corrosion resistance and strength-to-weight ratio make it ideal for aircraft manufacturing. Corrosion is a significant and costly problem, but aluminum can last for decades with minimal corrosion. While steel offers high strength, its weight is prohibitive, negatively affecting the aircraft's aerodynamics. Steel is typically only used for parts like landing gear, where strength is necessary.

Aluminum in Food Service
Aluminum is widely used in the food service industry. Although stainless steel remains more popular, it's hard to find a modern commercial kitchen that doesn’t feature numerous aluminum appliances and utensils.

The rust resistance of aluminum, due to its chemical makeup, makes it an attractive choice in food service applications. Additionally, aluminum’s versatility and ability to conduct heat efficiently are key advantages. It reaches the desired temperature quickly and retains heat or cold for longer periods, making it ideal for wrapping leftovers or serving food from piping hot to frosty.

Uses in Sporting Goods
Sporting goods often feature anodized aluminum. Anodizing is a process that provides a durable, corrosion-resistant finish, which can also be decorated. While other non-ferrous metals can be anodized, aluminum is particularly well-suited for this process.

Anodized aluminum is used in:

• Baseball/softball bats
• Golf carts
• Fishing boats
• Bicycles
• Skates and skateboards

​"Necessity is the mother of all invention." Aluminum alloys were developed as a more efficient alternative to steel. Their versatility has revolutionized multiple industries, and their long history continues to shape the world in profound ways.

How Aluminium Is Made

Bayer's Process and Aluminum Production
Bayer's process remains the standard for most industrial aluminum production today. This complex method involves several stages, including mining, extraction, smelting, and casting.

The discovery of bauxite made aluminum production cost-effective for mass use. Bauxite, first discovered in 19th-century France, is a rock that serves as the primary ore for aluminum. While there are some deposits in Europe, most bauxite today is sourced from subtropical and tropical regions like:

• Africa
• West Indies
• South America
• Australia

The most significant cost in aluminum production is incurred during the extraction process. The first step is to purify the bauxite into aluminum oxide, a white powder from which aluminum can be extracted.

Aluminum Extraction Process
To extract aluminum, the aluminum oxide must be transformed into a molten form. This is achieved by dissolving it into a compound with a lower melting point. Once the aluminum compound is ready, electrolysis is used to extract the metal. The aluminum is then purified through smelting to around 99.97%.

The aluminum oxide is often combined with other metals to form alloys with various properties and applications. For example, 6061 aluminum, which contains magnesium and silicon, is a versatile alloy used for truck and marine components, pipelines, and other general-purpose applications. 7075 aluminum, alloyed with zinc, is highly strong and corrosion-resistant, often used in aircraft construction, bicycle manufacturing, and sports equipment. On the other hand, 1100 aluminum is one of the most pure and malleable alloys, used for chemical equipment and railroad tank cars.

Aluminum Processing Methods
Once extracted, aluminum can be processed through several methods, including casting, extrusion, and rolling.

• Casting: Aluminum casting is a process that molds aluminum into various shapes for its intended function, known as its aluminum profile.
• Extrusion: In aluminum extrusion, aluminum is forced through a shaped die under high pressure to create specific shapes, such as bars or rods.
• Rolling: During rolling, aluminum is turned into coils, plates, strips, and sheets. The rolling process makes the metal more ductile, less brittle, and capable of creating thin products.
• Roll Forming: This method uses specially shaped rollers to create hollow products like aluminum tubing and pipes.
• Stamp Pressing: Flat aluminum sheets are shaped into parts using a die cavity and tremendous pressure.
• Forging: This process involves hammering, pounding, or squeezing aluminum into parts.
• Casting: There are two methods of casting aluminum: sand casting, where a temporary mold is made from sand, and die casting, where molten aluminum is poured into a permanent mold, typically made from steel or cast iron.

Aluminum can also be bent, made into a powder, welded, or milled depending on the desired product. After these processes, further fabrication can be done, including cutting to length, drilling, and machining.

Applications and Finishing
Aluminum is widely used in industrial applications, including plates, coils, and other forms for household appliances, utensils, and more. Additionally, aluminum is ideal for powder coating, which provides a durable and decorative finish.

Conclusion
Understanding the aluminum production process is key, but finding a reliable supplier that offers high-quality products and excellent service is equally important.

Aluminum Alloys

Because of its highly-reactive nature, aluminum is almost always alloyed.
Materials such as copper, zinc, magnesium, manganese, and silicon are commonly combined with aluminum to improve its properties. Even small amounts of these elements enhance the characteristics of the final product, making it far superior to the individual substances on their own.

Copper in Aluminum Alloys
Copper is typically alloyed with aluminum in amounts ranging from 2% to 10%. While copper improves strength, it reduces ductility and corrosion resistance. As a result, copper-aluminum alloys are mainly used in military and aerospace applications where their specific properties are most needed.

Aluminum Manganese Alloys
These alloys produce moderate-strength metals that maintain their strength even at high temperatures. While they are not the strongest alloys, they are often used for kitchen utensils due to their resistance to heat.

Magnesium and Aluminum
Magnesium and aluminum alloys are among the strongest combinations. These alloys are regularly used in structural applications such as truck bodies, train cars, armored vehicles, and boats, where high strength and low weight are essential.

Other Alloying Agents
In addition to copper, manganese, and magnesium, several other elements are commonly alloyed with aluminum to modify its properties, including:

• Iron
• Chromium
• Titanium
• Lithium
• Lead

Now that we've explored a few of the most common aluminum alloys, let's take a closer look at their specific applications.

The Rise of Aluminum Suppliers

Aluminum's significance and the success of aluminum manufacturers have led to an increased number of suppliers.
Aluminum suppliers are companies that produce basic aluminum shapes, such as sheets, rods, and plates, for purchase by metalworking and manufacturing industries. Many countries have subsidized their aluminum industry, which has created challenges for American manufacturers.

Fewer Aluminum Manufacturers in the U.S.
There are fewer aluminum manufacturers in the United States today than there were a decade ago. However, the current administration's push to bring back jobs could help revive the industry. Despite this, aluminum remains heavily imported due to its vital importance.

The Importance of Aluminum
Aluminum has become one of the most essential materials worldwide. It is lighter than steel but incredibly strong, making it ideal for various applications. As industrial areas age, the steel and concrete structures begin to deteriorate, as these materials were never designed to last beyond a generation or two. Aluminum emerged in the 19th century as a promising alternative to both steel and concrete. Aluminum tubing and plates are now used to reinforce or replace aging structures.

Aluminum’s Durability vs. Steel
While stainless steel and carbon steel are stronger than aluminum, they tend to corrode over time. Aluminum’s resistance to corrosion allows it to outlast these materials, making it a preferred choice in many applications.

The Discovery of Aluminum
Aluminum, being a metal that does not naturally occur in its pure form, was discovered much later than other metals. Though compounds exhibiting aluminum-like properties were known to ancient civilizations, the real metal itself wasn’t fully understood until the 19th century.

A Collective Effort Leading to Practical Aluminum Production
A joint effort by many individuals led to the discovery and advancement of aluminum production. This marked the beginning of a revolution in various industries, where materials like stainless steel and copper were gradually replaced with aluminum due to its strength, durability, and versatility.

Where Aluminum Is Found

6061 Aluminum
An aluminum alloy primarily composed of aluminum, magnesium, and silicon.

7075 Aluminum
An alloy made mainly from aluminum and zinc.

Aluminum
A metallic element with the atomic number 13.

Aircraft Aluminum
A term for aluminum alloys designed specifically for aircraft component construction.

Aluminum 1100
An aluminum alloy known for its high aluminum content, with purity levels reaching up to 99.6%.

Aluminum Bars
Solid, straight, and uniform aluminum products that can be extruded into various cross-sectional shapes, including circular, square, or triangular.

Aluminum Coil
A product with a uniform cross-section, typically supplied in coil form, which is commonly used for a variety of applications.

Aluminum Foil
Formed by rolling aluminum to a thickness of less than 0.2 mm, typically used in packaging and electrical applications.

Aluminum Pipe
A hollow tubing product made from aluminum.

Aluminum Plate
Rolled aluminum with a thickness greater than 6 mm, often used in bridges, buildings, and other large-scale structures.

Aluminum Powder
A fine powder form of aluminum, used in applications such as paints, explosives, and chemical processes.

Aluminum Profiles
Extruded aluminum products with a uniform cross-section, commonly straight in length but can also be coiled.

Aluminum Rods
Solid cylindrical aluminum shapes used across various industries and applications.

Aluminum Sheet
Rolled aluminum with thickness ranging between 0.2 mm and 6 mm, used primarily in construction and transport industries.

Aluminum Strip
A long, narrow sheet of aluminum metal with a length many times greater than its width.

Aluminum Suppliers
Companies that sell minimally processed aluminum to industries such as metalworking and manufacturing.

Aluminum Tubing
A hollow aluminum product, typically used in various applications requiring tubing.

Aluminum Wire
Wire made from aluminum, used in a variety of electrical and other industrial applications.

Aluminum Grades

*These figures are guidelines based on industry research; they should not be presumed accurate under all circumstances and are not a substitute for certified measurements. The information is not to be interpreted as absolute material properties nor does it constitute a representation or warranty for which we assume legal liability. User shall determine suitability of the material for the intended use and assumes all risk and liability whatsoever in connection therewith.

Choosing the Right Aluminum Manufacturer

Aluminum manufacturing is a precise and intricate process that demands a high level of expertise and years of experience. Choosing the right aluminum supplier is crucial for ensuring the production of high-quality aluminum products.

A reputable manufacturer fully understands the process, enabling them to produce cost-effective products without compromising quality. However, it's important to be cautious of suppliers offering excessively low prices, as this could indicate inferior quality materials.

Many aluminum products are critical for safety and performance. For example, aircrafts often rely on , and using subpar material could jeopardize the safety of the vehicle and the lives of those aboard.

Even in less critical applications, such as household products, the quality of aluminum still matters. Inferior aluminum results in poor products that can negatively impact a business's reputation. While aluminum remains the most widely used metal, customers dissatisfied with low-quality aluminum items may turn to stainless steel as an alternative.

Customer service is another key factor when choosing an aluminum supplier. Reliable companies stand behind their products and are willing to resolve any issues that arise. We provide a curated list of trusted manufacturers and suppliers at the top of this page, making it easier for you to find the right partner for your aluminum needs.

Aluminum Terms

Alloy
A combination of a metal and at least one other element.

Alloying Element
An element added to another metal to modify its properties and characteristics.

Alumina
Also known as aluminum oxide.

Aluminothermy
A reaction between crushed aluminum and a metal oxide, which generates a significant amount of heat and produces a metal.

Aluminum Dross
A byproduct of aluminum melting that contains impurities and is often recycled in secondary aluminum production.

Annealing
The process of treating an aluminum alloy with heat to soften it.

Anodizing
The process of creating a protective coating on a material through electrolysis.

Bayer Process
The method used to extract alumina from bauxite ore.

Bauxite
The primary ore from which aluminum is extracted using the Bayer process.

Bend Test
A test used to determine the toughness of a metal by bending it.

Billet
A cast, cylindrical piece of aluminum used to make extrusions.

Blank
A piece of metal that is cut or shaped in preparation for further processing.

Casting
The process of pouring molten aluminum into a mold to form a product.

Conductivity
The ability of a metal to conduct electricity. Aluminum is an excellent conductor, making it ideal for use in wires.

Degassing
The process of reducing the hydrogen content in molten aluminum.

Ductility
The ability of a metal to deform both elastically and plastically without breaking.

Extrusion
The process of forcing a cylindrical billet of solid aluminum through a die to create a product with a uniform cross-section.

Forging
The process of shaping solid aluminum by hammering or squeezing it into a mold.

Formability
A measure of a metal’s ease of being deformed.

Foundry
A facility that melts and casts metals into various shapes.

Hall-Heroult Process
The post-Bayer process in which aluminum oxide is converted into aluminum metal.

Heat Treatment
The process of applying heat to alter the properties of aluminum.

Reflectivity
The ability of a metal to reflect heat, radar, and radio waves. Aluminum is a good reflector, making it ideal for use in radio antennas.

Rolling
The process of flattening aluminum by squeezing it between two rollers to create plates, sheets, or foil.

Smelting
The process by which molten aluminum is extracted from alumina.

Thermal Conductivity
The ability of a metal to transfer heat. Aluminum is the most efficient metal for this property among common metals.