Explore the ultimate aluminum alloys chart with key properties types and selection tips for aerospace automotive and industrial applications.

Understanding Aluminum Alloy Basics From Pure Al to Advanced Blends

When you hear aluminum alloys, what comes to mind? Simply put, aluminum alloys are mixtures of aluminum with other elements like copper, magnesium, manganese, silicon, or zinc. These added elements change aluminum’s natural properties, making it stronger, lighter, or more corrosion-resistant depending on the blend.

What Are Aluminum Alloys

• Pure Aluminum (1xxx series) is soft, highly ductile, and great for electrical applications, but it lacks strength.
• Adding elements such as copper, magnesium, or zinc creates alloys that can handle tougher jobs and specialized uses.
• These alloys are essential for industries from aerospace to automotive because they balance weight, strength, corrosion resistance, and cost.

Wrought vs Cast Aluminum Alloys

Knowing the difference helps when browsing an aluminum alloys chart:

• Wrought alloys are shaped by mechanical processes like rolling, extruding, or forging. They usually have better mechanical properties and are easier to work with.
• Cast alloys are melted and poured into molds, allowing complex shapes but often with lower strength and ductility compared to wrought alloys.

The 4-Digit Naming System

Aluminum alloys follow a simple 4-digit system that tells you what elements dominate:

• 1xxx series – basically pure aluminum (≥99%)
• 2xxx series – copper as the main alloying element
• 3xxx series – manganese
• 4xxx series – silicon
• 5xxx series – magnesium
• 6xxx series – magnesium and silicon
• 7xxx series – zinc
• 8xxx series – other elements (like lithium)

For example, 6061 is a popular 6xxx series alloy, containing magnesium and silicon, known for versatility.

Why Aluminum Alloys Charts Matter

Choosing the right aluminum alloy isn’t guesswork. A well-designed aluminum alloys chart puts essential data—like strength, density, corrosion resistance, weldability, and temper conditions—all in one accessible place.

• They simplify comparisons across hundreds of alloys.
• Save time and avoid costly mix-ups.
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• Strengths: Excellent corrosion resistance, high ductility, and great electrical conductivity.
• Weaknesses: Low strength compared to other alloys.
• Uses: Electrical conductors, chemical industries, and food packaging.

2xxx Series – Copper Alloys

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• Strengths: High strength and good machinability.
• Weaknesses: Poor corrosion resistance and can be costly.
• Uses: Aerospace parts, military applications, and high-strength structural components.

3xxx and 5xxx Series – Manganese and Magnesium Alloys

• Characteristics: 3xxx uses manganese; 5xxx features magnesium as the main alloy.
• Strengths: Good formability, excellent corrosion resistance (especially 5xxx), and decent strength.
• Weaknesses: Not heat-treatable, lower strength than 2xxx or 7xxx series.
• Uses: Roofing, siding, marine environments, and automotive panels.

6xxx Series – Magnesium Silicon Alloys

• Characteristics: Magnesium and silicon for a balanced alloy.
• Strengths: Versatile, good strength, excellent corrosion resistance, and good weldability.
• Weaknesses: Moderate strength, not as strong as 7xxx.
• Uses: Automotive parts, structural applications, bicycle frames.

7xxx Series – Zinc Alloys

• Characteristics: Zinc is the primary alloying element.
• Strengths: Ultra-high strength, great for aerospace-grade materials.
• Weaknesses: Lower corrosion resistance and more expensive; sometimes prone to stress corrosion cracking.
• Uses: Aerospace components, sporting equipment, high-performance vehicles.

Cast Aluminum Alloys

• Characteristics: Designed for casting with better fluidity.
• Strengths: Complex shapes possible, good wear resistance.
• Weaknesses: Generally lower strength compared to wrought alloys.
• Uses: Engine blocks, housings, pump components.

Understanding these differences helps you select the right aluminum alloy for your specific needs, whether it’s for high strength, corrosion resistance, or formability.

How to Read and Use an Aluminum Alloys Chart for Optimal Selection

Using an aluminum alloys chart may seem tricky at first, but it’s really about matching your project needs with the right alloy features. Here’s a simple step-by-step guide to help you navigate the chart and make the best choice:

Step 1: Identify Your Key Needs

Think about what matters most—weldability, strength, corrosion resistance, or formability. For example, if you need an alloy that welds easily, look for options marked with good weldability.

Step 2: Understand Temper Designations

The temper codes (like T6 or O) show how the alloy has been treated, which directly affects strength and flexibility. Make sure to pick the temper suited for your use, such as T6 for high strength or O for soft and malleable.

Step 3: Check Processing and Application

Some alloys are better for machining, others for casting or forming. The chart breaks these down. Match your processing method so you avoid costly mistakes.

Common Pitfalls to AvoidDon’t assume all aluminum alloys are interchangeable — strength, weight, and corrosion resistance vary widely.
Avoid alloys that aren’t designed for your environment (like choosing poor corrosion resistance in marine applications).
Don’t overlook the temper; it can make or break performance.Try Vast’s Alloy Selector Quiz and Download the Chart

To make things easier, Vast offers an interactive alloy selector quiz to guide you based on your specific application. Plus, grab our downloadable aluminum alloys chart to have all the essential info at your fingertips.

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Marine Applications

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• 1xxx series (pure aluminum): ~2.70 g/cm³
• 2xxx and 7xxx series (copper and zinc alloys): slightly higher density, around 2.78–2.85 g/cm³
• 5xxx and 6xxx series (magnesium and silicon alloys): about 2.68–2.72 g/cm³
  These small differences matter for weight-sensitive projects like aerospace or transportation.

What are the main differences between 6061 and 6063 alloys

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Extrudability	Good	Excellent
Surface Finish	Moderate	Very good for anodizing
Common Uses	Structural parts, frames	Architectural, trim

6061 is stronger and more versatile for structural applications, while 6063 is preferred when surface finish and precise shapes matter.

What is the best aluminum alloy for welding

For easy welding, look into 5xxx series alloys like 5052 cURL Too many subrequests. 5356 filler metals. They combine good strength and excellent weldability with corrosion resistance. The 6xxx series alloys like 6061 weld well but usually require special preparation and post-weld heat treatment for best results.

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If you’re still unsure about which alloy fits your project, check out our full aluminum alloys chart and use our alloy selector quiz for personalized help.