Material Comparisons in Aluminum Extrusions

When searching for a product or component design solution, you'll likely consider both the properties of alternative materials and the manufacturing implications of material and process selection. In some cases, the complexity of the part may make the choice straightforward, but in others, you'll be faced with trade-offs and choices. This selection provides information comparing the properties of aluminum extrusions to commonly considered alternative materials, as well as comparative tooling costs and lead times.

Material Comparisons:

Typical Tooling Cost Chart

Process Typical Tooling Cost
Vinyl Extrusion $1,500 & up
Injection Molding  $25,000 & up
Die Casting  $25,000 & up
Roll Forming  $30,000 & up
Stampings $5,000 & up
Aluminum Extrusions $500 to $5,000

 

Typical Tooling Lead Times Chart

Typical tooling lead time by material chart

Aluminum Extrusion vs Roll Formed Steel, Copper Extrusions

Property Aluminum Extrusions Roll-Formed Steel Copper Extrusions (Deoxided; Low Phosphorus)
Strength (Tensile) Very good mechanical properties Very high mechanical properties  Average to low mechanical properties 
Density Lightweight; about 1/3 that of copper or steel High density; high pounds per cubic foot  About three times heavier than aluminum
Strength to Weight Ratio Very good Good Low
Corrosion Resistance  Excellent, it can be further increased, along with enhanced appearance, through anodizing or other coatings Poor; usually requires protective coatings for corrosion service Excellent 
Formability Easily formable and extruded in a wide variety of complex shapes including multi-void hollows. Formable to net shapes, and extrusions provide for the placement of metal where it's needed. Readily formable; thinner cross-sections than aluminum extrusions metal cannot always be located where best used in design. Excellent formability and easily extrudable. Formable to net shapes.
Electrical Conductivity Excellent; on a pound-for-pound basis, twice as efficient as copper, used in bus bar and electric connector applications. Poor; cannot usually be used as an electrical conductor. Excellent electrical conductivity.    
Thermal Conductivity Excellent; ideal for heat exchanger applications. Poor; cannot usually be used as a heat exchanger.
 		 Excellent thermal conductivity, second only to silver in industrial applications.
 
Finishing A near limitless array of finishes can be applied including mechanical and chemical prefinishes, anodic coatings, paints and electroplated finishes.
 		 Protective coatings such as paint finishes are employed along with electroplated finishes.    
 		 A variety of coatings and platings can be employed.
Recyclability High scrap value; routinely reprocessed to generate new extrusions.     Low scrap value  Very high scrap value
Tooling Economics  Extrusion tooling is relatively inexpensive. Generally, a simple shape will cost only a few hundred dollars. Short lead times for tooling construction. Typical tooling costs are thousands of dollars. Long lead times are required. Inexpensive tooling costs for extrusions.
Energy Savings Lightweight aluminum extrusions can offer energy savings for transportation vehicles.    
 		 Lifetime energy requirements for wrought steel vehicle components are twice those for aluminum components.     In transportation vehicles, copper is less energy-efficient than aluminum.
Combustibility Noncombustible; does not emit any toxic fumes when exposed to high temperatures.     Noncombustible; does not emit any toxic fumes when exposed to high temperatures.     Noncombustible; does not emit any toxic fumes when exposed to high temperatures.

 

Aluminum Extrusion vs Molded Plastic, Wood, Vinyl

Property Aluminum Extrusions Molded Plastic  Wood Vinyl (Polyvinyl Chloride)
Strength (Tensile) Very good mechanical properties. Wide variation in properties from .08 to .8 tensile strength of aluminum extrusions for glass filled compounds. Good comprehensive properties, variable with the species of wood and moisture content.  Low mechanical properties.
Density Lightweight about 1/3 that of copper or steel Very lightweight about 60% the weight of aluminum. Very lightweight about 1/3 the density of aluminum. Very lightweight about 60% the density of aluminum.
Strength to Weight Ratio Very good Low-good Low-good Low-good
Corrosion Resistance  Excellent; it can be further increased, along with enhanced appearance, through anodizing or other coatings. Excellent; choice of compound and color important for weatherability (UV). Not directly applicable; decomposes in the presence of some acids. Excellent; high resistance to alkalis and salts but is attacked by organic solvents and strong acids.    
Formability  Easily formable and extruded in a wide variety of complex shapes including multi-void hollows. Formable to net shapes, and extrusions provide for the placement of metal where it's needed.     Easily formed or molded into complex shapes. Poor; cannot be routinely formed. Easily formed or molded into complex shapes.
Electrical Conductivity Excellent; on a pound for pound basis, twice as efficient as copper, used in bus bar and electric connector applications.     Poor; used as an insulator, high dielectric capability. Poor; cannot be used as an electrical conductor Usually cannot be employed as an insulator.
 		 Poor; electrical and thermal insulating characteristics.
Thermal Conductivity Excellent; ideal for heat exchanger applications.     Poor; low coefficient of thermal (heat) transfer. Poor Poor 
Finishing  A near limitless array of finishes can be applied including mechanical and chemical prefinishes, anodic coatings, paints and electroplated finishes. Color can be integral with material as well as plated, painted, and hot stamped. Paint and stain coatings can be employed. Color can be integral with material.
Recyclability High scrap value; routinely reprocessed to generate new extrusions. Routinely reprocessed but loses properties; reprocessed material is added to new stock. Low scrap value. Low scrap value routinely reprocessed.
Tooling Economics Extrusion tooling is relatively inexpensive. Generally, a simple shape will cost only a few hundred dollars. Short lead times for tooling construction. Tooling is expensive; generally in the thousands of dollars. Long lead times required.     Very inexpensive. Relatively inexpensive.
Energy Savings Lightweight aluminum extrusions can offer energy savings for transportation vehicles.     Savings for vehicles, processing, insulation. In certain applications. Can offer energy savings in appropriate transportation applications.    
Combustibility Noncombustible; does not emit any toxic fumes when exposed to high temperatures.     Combustible; may emit toxic fumes when exposed to high temperatures.
 		 Combustible; emits toxic fumes while burning. Combustible. May emit toxic fumes when exposed to high temperatures.