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Glossary

Aluminum Fabrication

The cutting, forming, welding, and finishing of aluminum alloys to produce lightweight, corrosion-resistant components and assemblies.

Definition

What is Aluminum Fabrication?

Aluminum fabrication applies the same fundamental processes as steel fabrication — laser cutting, bending, welding, and finishing — to aluminum alloys (typically 5052, 6061, 6063, or 3003 series). Aluminum's low density (one-third of steel's), natural corrosion resistance, and excellent machinability make it the preferred material for weight-sensitive, corrosion-exposed, and architectural applications. Challenges specific to aluminum include its higher thermal conductivity (requiring faster weld travel speeds), the tenacious oxide layer (requiring AC TIG or MIG with dedicated wire), and its tendency to distort during welding due to high thermal expansion. ATS Metal Fabrication's team is experienced in all aspects of aluminum sheet and plate fabrication.

Types & Variants

  • • 5052-H32 (excellent formability and corrosion resistance)
  • • 6061-T6 (structural, heat-treated — best strength)
  • • 6063-T5/T6 (architectural extrusions)
  • • 3003-H14 (excellent formability — food equipment)

Common Applications

  • • Lightweight structural frames
  • • Food processing and medical equipment
  • • Architectural panels and trim
  • • Transportation and automotive components
  • • Marine and outdoor equipment

FAQ

Frequently Asked Questions

Can aluminum be welded as strongly as steel?
Welded aluminum joints in the heat-affected zone (HAZ) are typically 40–60% of the base alloy's strength in heat-treatable alloys like 6061. For 5xxx series alloys (5052, 5083), HAZ softening is less pronounced. Post-weld heat treatment can restore strength for structural 6061 applications. For most fabricated assemblies, weld strengths are adequate for design loads.
What is the best aluminum alloy for sheet metal fabrication?
5052-H32 is the most common sheet metal fabrication alloy — excellent formability, good weld-ability, and high corrosion resistance. 6061-T6 is used when higher strength is required but has limited formability. 3003 is used for food-grade applications requiring easy forming and excellent corrosion resistance.
How do you finish aluminum after fabrication?
Aluminum can be left with its natural oxide finish (suitable for many industrial applications), powder coated (with zinc phosphate pre-treatment for adhesion), anodized (electrolytic surface hardening — excellent for architectural), or chemically treated (alodine/chromate conversion for corrosion protection before painting).

Related Terms

See Also

TIG Welding (GTAW) CNC Laser Cutting Sheet Metal Fabrication Metal Fabrication

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ATS Metal Fabrication provides professional aluminum fabrication services across Toronto and the GTA.

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