7075-T651 Aerospace Aluminum - AAA Air Support

-T651 Aerospace Aluminum:

High-Strength and Excellent Fatigue Resistance

-T651 aerospace aluminum is a high-strength material that is commonly used in the aerospace industry for its toughness, fatigue resistance, and excellent strength-to-weight ratio. It is ideal for use in applications where weight is a critical factor, such as aircraft, spacecraft, and other vehicles.

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Product Features

High Strength: -T651 aluminum has a tensile strength of 572 MPa and a yield strength of 503 MPa, making it a strong material for use in high-stress applications.
Fatigue Resistance: This aluminum alloy is highly resistant to fatigue, making it a durable material for use in high-stress applications.
Corrosion Resistance: -T651 aluminum has good corrosion resistance, although it is not recommended for use in saltwater environments.
Machinability: This alloy is known for its good machinability, making it easy to work with and to create complex shapes.

Applications
-T651 aerospace aluminum is used in a wide range of aerospace applications, including:

• Aircraft structures
• Wing skins and spars
• Fuselage frames
• Helicopter rotor hubs
• Missile components
• Structural components

Ordering Information

We offer -T651 aerospace aluminum in a variety of forms, including sheets, plates, bars, and tubes. Our aluminum products are available in a range of sizes and thicknesses, and can be customized to meet your specific needs.

aluminum alloy is widely recognized in the metals industry as a premier high-strength material, and is frequently compared in performance to many steel alloys. Its exceptional strength-to-weight ratio, low density, and machinability make it a preferred choice for critical, highly-stressed structural components across a diverse range of industries. The unique properties of aluminum stem primarily from its high zinc content, with magnesium, copper, and chromium also contributing to its superior performance characteristics. If you are seeking a material that can deliver both strength and lightweight efficiency, aluminum is an industry benchmark worth considering.

While aluminum boasts exceptional strength, it is important to note that it does not offer the same level of machinability or weldability as some other common aluminum alloys, such as or . Additionally, compared to other aluminum alloys, exhibits somewhat lower corrosion resistance. Buyers and engineers should carefully evaluate these trade-offs based on their specific application requirements.

What is Aluminum? Key Properties and Chemical Composition

aluminum belongs to the 7xxx series of aluminum alloys, which are characterized by the addition of zinc as the principal alloying element. This alloy typically consists of approximately 90% aluminum, 5.6% zinc, 2.5% magnesium, and 1.6% copper, with trace amounts of chromium, iron, silicon, manganese, and titanium. The result is a metal with a density of about 0.102 pounds per cubic inch (2.81 g/cm³), delivering tremendous yield and tensile strength while remaining significantly lighter than steel.

Some notable mechanical properties of aluminum include:

• Tensile strength: Up to 83,000 psi (T6 temper)
• Yield strength: Up to 73,000 psi (T6 temper)
• Brinell hardness: 150 (T6 temper)
• Excellent fatigue resistance and high stress corrosion resistance (notably in T and T173 tempers)
• Good thermal conductivity and moderate electrical conductivity

Curious about how aluminum compares to other alloys? Compare vs. aluminum or vs. titanium for specific aerospace and engineering applications using our detailed materials comparison guides.

How is Aluminum Processed and Manufactured?

What steps are involved in turning raw materials into finished aluminum products? The production of aluminum alloy is a multi-stage process designed to optimize its strength and performance. Here’s a closer look at the process:

1. Alloying: Pure aluminum is combined with zinc (the main alloying element), as well as magnesium, copper, and trace elements like chromium. These ingredients are melted together at high temperatures to achieve a uniform composition.
2. Direct Chill (DC) Casting: The molten alloy is poured into a vertical mold, initiating solidification at the base (direct chill). Continuous cooling is applied using a water film, which extracts around 80% of the heat, while the rest is conducted through the mold walls. This semi-continuous casting method results in solid billets or aluminum bars with tightly controlled microstructure and minimal defects.
3. Secondary Processing: The solidified billets undergo further processing such as hot rolling, forging, or extrusion. These steps refine the grain structure, enhance strength, and shape the material into forms suitable for various industrial needs, including plates, sheets, rods, and custom profiles.
4. Heat Treatment: aluminum is typically subjected to solution heat treatment and aging (such as T6 or T73 tempers), which further increases its mechanical strength and tailors its performance for specific applications.

The advanced metallurgy and precise thermal processing of aluminum are what give it the edge over other materials in demanding environments. If you are interested in learning more about the manufacturing process of high-strength aluminum alloys, browse our in-depth resources or request a manufacturing consultation.

Advantages and Benefits of Aluminum Alloy

Why do engineers and manufacturers choose aluminum over other grades? Here’s a comprehensive look at its advantages:

• Superior strength-to-weight ratio: aluminum is among the strongest commercially available aluminum alloys, with mechanical properties rivaling those of certain steels. This makes it ideal for load-bearing and structural applications where minimizing weight is critical.
• Lightweight construction: With a density significantly lower than steel, aluminum delivers substantial weight savings—an essential factor in aerospace, automotive, and sports equipment manufacturing.
• High fatigue resistance: The alloy’s microstructure and tempering processes afford outstanding resistance to cyclic loading, ensuring long-term reliability in dynamic, high-stress environments.
• Good corrosion resistance: While not as corrosion-resistant as some other aluminum grades (e.g., or ), offers satisfactory protection in most environments, especially in T73 or T tempers, which are optimized for stress corrosion resistance.
• Excellent machinability: Despite its high strength, aluminum can be precisely machined to tight tolerances, making it suitable for complex parts requiring accurate dimensions and fine surface finishes.
• Aesthetic finish: The alloy’s natural reflectivity and ability to take on a high polish often eliminate the need for additional surface treatments, enhancing both functional and visual appeal in finished products.
• Wide availability: aluminum is available in a variety of tempers (T6, T651, T73, T, T76, T) and product forms (bar, plate, sheet, extruded shapes), allowing buyers to select the most appropriate configuration for their application.
• Proven performance in critical applications: From sheet metal for aircraft skins to machined components for defense and sporting goods, aluminum’s track record is unmatched.

Aluminum vs. Other Alloys: How Does It Compare?

When selecting a material for high-performance applications, buyers often ask:

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• Is aluminum stronger than ? Yes, is significantly stronger and is typically used where strength is the primary requirement.
• Can aluminum be welded? While possible, welding is challenging due to increased risk of cracking; alternative joining methods are usually recommended.
• Does aluminum resist corrosion as well as or ? offers good corrosion resistance, especially in certain tempers, but is less resistant than marine-grade alloys like .
• What are the main applications for aluminum? See below for an extensive list of common uses across industries.

Applications and Use Cases for Aluminum Alloy

The unique blend of high strength, light weight, and fatigue resistance makes aluminum a top choice for demanding applications across multiple industries. Explore how leading manufacturers and engineers leverage aluminum for superior performance:

• Aerospace and Aviation: aluminum is a staple material in aircraft manufacturing, used for structural airframe parts, wing spars, fuselage frames, bulkheads, landing gear components, and more. Its ability to withstand high stresses and fatigue loads at elevated altitudes makes it indispensable for both commercial and military aircraft.
• Automotive and Motorsports: Performance vehicles and race cars utilize aluminum for high-stress components such as suspension parts, drive shafts, transmission gears, and wheel hubs. The alloy’s combination of strength and weight reduction improves acceleration, handling, and fuel efficiency.
• Defense and Firearms: is widely used in military and tactical equipment. Notably, the receivers and frames of M16 rifles and other small arms are often machined from due to its toughness and reliability under combat conditions.
• Sports and Recreation: High-end sporting goods—including bicycle frames, rock climbing equipment, archery components, and golf club heads—commonly feature aluminum for its lightweight durability and resistance to deformation.
• Industrial and Tooling: Heavy-duty molds for plastic injection, high-strength gears, and critical machine components are frequently produced from aluminum to ensure dimensional stability and long service life under repeated loading.
• Marine and Transportation: While not as corrosion-resistant as 5xxx series alloys, aluminum is nonetheless used in select marine and transportation applications where high strength is essential and corrosion can be managed with protective coatings.
• Consumer Electronics and Custom Fabrication: The alloy’s machinability and attractive finish lend themselves to premium housings, brackets, and structural parts in electronics and custom projects.

Common Product Forms of Aluminum

Looking for a specific format of aluminum for your project? This versatile alloy is widely available as:

• aluminum plate (thick gauge, ideal for structural and tooling applications)
• aluminum sheet (thin gauge, used for skins, covers, and lightweight panels)
• aluminum bar (round, square, and flat, for machining precision parts)
• aluminum rod (cylindrical forms for shafts and pins)
• aluminum tubing (hollow forms for frames, sporting goods, and aerospace)
• Extruded and forged shapes (custom profiles for specialized applications)

Not sure which form is best for your application? Contact a aluminum supplier or request a sample to compare machinability and finish in your actual production environment.

Factors to Consider When Buying Aluminum

When sourcing aluminum for your manufacturing or engineering needs, it’s essential to evaluate several key decision factors to ensure optimal performance, value, and supply chain reliability. Here are important considerations to keep in mind:

• Required temper and mechanical properties: Determine whether your application demands maximum strength (T6), increased stress corrosion resistance (T73 or T), or specific fatigue life characteristics.
• Form factor and dimensions: Specify whether you need in plate, sheet, bar, rod, or custom extrusions. Confirm standard sizing and tolerances with your supplier.
• Certification and traceability: For aerospace, defense, and critical engineering applications, ensure your material comes with full mill test reports (MTRs), quality certifications (e.g., ASTM B209, AMS ), and traceability documentation.
• Secondary processing needs: Consider if you require pre-machined blanks, custom cuts, surface treatments (anodizing, chromate conversion), or finished assemblies.
• Corrosion protection: If your operating environment is highly corrosive, discuss additional coatings or treatments with your supplier.
• Supplier reputation and support: Choose a supplier with a proven track record in supplying high-strength aluminum alloys, responsive technical support, and the ability to fulfill both small and large orders reliably.

Frequently Asked Questions About Aluminum

How much does aluminum cost compared to ? aluminum typically commands a premium over due to its superior strength and more complex production processes. However, its higher performance often justifies the added expense for critical applications.

Is aluminum suitable for welding? Welding is challenging due to its susceptibility to hot cracking and reduced strength in the heat-affected zone. Mechanical fastening or adhesive bonding is generally recommended for joining.

What are the main alternatives to aluminum? Alternatives include aluminum (noted for high fatigue resistance), aluminum (for better weldability and corrosion resistance), and titanium (for extreme strength and corrosion resistance, at a higher cost).

Which tempers are most commonly used for aluminum? The most common tempers are T6 (for maximum strength), T651 (stress-relieved), T73, and T (for enhanced stress corrosion resistance).

How to Choose the Best Aluminum Supplier for Your Project

To ensure the most successful outcome when purchasing aluminum, it’s crucial to compare multiple reputable suppliers. Here’s a step-by-step approach to finding the right partner for your needs:

1. Identify qualified manufacturers: Use our curated list of aluminum manufacturers to find companies with the capabilities and certifications required for your application.
2. Review business profiles: Each supplier’s profile details their areas of expertise, available product forms, and technical support offerings.
3. Compare pricing and lead times: Request quotes using our RFQ form to evaluate cost, minimum order quantities, and delivery schedules from multiple vendors.
4. Evaluate technical support: Directly contact suppliers to discuss your specific requirements, request material samples, and verify certifications.
5. Check references and reputation: Research customer reviews, case studies, and industry partnerships to assess supplier reliability.

Ready to source high-strength aluminum for your next project? Browse our directory of aluminum suppliers or request a competitive quote today.

Conclusion: Is Aluminum Right for Your Application?

aluminum alloy stands out as one of the strongest and most reliable materials available for structural and high-performance engineering applications. Its unique combination of strength, low weight, fatigue resistance, and machinability makes it the preferred choice for aerospace, automotive, defense, sporting goods, and industrial manufacturing. While it does have limitations in weldability and corrosion resistance compared to other alloys, these are often outweighed by its outstanding mechanical properties.

When evaluating materials for your next project, consider the specific demands of your application—load requirements, operating environments, fabrication needs, and cost constraints. Consult with experienced aluminum suppliers and engineers to determine if aluminum is your best solution.

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Explore More About Aluminum Alloys

• Types of Aluminum Bars: Grades, Applications, and Selection Guide
• Aluminum Sheet Grades and Their Applications
• Contact Leading Aluminum Manufacturers