Aluminum is one of the world’s most abundant metals and therefore cost-efficient. High strength-to-weight ratio combined with extraordinary corrosion resistance and flexibility make aluminum a desirable solution to product design. Aluminum is cost efficient and meets the production needs for a variety of uses. Compare for yourself·
ALUMINUM EXTRUSIONS
ROLL FORMED STEEL
COPPER EXTRUSIONS
MOLDED PLASTIC
WOOD
VINYL
Strength (Tensile)
Very good mechanical properties.
Very good mechanical properties.
Average to low mechanical properties.
Wide variation in properties from .08 to .8 tensile strength of aluminum extrusions for glass filled compounds
Good compressive properties; variable with the species of wood and moisture content.
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
Very lightweight; about 60% the weight of aluminum.
Very Lightweight: about 1/3 the density of aluminum.
Very lightweight; about 60% the weight of aluminum.
Strength-to-Weight Ratio
Lightweight: about 1/3 that of copper or steel.
High density; high pounds per cubic foot
About three times heavier than aluminum
Very lightweight; about 60% the weight of aluminum.
Very Lightweight: about 1/3 the density of aluminum.
Very lightweight; about 60% the weight of aluminum.
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.
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
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
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 and electric connector applications
Poor; cannot usually be used as an electrical conductor.
Excellent thermal conductivity.
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; cannot usually be used as a heat exchanger
Excellent thermal conductivity; second only to silver in industrial 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.
Protective coatings such as paint finishes are employed along with electroplated finishes.
A variety of coatings and platings can be employed
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
Low scrap value.
Very high scrap value.
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
Typical tooling cost are thousands of dollars. Long lead times are required
Inexpensive tooling costs for extrusions
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.
Life time energy requirements for wrought steel vehicle components are twice those for aluminum components
In transportation vehicles, copper is less energy-efficient than aluminum
Savings for vehicles, processing, insulation
In certain applications
Can offer energy savings in appropriate transportation applications.
Combustibility
Non-combustible; does not emit any toxic fumes when exposed to high temperatures
Non-combustible; does not emit any toxic fumes when exposed to high temperatures
Non-combustible; does not emit toxic fumes when exposed to high temperatures
Combustible; may emit toxic fumes when exposed to high temperature
Combustible; emits toxic fumes while burning.
Combustible. May emit toxic fumes when exposed to high temperatures.