Aluminium Stamping: Processes, Alloys, and Costs

Alumin is the second most used metal after steel, and it is used in everything from construction to the aerospace field. Aluminium stamping is a manufacturing process used to produce desired shapes of Aluminum metal. Aluminum has many alloys, 6063, 2024, and 5083 are common for aluminium stamping. This article contains information about Aluminum stamping, how it is done, which alloys are used for stamping, and the costs of these processes.

What is Aluminum Stamping?

Aluminium stamping is like a forging process and is used in the manufacturing industries. In this process, the Al plates are places placed between the two dies. These top and bottom dies contain the desired shapes. One of the dies is stationary and the other moves vertically. When you place the plate, and press the dies, the plates are converted into the desired shape.

Precision Aluminum Stamping Process Explained

Aluminium stamping is a step during the manufacturing process. It produces the parts with fine precision. Metal plates are converted into difficult shapes after the stamping process because the excessive material is removed during this process. To achieve tight tolerance and extra precision, you need to perform extra operations such as grinding and polishing.

Why Choose Aluminum for Stamping?

Aluminum provides greater machinability and doesn't burn during the heating process. It's melting temperature is low due to which at low temperatures and in less time, Al becomes able for the stamping process. After getting cold, it becomes stronger.

Advantages of Stamping Aluminum

There are many advantages of using Al metal for the stamping process. For instance:

1. Al is a lightweight metal and contains good strength, that's it is used in making multiple parts of an aircraft. It is easy to machine and does not require higher loads or higher temperatures to deform it.
2. Al has great corrosion resistance, that's why it is highly applicable for critical applications such as in aerospace or automotive etc.
3. Al is a commonly found metal which is why it is not so expensive. This is the reason why we use Al for the stamping process commonly. Its easier machinability and fabrication make Al as cost-effective material. It is a big advantage which saves money and time as well.
4. The mechanical properties of Al are very good like high ductility with moderate strength is a big advantage. Its high ductility provides the feasibility of convertible Al metal plates into desired shapes easily. This property enables us to make complex structures for automobiles to aircraft parts.

Common Challenges in Aluminum Stamping

This section will make you introduce with some challenges you can face during the Al stamping:

Galling and Wear Issues

It is the most common challenge you can face during the stamping process. In this type of challenge, the Al material adheres to the surface of the die which makes the Al surface rough. That kind of surface leads towards lower tool or components life and money or material loss. To mitigate this issue, you can use lubrication or pre-heating of the die.

Springback in Aluminum Parts

Since the Al metal is lightweight it is a common phenomenon in which stamped Al parts revert to their original position. Springback can cause some serious injuries so it should be avoided by managing precise tool adjustments.

Wrinkling and Tearing

There are two main causes why these issues occur when:

• Compressive stresses are higher
• Blank holding force is very high (the force which engages the material to the die)

To avoid this issue, you should optimize the design of the die and stamping speed.

Tooling Wear and Maintenance

Tools can be worn during the stamping process. The main tools are the dies. When the die is cold, and material at 400-500°C comes into the die so the die cracks. It can be tackled by pre-heating the die and daily maintenance.

How to Calculate Aluminum Stamping Costs

If you are interested in preparing a batch of Al parts through the stamping process, you can calculate by yourself using the following criteria.

Material Costs

The type of the material is an important factor affecting the overall costs. There are over 500 total alloys of Al, some are easy to machine, and some are difficult. The other factor is the sheet's thickness. The very thin and thick Al plates are difficult to convert into desired shapes.

Tooling Costs

Keep in mind that the tools can be damaged during the processing, or you can say the production. So, these tools and die wear need proper maintenance. That's why you should calculate the tooling costs well before selecting any manufacturing method.

Production Costs

• Production costs involve the costs of electricity, the volume of the production, the type of suppliers if they or domestic or international etc.
• Some workpieces require higher press tonnage (force required to cut the Al metal during the stamping process) which affects the overall costs. Higher tonnage means higher energy, so ultimately higher costs.
• Cycle time means the required to complete a production cycle. Shorter cycle times mean a higher rate of production, so the production costs will become less.
• Higher production volume reduces the overall costs. If the tonnage press is not consistent throughout the process, then the costs will rise due to tool maintenance.

Labor Costs

You can make your products through an automated or manual Al stamping process.

• In the manual Stamping process, you will higher number of people as labour which means its cost will be higher because of the increased number of daily wedges. The chances of human errors are higher, and production is slow and less efficient. In this process, it is not so important that labour should be skilful.
• In the automatic stamping process, you will need fewer people, which means the less daily wedges so the overall costs will be lower. But the main difficult is the installation costs of these machines. The operators should be highly skilled to operate the automatic stamping process.

Surface Finishing Costs

The stamping process does not produce parts of highly smoother finishes. Some scrap remains on the surface which must be removed after the stamping process. To get better surface roughness, you will need further processes like polishing, anodizing or some types of coating. These processes will raise the overall costs.

Overhead and Maintenance

Overhead costs mean maintenance costs which are used to keep the equipment in good working condition. Maintenance takes money when you maintain the tools daily, some repair costs etc. Other expenses include power usage, and depreciation (when equipment deteriorates).

Shipping and Logistics

Shipping and logistics costs mean the money spent on transporting material or machines. These costs depend on the volume of the materials, prices of the fuels, aluminium parts weight and the distance between two locations.

Methods to Reduce Costs

Earlier we have studied those factors which are the causes of increased costs. Now, the following methods will help you control the overall costs.

• Optimization of Designs
• Increase your batch sizes
• Use the cost-effective materials

Aluminum Stamping Applications Across Industries

Let's find out where Al stamping is used:

Aerospace Industry

Wing panels

Fuselage components

Al is a lightweight, cost-effective and corrosion-resistant metal, which is why it is used in the aerospace industry commonly.

Automotive Industry

Al stamping is used to manufacture the following parts:

• Diverse array of components
• Body panels
• Engine parts

Electronics and Consumer Goods

• Casings
• Connectors
• Brackets for electronic devices

Medical Equipment Manufacturing

• Surgical Equipment
• Diagnostic Devices
• Components of the various medical instruments

Construction and Architecture

• Frames
• Panels
• Structural Supports

Common Aluminum Alloys in Stamped Sheet Metal Parts

Every series of Al alloys contains specific properties:

1100 Aluminum Alloy

1100 Al alloy series is used for stamping due to:

• Excellent corrosion resistance
• Workability

3003 Aluminum Alloy

This series is commonly used for stamping applications because of its strength and corrosion resistance.

5052 Aluminum Alloy

Used in critical applications such as automotive and aerospace due to:

• Strength-to-weight ratio
• High Durability

6061 Aluminum Alloy

This alloy becomes stronger when heat-treated and it becomes suitable for high performance.

6063 Aluminum Alloy

This alloy is used for stamping due to the following properties:

• Lightweight
• Formability
• Corrosion resistance
• Excellent weldability

2024 Aluminum Alloy

The following properties are the reason why we use this alloy for the stamping process:

• Good Formability
• Higher strength and durability
• Good weldability
• Higher fatigue resistance

7075 Aluminum Alloy

This grade is used in the aerospace and automotive fields because of:

• Good machinability
• Fatigue resistance
• High strength-to-weight ratio

5083 Aluminum Alloy

The parts of 5083 Al alloy are used in the marine, aerospace and automotive industries due to:

• Good weldability and formability
• Excellent fatigue and corrosion resistance

Aluminum Grads for Stamping Parts

Key Considerations for Alloy Selection

You should consider the following factors before selecting an alloy section:

1. Application
2. Mechanical Properties
3. Machining properties (weldability, formability etc.)

Impact of Alloy Properties on Stamping Quality

The following things can be affected due to selection of the wrong alloy:

1. Surface finish
2. Durability of the components
3. Formability
4. Metal stamping equipment
5. Tools wear

Types of Aluminum Stamping Operations

These are the multiple types of stamping operations:

Blanking Aluminum

Flat sheets are converted into the desired shapes in the first step in Al stamping.

Piercing and Cutting Aluminum

Piercing:Making holes in stamped Al sheets

Cutting Al:Internal cutouts are made

Coining and Embossing Techniques

Coining:A high-pressure stamping to make marks on the stamped sheets

Embossing:Used to make a reassessed design on the Al sheet

Deep Drawing Aluminum

In the deep drawing aluminium type, pull the Al sheets into a die cavity to produce complex shapes

Flanging Aluminum Parts

This process is responsible for bending the edges of Al sheet metal making parts suitable for automotive components.

Specialized Aluminum Stamping Techniques

You should use the following specialized Al stamping techniques:

Progressive Die Stamping

• For the mass production of Al-stamped parts
• Ensures consistent quality and cost savings

Transfer Die Stamping

It is a metal stamping aluminium process, used to make larger and more complex parts of stamped Al panels.

Four-slide Stamping

It's an aluminium stamping process which is:

• Best suited stamping process because of producing highly precise and small intricate parts
• Used for Electronics and Medical devices

Fine Blanking for Aluminum Parts

This process is used to produce parts with clean edges and tight tolerances.

Aluminum Stamping and Surface Treatments

Only the aluminium stamping processes are not enough to produce fine surface finishes, so, you will need the following processes to be done to get desired surface finish:

Anodizing Stamped Aluminum Parts

Anodizing makes stamped Al parts resist corrosion even in harsh conditions. Anodizing is a coating process in which an oxide layer is deposited.

Lubrication Techniques for Aluminum Stamping

1. Oil-based Lubrication:spraying/dipping; suitable for heavy-duty stamping
2. Water-based Lubrication:Sprayed or wiped; environment-friendly
3. Dry film Lubrication:Coating/Brushing; ideal for high-temperature applications
4. Synthetic Lubrication:Can be sprayed or roller-applied

Preventing Oxide Build-Up during Stamping

You can use one of the following methods:

• Anodizing the Al
• Ultrasonic cleaning with a diluted HCl acid
• Use Draw leads and Lock beads

Tuofa Aluminum Stamping Supplier

Tuofa uses the most advanced stamping techniques to ensure the precision and tolerance of the Al parts. We know that Al is used in critical industries, so we will use advanced machines to take care of the precision machining of the components. You can also come to us for custom tooling and die design. The products will be delivered faster and at the best prices.

Frequently Asked Questions (FAQs) about Aluminum Stamping

Why is aluminium being used more in vehicle production?

Because of its high strength-to-weight ratio, corrosion resistance, and lightweight and fatigue strength.

How Thick of Aluminum Can You Stamp?

0.2mm to 0.6mm thick Al sheets can be stamped.

Stamping Aluminum vs Steel

Stamping Al is easier as compared to steel because:

• it requires low temperatures to deform
• It is softer than steel, so lower press loads are required
• It is easier to machine and weld

What Are the Best Stamping Lubricants for Aluminum?

1. Emulsions
2. Hot-melt lubricants
3. FDX 240 A

Conclusion: Why Aluminum Stamping is a Valuable Manufacturing Process

After reading this article, we can conclude that why Al stamping is a valuable manufacturing process. There are many reasons like it can be performed using automatic machines, applicable to stamp multiple Al alloy series and can be used for larger to smaller intricate parts. To get final surface finish, you will need to apply further operations such as polishing etc.