Which aluminium alloy is suitable for which application?

What is an aluminium alloy?

Aluminium alloys are created by the targeted addition of metals such as magnesium, silicon, manganese, zinc or copper to pure aluminium. The aim is to specifically improve the mechanical and physical properties of the material. Pure aluminium is very light and corrosion-resistant, but mechanically relatively soft and therefore unsuitable for many industrial applications.

Alloying influences strength, hardness, weldability, machinability and, depending on the composition, also corrosion or temperature resistance. Depending on the requirements, different alloy groups are used – for example for statically loaded structures, high-precision components or decorative visible surfaces.

An aluminium alloy is a compound of aluminium and other metals such as magnesium, silicon, zinc or copper. The targeted addition of these elements allows properties such as strength, corrosion resistance or machinability to be specifically adjusted.

Why choosing the right alloy is crucial

Aluminium is not the same as aluminium. Depending on the alloy, strength, corrosion resistance, machinability, weldability and anodisability differ considerably in some cases. Anyone selecting an aluminium sheet, a plate or a component should therefore specifically check which requirements the material must fulfil.

Choosing the wrong alloy can not only impair the service life and function of a product, but also lead to unnecessary machining costs or material failure.

Key selection criteria at a glance

• Mechanical load: What tensile, bending or compressive strength is required?
• Corrosive environment: Does the component come into contact with water, chemicals or salty air?
• Processing: Does the alloy need to be welded, bonded or machined?
• Surface appearance: Is a visible, anodisable or paintable surface required?
• Standards & approvals: Are there industry-specific requirements (e.g. food, aviation)?

Aluminium alloys at a glance

Pure aluminium (e.g. EN AW-1050A)

This alloy consists of at least 99.5% aluminium and is characterised by good corrosion resistance and excellent electrical conductivity. However, its strength is comparatively low. Ideal for applications with low mechanical requirements, e.g. in the electrical engineering sector or for chemical reflection.

Processing note: Very good weldability and good cold formability, poor anodisability.

AlMg alloys (e.g. EN AW-5754)

Contain magnesium as the main alloying element. They offer good corrosion resistance, medium strength and good weldability. These alloys are difficult to anodise, but are well suited to maritime environments, vehicle parts and chemical containers.

Processing note: Very good weldability, moderate anodisability, good cold formability.

AlMgSi alloys (e.g. EN AW-6060, 6082)

This alloy group combines magnesium and silicon. It offers a balanced property profile: good strength, very good anodisability, high corrosion resistance and good machinability. EN AW-6082 is one of the most widely used alloys in mechanical and plant engineering.

Processing note: Good weldability, excellent anodisability, good machinability.

AlZnMgCu alloys (e.g. EN AW-7075)

Extremely high-strength aluminium alloy with zinc, magnesium and copper. It achieves strength values comparable to steel. However, corrosion resistance is lower and weldability is limited. Ideal for highly stressed components in the automotive and aviation sectors.

Processing note: Not weldable, very good machinability, poor anodisability.

Choosing an alloy – by application

Mechanical engineering & construction

For structures with high mechanical requirements, EN AW-6082 is recommended. This alloy offers high strength, good machinability and is available as a standard stock item. Alternatively, EN AW-5754 is also suitable for less stressed applications.

Vehicle construction & aviation

In lightweight construction, every gram counts. High-strength alloys such as EN AW-7075 are used here. They are not only extremely strong, but also relatively light. Please note: weldability is limited. Riveting or adhesive bonding is therefore often used.

Food and medical technology

Here, corrosion resistance and surface quality play a central role. EN AW-1050A (pure aluminium) and EN AW-5754 are proven materials, as they are considered physiologically harmless. The anodisability of EN AW-6060 is advantageous when it comes to attractive, hygienic surfaces.

Architecture & façade construction

For visible parts, appearance and weather resistance count. Anodisable alloys such as EN AW-6060 are the first choice here. They can be easily processed, anodised and painted. At the same time, they offer solid strength.

Hobby, model making & DIY

For simple applications without high mechanical load, EN AW-1050A is ideal. The alloy is easy to cut, to bend and inexpensive. Anyone planning somewhat more robust projects is well advised to use EN AW-5754.

Table: Properties of common aluminium alloys compared

Alloy	Main alloying elements	Strength	Weldability	Corrosion resistance	Anodisability	Application areas
EN AW-1050A	–	low	very good	very good	poor	Electrical, model making, food technology
EN AW-5754	Mg	medium	very good	very good	limited	Vehicle construction, containers, DIY
EN AW-6060	Mg + Si	medium	good	good	very good	Architecture, visible parts
EN AW-6082	Mg + Si	high	good	good	good	Mechanical engineering, construction
EN AW-7075	Zn + Mg + Cu	very high	poor	limited	poor	Aviation, motorsport

Glossary of technical terms

Anodising: Electrochemical process for producing a protective oxide layer on aluminium. Improves corrosion protection and appearance.

Corrosion resistance: A metal's resistance to decomposition by water, air or chemicals.

Weldability: Indicates how well a material can be welded without cracking or loss of strength.

Pure aluminium: Aluminium with a very high degree of purity (usually >99.5%), particularly soft and conductive.

Strength: Mechanical property that describes a material's resistance to deformation or fracture.

How to make the right choice

Choosing the right aluminium alloy always depends on the specific area of application and the technical requirements. Anyone who needs high strength should opt for 6082 or 7075. Anyone looking for good corrosion resistance is well advised to use 5754 or 1050A. Visible parts benefit from anodisable alloys such as 6060. If you are unsure, it is worth consulting a specialist company or taking a look at the technical data sheets.

Tip: We supply dimensionally accurate aluminium sheet cut pieces in various alloys – tailored to your requirements. Send us your requirements and we will be happy to help you with the selection.

Frequently asked questions about choosing the right aluminium alloy

Which aluminium alloy is particularly strong? EN AW-7075 is one of the high-strength aluminium alloys and is often used in aircraft construction.

Which alloy is suitable for anodising? Alloys such as EN AW-6060 or EN AW-6082 are the easiest to anodise.

What is the difference between 1050A and 5754? 1050A is pure aluminium with very high corrosion resistance, 5754 contains magnesium and is stronger and easier to weld.

Which alloy is suitable for food contact? EN AW-1050A and EN AW-5754 are considered safe for contact with food.