Metal Forming Industries has the proven capability to provide its customers with components manufactured from a variety of different materials. Since 1999, MFI has developed specialty cold forming, impact extrusion, and precision machining processes in copper, aluminum, and brass materials.
MFI process engineering can provide specific material recommendations based on a detailed review of the customer designed part application.
Aluminum in Cold Forming and Impact Extrusion
Aluminum is one of the most popular materials used in both cold forming and impact extrusion due to its light weight, corrosion resistance, and excellent formability. Aluminum and its alloys are especially prevalent in the automotive, aerospace, and packaging industries.
Cold Forming with Aluminum
Aluminum’s lightweight nature and ability to form complex shapes make it an excellent choice for cold forming. Aluminum parts are commonly used in the automotive and aerospace industries, where reducing weight is crucial.
Advantages of Aluminum in Cold Forming:
- Lightweight: Aluminum has a low density, making it ideal for applications that require weight reduction, such as in the automotive and aerospace industries.
- Corrosion Resistance: Aluminum naturally forms a protective oxide layer, giving it excellent resistance to corrosion, even in harsh environments like marine or outdoor conditions.
- Good Strength-to-Weight Ratio: While not as strong as steel, aluminum offers a good balance of strength and weight, making it suitable for structural components and automotive parts.
Common Aluminum Alloys Used in Cold Forming:
- 3000 Series: Primarily used for applications that require good formability and corrosion resistance, such as beverage cans and roofing materials.
- 5000 Series: Known for excellent resistance to corrosion and higher strength, it’s used in marine environments and for architectural applications.
- 6000 Series: Offers a good balance of strength, formability, and resistance to corrosion, making it ideal for structural parts and automotive components.
Impact Extrusion with Aluminum
Aluminum is widely used in impact extrusion due to its excellent malleability and relatively low deformation resistance. Aluminum impact-extruded parts are used in a variety of applications, including packaging, automotive, and consumer goods.
Advantages of Aluminum in Impact Extrusion:
- Excellent Extrudability: Aluminum’s low strength makes it easy to deform during impact extrusion, allowing for the creation of complex geometries like hollow tubes and containers.
- Lightweight and Durable: Aluminum extrusions are lightweight but still durable enough to meet the needs of many industrial and consumer applications.
- High-Corrosion Resistance: The natural oxide layer on aluminum extrusions helps protect against corrosion, making aluminum ideal for both indoor and outdoor applications.
By selecting the appropriate material for cold forming and impact extrusion, manufacturers can create high-quality, durable parts that meet the specific requirements of their applications. Whether for lightweight automotive components, high-performance electrical connectors, or corrosion-resistant plumbing fittings, these metals continue to play a vital role in modern manufacturing.
