Aluminum alloys have a high strength-to-weight ratios, high electrical and thermal conductivity, low density, and natural resistance to corrosion. They can be anodized using a variety of techniques.
Advantages of aluminum alloy:
Lightweight and high strength-to-weight ratio
Excellent corrosion resistance
Good thermal and electrical conductivity
Easily recyclable and environmentally friendly
Corrosion resistance: Surface treatments like anodizing or painting can form a protective layer on the aluminum alloy, enhancing its resistance to corrosion and increasing its lifespan.
The advantages of aluminum alloy surface treatment are reflected in:
Improved aesthetics: Surface treatments can enhance the appearance of aluminum alloys by providing a uniform finish, offering a variety of colors or textures to match design preferences.
Increased durability: Surface treatments like hard anodizing or powder coating can improve the hardness and wear resistance of the aluminum alloy, making it more resistant to scratches, abrasion, and general wear and tear.
Improved electrical conductivity: Some surface treatments like chemical conversion coating can improve the electrical conductivity of aluminum alloys, making them ideal for applications that require efficient electrical transmission.
Adhesion promotion: Surface treatments can enhance the bonding and adhesion properties of the aluminum alloy, making it easier to apply additional coatings, paints, or adhesives onto the surface.
Easy cleaning and maintenance: Surface treatments can provide a smooth, non-porous, and easy-to-clean surface, helping to prevent dirt, grime, or contaminants from adhering to the aluminum alloy, reducing the need for frequent cleaning and maintenance.
Disadvantages of aluminum alloy:
Lower overall strength compared to steel alloys
Limited hardness and wear resistance
Vulnerable to stress and cracking under high loads
Higher cost compared to other metals like steel
Grade
6061-T6 | 3.3211| 65028| AlMg1SiCu
6060 | 3.3206 | AlMgSi
6082 | 3.2315 | 64430| AlSi1MgMn
6082-T651 | 3.2315 | 64430 | AlSi1MgMn
6063 | EN AW-6063 | 62400| AlMg0,7Si
6061-T651 | 3.3211 | 65028 | AlMg1SiCu
7075-T6 | 3.4365 | 76528 | AlZn5,5MgCu
7075-T651 | 3.4365 | 76528 | AlZn5.5MgCu
7075-T7351 | 3.4365 | 76528 | AlZn5.5MgCu
7050 | EN AW-7050 | 3.4144| AlZn6CuMgZr
5083-H111 | 3.3547 | 54300| AlMg4.5Mn0.7
5052 | EN AW-5052 | 3.3523 | AlMg2,5
2017A | 3.1325 | 24530 | AlCu4MgSi
2014 | 3.1255 | 24345 | AlCu4SiMg
Stainless steel
The stainless steel alloys are characterized by their excellent strength, ductility, corrosion and wear resistance. They can be easily joined and machined as well as polished.
Advantages of stainless steel:
Enhanced corrosion resistance: Stainless steel is already known for its excellent resistance to corrosion, but surface treatments like passivation or electropolishing can further enhance this property, making it suitable for even more demanding environments.
Excellent corrosion resistance
High strength and durability
Hygienic and easy to clean
Aesthetic appeal and versatility in design
The advantages of stainless steel surface treatment are reflected in:
Improved aesthetics: Surface treatments like polishing or brushing can provide a smooth and attractive finish to stainless steel, enhancing its appearance and making it suitable for applications where aesthetics are important.
Increased durability: Surface treatments can improve the hardness and wear resistance of stainless steel, making it more resistant to scratches, abrasion, and general wear and tear, thereby extending its lifespan.
Bacterial resistance: Surface treatments like antimicrobial coating can provide an additional layer of protection against bacteria, fungi, and other pathogens, making stainless steel surfaces more hygienic and suitable for applications in healthcare, food processing, or other sterile environments.
Easy cleaning and maintenance: Surface treatments can provide a smooth and non-porous surface, making stainless steel easier to clean and maintain. This is particularly important in applications where cleanliness and hygiene are essential
Adhesion promotion: Certain surface treatments can enhance the bonding properties of stainless steel, making it easier to apply additional coatings, paints, or adhesives onto the surface, allowing for further customization or added functionality.
Heat resistance: Some surface treatments can improve the heat resistance of stainless steel, making it suitable for applications involving high temperatures, such as cookware or industrial equipment.
Disadvantages of stainless steel:
Relatively high initial cost can be more difficult to shape and form compared to other metals
Can be susceptible to scratches and staining
Can have lower thermal conductivity compared to other metals like aluminum
17-4 PH | 1.4542 | X5CrNiCuNb16-4 - Annealed state
Alloy steel
Alloy steels incorporate additional alloying elements aside from carbon, leading to enhanced qualities such as increased hardness, toughness, fatigue resistance, and wear resistance.
Advantages of alloy steel:
High strength and durability
Better resistance to corrosion and wear
Improved heat resistance
Enhanced toughness and impact resistance
The advantages of alloy steel surface treatment are reflected in:
Enhanced corrosion resistance: Alloy steel, like stainless steel, can be prone to corrosion in certain environments.
Surface treatments such as galvanization or protective coatings help improve its resistance to corrosion, extending its lifespan and ensuring durability.
Increased hardness and strength: Alloy steel surface treatment methods like heat treatment or surface hardening can significantly increase the hardness and strength of the material.
This makes it suitable for applications requiring high levels of toughness and resistance to wear, such as in automotive or industrial equipment.
Improved wear resistance: Alloy steel surface treatments can increase the material's ability to resist wear, abrasion, and friction.
This is especially beneficial in applications involving moving parts or high-stress environments, as it helps prevent damage and extends the component's service life.
Customized surface properties: Surface treatments allow for the customization of properties such as friction coefficient, surface roughness, or electrical conductivity of the alloy steel.
This enables the material to meet specific requirements and function optimally in various applications.
Protection against environmental factors: Certain alloy steel surface treatments, such as chromating or phosphating, provide protection against environmental factors like moisture, chemicals,
or temperature fluctuations.
This helps prevent surface degradation and ensures the material retains its functional properties over time.
Enhanced aesthetic appeal: Surface treatments like plating or coating can improve the appearance of alloy steel, making it visually appealing.
This can be beneficial in applications where aesthetics are important, such as architectural or decorative applications.
Disadvantages of alloy steel:
Higher cost compared to carbon steel
Difficult to weld and work with
Variation in mechanical properties due to different alloying elements
Requires specific heat treatment for optimal performance
Grade
1.7131 | 16MnCr5
4140 | 1.7225 | EN19 | 42CrMo4
1215 | EN1A | 1.0715
1.0718 | 11SMnPb30
St 37-2 | 1.0037 | Q235A
S355JR | 1.0045 | Q255A
ST35NBK DIN 2391/2 | 1.0038 | Q235B
X30Cr13 | 1.4028 | 3Cr13
1.1201 | 65Mn
X165CrMoV46 /X165CrMoV12
| 1.2601 | SKD11
C45 (DIN) | 1.0503 | 1045
Brass
Brass displays outstanding easiness to machine, favorable ratio of strength to weight, resistance to corrosion, and proficient conduction of electricity and heat.
Advantages of brass:
Good corrosion resistance
Attractive and decorative appearance
High machinability and formability
Good conductivity for heat and electricity
The advantages of brass surface treatment are reflected in:
Corrosion resistance: Brass is naturally corrosion-resistant to a certain extent due to its copper content. However, surface treatments like electroplating with materials like nickel, chrome, or tin can provide an additional layer of protection against corrosion, making brass more resistant to environmental conditions and extending its lifespan.
Improved aesthetics: Brass surface treatments such as polishing, lacquering, or plating can enhance its appearance, giving it a bright and lustrous finish. These treatments help brass maintain its visual appeal, making it a popular choice for decorative applications, architectural fittings, and jewelry.
Enhanced durability: Surface treatments like coating or plating can add a protective layer that improves brass's resistance to wear, scratching, and oxidation. This makes brass more durable, ensuring it maintains its original finish and properties for longer periods.
Anti-fouling properties: Certain surface treatments can offer anti-fouling properties, preventing the accumulation of dirt, oils, or fingerprints on the surface of brass. This makes it easier to clean and maintain, particularly in applications where cleanliness and hygiene are crucial, such as in healthcare or kitchen environments.
Improved solderability: Brass surface treatments can improve its solderability, making it easier to join brass components together using soldering techniques. This is particularly advantageous in manufacturing processes that require the assembly of brass parts or plumbing applications.
Protection against tarnishing: Brass is prone to tarnishing over time due to exposure to air and moisture. However, surface treatments like clear coating or lacquering can provide a barrier against tarnish formation, preserving the brass's appearance and reducing the need for frequent polishing or maintenance.
Disadvantages of brass:
Lower strength compared to steel
Can tarnish over time and require maintenance
May contain lead, which can pose health risks
Relatively higher cost compared to other materials like aluminum
Grade
C26800 | 2.0280 | H68
C27000 | 2.0335 | H65
C27200 | 2.0321 | H63
C28000 | 2.0360 | H62
C35000 | 2.0371 | H60
C360 | 2.0375 | CuZn36Pb3 | 319 grade 2
C37700 | 2.0380 | HPb59-1
C38500 | 2.0401 | HPb58-2.5
C38000 | 2.0402 | CuZn40Pb2
Copper
Copper, a remarkably malleable metal, finds utility in various applications determined by its mechanical characteristics. It exhibits commendable durability, hardness, exceptional thermal and heat conduction abilities, and corrosion resistance. As a result, it has become a highly sought-after material highly regarded for both its practical functionality and its aesthetic appeal. Furthermore, copper possesses the versatility to be alloyed, thereby enhancing its mechanical attributes.
Advantages of copper:
Copper is widely used for its excellent electrical and thermal conductivity, making it ideal for electrical wiring and heat transfer applications.
Copper is exceptionally malleable and malleable, making it easy to mold and form into a variety of products.
Copper has excellent corrosion resistance and exceptional durability, making it suitable for long-term applications.
The advantages of copper surface treatment are reflected in:
Improve corrosion resistance: The copper surface can be treated with various coatings or electroplating to enhance its corrosion resistance and extend its service life, making it suitable for outdoor or corrosive environments.
Enhanced Electrical Conductivity: Copper surface treatments help optimize the electrical conductivity of copper, making it more efficient in electrical and electronic applications.
Increased Durability: Surface treatments can increase the hardness and wear resistance of copper, making it more durable for applications requiring high strength or wear resistance.
Enhanced Aesthetics: Copper surface treatments can enhance the appearance of copper by imparting desired color, texture or finish to the copper, resulting in a more aesthetically pleasing and customizable end product.
Disadvantages of copper:
Higher cost compared to alternative materials, and relatively heavy weight,
which increases shipping and installation costs. Copper oxidizes over time, resulting in a green patina that requires regular cleaning and maintenance.
Additionally, its high conductivity can pose safety concerns if not properly insulated or grounded,
and its reactivity to certain substances limits its use in certain industrial or chemical applications.
Grade
C10100 | 2.0040 | TU2 C11000 | 2.0065 | T2
C11000 | 2.0065 | T2
C12200 | 2.0090 | TP2
C12000 | 2.0076 | TP1
Titanium
Titanium possesses a variety of material characteristics that designate it as the optimal metal for challenging applications. These traits encompass exceptional resilience against corrosion, chemicals, and extreme temperatures, as well as an exceptional ratio of strength to weight.
Advantages of Titanium Alloy:
High strength-to-weight ratio
Excellent corrosion resistance
Biocompatible and commonly used in medical implants
Superior heat resistance compared to other metals
Disadvantages of Titanium Alloy:
Expensive compared to other metals
Difficult to process and work with due to its high strength
Limited availability and significant production challenges
Susceptible to galling and wear when in contact with other metals under certain conditions
ABS, a frequently used thermoplastic, displays favorable mechanical characteristics, outstanding impact resilience, reliable heat tolerance, and commendable machinability.
Advantages of ABS (Acrylonitrile Butadiene Styrene):
High impact strength
Good dimensional stability
Excellent chemical resistance
Easy to process and can be easily molded
Disadvantages of ABS:
Not suitable for outdoor applications due to UV degradation
Can be prone to warping or shrinking during cooling
Limited heat resistance compared to some other materials
Can emit toxic fumes when burned
FR4
FR4, boasting excellent mechanical strength, superior electrical insulation, and superior machinability, is the ideal choice for electronic applications.
Advantages of FR4:
Excellent electrical insulation properties
High mechanical strength
Flame retardant
Good dimensional stability
Disadvantages of FR4:
Can be brittle
Relatively high cost compared to other materials
Limited resistance to certain chemicals
Requires special equipment and processes for fabrication
HDPE
HDPE exhibits outstanding resilience to impact, remarkable strength, and impressive machinability, making it well-suited for the production of resilient and sturdy machine components.
Advantages of HDPE (High-Density Polyethylene):
High chemical resistance
Excellent impact strength
Lightweight and durable
Excellent moisture barrier
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Disadvantages of HDPE:
Relatively low heat resistance
Susceptible to stress cracking under certain conditions
Limited UV resistance without additives
Can be difficult to bond or weld together
PE
PE is characterized by its remarkable impact resistance, exceptional ductility, and minimal friction, which render it an ideal choice for fabricating wear-resistant parts using machining techniques.
Advantages of PE (Polyethylene):
High chemical resistance
Low moisture absorption
Good impact strength
Cost-effective and easy to process
Disadvantages of PE:
Limited temperature resistance
Prone to stress cracking
Can be difficult to bond or weld together
Relatively low tensile strength
PA6 (Nylon)
In machining applications where parts undergo significant mechanical stress, PA proves to be an excellent choice due to its combination of high strength, wear resistance, and elasticity.When it comes to machining components that experience substantial mechanical stress, PA stands out as an exceptional material option due to its impressive strength, resistance to wear, and elasticity.
Advantages of PA6 (Nylon):
High strength and stiffness
Excellent wear resistance
Good chemical resistance
Self-lubricating properties
Disadvantages of PA6:
Absorbs moisture, leading to dimensional changes
Limited heat resistance
Can lose strength when exposed to UV radiation
Higher cost compared to some other materials
PA66 (Nylon)
PA66 displays favorable characteristics like high rigidity, hardness, wear resistance, and thermal dimensional stability. Furthermore, it showcases exceptional wear resistance, low friction, and excellent temperature, chemical, and impact resistance. Nevertheless, caution must be exercised during the processing of PA66 due to its propensity to absorb moisture, which can impact its dimensional stability.
Advantages of PA66 (Nylon):
Higher heat resistance compared to PA6
Excellent mechanical properties
Good chemical resistance
Low friction coefficient
Disadvantages of PA66:
Absorbs moisture, leading to dimensional changes
Can become brittle when exposed to UV radiation
Relatively high cost
Generates toxic fumes when burned
PC (Polycarbonate)
PC, a thermoplastic material, possesses remarkable resilience, exceptional resistance to impacts, and ease of machining. Additionally, it has the capability to exhibit optical transparency.
Advantages of PC (Polycarbonate):
Excellent impact strength
High transparency
Good dimensional stability
Flame retardant
Disadvantages of PC:
Relatively high cost
Scratches easily
Limited resistance to some chemicals
Can be prone to yellowing over time when exposed to UV radiation
PEEK
PEEK is characterized by its impressive strength, outstanding ability to withstand high temperatures, and excellent machinability — making it an ideal choice for various high-performance applications. PEEK offers exceptional strength, remarkable thermal resistance, and superior machinability, making it perfectly suited for demanding high-performance uses.
Advantages of PEEK (Polyetheretherketone):
Excellent mechanical properties at high temperatures
Excellent resistance to chemicals
Low moisture absorption
Good dimensional stability
Disadvantages of PEEK:
Relatively high cost
Difficult to process and requires specialized equipment
Limited impact strength compared to some other materials
Can be prone to thermal degradation if processing temperatures are not controlled properly
PMMA
PMMA provides remarkable light transmission, impressive mechanical strength, and impeccable machinability, making it a perfect material for optical and aesthetic applications. PMMA exhibits exceptional light transmission, superior strength, and excellent machinability, making it an ideal choice for optical and aesthetic purposes.
Advantages of PMMA (Polymethyl Methacrylate):
Excellent optical clarity
Good weather resistance
Easy to process and mold
Lightweight
Disadvantages of PMMA:
Relatively low impact strength
Prone to scratching
Limited heat resistance compared to some other materials
Can become brittle over time
POM
Precision parts that seek elevated rigidity, minimal friction, and outstanding dimensional stability benefit from the usage of POM, an engineering thermoplastic.
Advantages of POM (Polyoxymethylene):
Excellent mechanical properties
Low friction and wear resistance
Good dimensional stability
Good chemical resistance
Disadvantages of POM:
Prone to thermal degradation at high temperatures
Can have a high coefficient of friction
Vulnerable to stress cracking under certain conditions
Relatively high cost
PP
With exceptional fatigue resistance, excellent chemical resistance, and impressive elasticity, PP is perfectly suited for fabricating machined parts that are lightweight and flexible.
Advantages of PP (Polypropylene):
Excellent chemical resistance
Good impact strength
Lightweight and durable
Low moisture absorption
Disadvantages of PP:
Relatively low heat resistance
Can be prone to stress cracking under certain conditions
Scratches easily
Limited resistance to UV radiation without additives
PPS
PPS exhibits superb resistance to chemicals, possesses remarkable strength, and demonstrates exceptional machinability; making it an optimal choice for the production of high-performance components.
Advantages of PPS (Polyphenylene Sulfide):
Excellent heat resistance
High strength and rigidity
Excellent chemical resistance
Low moisture absorption
Disadvantages of PPS:
Relatively high cost
Limited impact strength
Can be prone to thermal degradation if processing temperatures are not controlled properly
Difficult to process and requires specialized equipment
PVC
Among plastics, PVC stands as the third most widely employed, boasting well-balanced mechanical characteristics, outstanding resistance to chemicals and weather conditions, and notable toughness.
Advantages of PVC (Polyvinyl Chloride):
Excellent chemical resistance
Good electrical insulation properties
Durable and long-lasting
Low cost compared to other materials
Disadvantages of PVC:
Not biodegradable and can release toxic chemicals when burned
Can be brittle at low temperatures
Limited heat resistance compared to some other materials
Requires special equipment for fabrication and welding
When it comes to machining, carbon fiber, also known as graphite fiber, emerges as a top contender due to its remarkable strength and lightweight nature. Outperforming steel with its five-fold strength and double the stiffness, carbon fiber is a sought-after material in the machining industry.
Advantages
High strength-to-weight ratio: Carbon fiber is known for its exceptional strength, making it ideal for lightweight yet strong products.
Rigidity: Carbon fiber offers high rigidity and stiffness, providing stability and structural integrity to CNC processed products.
Corrosion resistance: Carbon fiber is highly resistant to corrosion, making it suitable for applications in harsh environments.
Design flexibility: Carbon fiber can be molded into complex shapes, allowing for intricate and optimized designs.
Vibration dampening: Carbon fiber has natural dampening properties, reducing vibrations and enhancing product performance.
Disadvantages
Cost: Carbon fiber is more expensive compared to traditional materials, leading to higher production costs.
Brittleness: Carbon fiber can be brittle and prone to fractures under excessive loads or impacts.
Conductivity limitations: Carbon fiber is a poor conductor of electricity and heat, which may limit its use in certain applications.
Manufacturing complexity: Working with carbon fiber requires specialized equipment and expertise, resulting in increased manufacturing complexity.
Recycling challenges: Carbon fiber is difficult to recycle, leading to environmental concerns and waste management challenges.
Wood
Wood is a structural tissue found in the stems and roots of trees and other woody plants. It is an organic material – a natural composite of cellulose fibers that are strong in tension and embedded in a matrix of lignin that resists compression.
Advantages
Natural aesthetic appeal: Wood offers a warm and visually pleasing appearance, adding a natural charm to products.
Versatility: Wood can be easily shaped and carved using CNC machines, allowing for intricate designs and customization.
Sustainability: Wood is a renewable resource, making it an environmentally-friendly choice for CNC processed products.
Cost-effectiveness: Compared to other raw materials, wood can be relatively affordable, making it a cost-effective option for production.
Durability: With proper maintenance and treatment, wood can have good resistance to wear, tear, and impact.
Disadvantages:
Limited strength: Wood may not possess the same strength and rigidity as some other materials, which can limit its applications.
Susceptibility to moisture: Wood can absorb moisture, leading to swelling, warping, or rotting, especially if not properly sealed or treated.
Dimensional instability: Wood can expand or contract with changes in humidity or temperature, which may affect precision and accuracy in CNC processing.
Environmental considerations: The use of wood may raise concerns about deforestation or unsustainable logging practices if not sourced responsibly.
Fire and pest susceptibility: Wood is flammable and can be vulnerable to damage from pests, requiring appropriate fireproofing and protection measures.
Die Casting Materials
These are just a few examples of the raw materials used in die casting. The choice of material depends on the specific requirements of the part being produced, such as strength, weight, corrosion resistance and electrical conductivity.
Aluminum is one of the most commonly used materials in die casting. It has good strength, lightweight properties and excellent corrosion resistance. In addition, aluminum has a low melting point, which is beneficial to the die casting process.
Commonly used Aluminum alloys:
A380, A360, A390. A413, ADC-12, ADC-1
Zinc
Zinc is another popular die casting material. It has excellent casting properties, good corrosion resistance, and is easy to plate or finish. Zinc is commonly used to make small, complex parts and has excellent dimensional stability.
Magnesium is known for its lightweight properties and high strength-to-weight ratio. It is often used in parts that require high strength and low weight, such as automotive components.
Commonly used Magnesium alloys:
AZ91D, AM60B, AS41B
Copper
Copper is used in die casting for its excellent thermal and electrical conductivity. It is commonly used in electrical components, as well as heat sinks and other applications where good heat dissipation is required.
Polylactic Acid (PLA) is a biodegradable and bioactive thermoplastic made from renewable resources, typically derived from corn starch or sugarcane. It has gained popularity as a 3D printing material and is also used in various other applications due to its favorable properties.
ABS
ABS is widely available and possesses advantageous mechanical and thermal characteristics. It is a popular thermoplastic choice due to its impressive impact resistance and reduced level of intricate features.
Nylon
In machining applications where parts undergo significant mechanical stress, PA proves to be an excellent choice due to its combination of high strength, wear resistance, and elasticity.When it comes to machining components that experience substantial mechanical stress, PA stands out as an exceptional material option due to its impressive strength, resistance to wear, and elasticity.
Stainless Steel
The stainless steel alloys are characterized by their excellent strength, ductility, corrosion and wear resistance. They can be easily joined and machined as well as polished.
Aluminum Alloy
Aluminum alloys have a high strength-to-weight ratios, high electrical and thermal conductivity, low density, and natural resistance to corrosion. They can be anodized using a variety of techniques.
Aluminum is a lightweight material that has many desirable properties. It is one of the most common materials used for sheet metal fabrication. It is also recyclable and generates the least amount of waste. Aluminum's other qualities include its high production rate, low resistance rates, and high thermal conductivity.
The best grades of aluminum to use for this process are 5052, 7075, 1060,5754and 6061.
Stainless Steel
Stainless steel contains a minimum of 10% of chromium in its weight. Stainless steel is used in many industries including automotive, aerospace, and building. The stainless steel material is versatile and can be used in many different applications.
The grades of stainless steel that are ideal for sheet metal engineering are 201,304,301 and 316.
Steel
Steel is a material that has many advantages in industrial applications, including durability, heat resistance, and hardness. Steel sheet metal can be used to create intricate elements and designs that require high precision. Steel is also easy to work with and offers superior polishing properties.
The best grades of steel to use for this process are SPCC SECC SGCC Q235 and S45C.
Copper
Copper is a good metal for sheet metal fabrication because it has the ductility and malleability required. Copper is also a metal that has excellent heat and electrical conductivity. It's the best choice for products that require high levels of conduction. The C1100 grade of copper is widely used in the sheet metal industry due to its antibacterial and biostatic properties.
Brass
Brass is highly malleable and spark- and wear-resistant. It also has excellent electrical conductivity. Low friction makes it a desirable material for many purposes. C28000 and C27400 brass grades are perfect for sheet metal fabrication.
