Why is Aluminum 5052-H32 Preferred Over 6061-T6 for Custom Sheet Metal Fabrication?

Aluminum 5052-H32 is a non-heat-treatable alloy. It has good weldability and formability and offers excellent corrosion resistance. It has a smooth, shiny surface and is widely used for applications where strength and durability are critical.

Aluminum 6061-T6 is a heat-treatable alloy. It has good machinability and can, therefore, be cut and drilled easily to create different shapes. T6 offers excellent corrosion resistance and has a high strength-to-weight ratio, which makes it the ideal choice for marine applications and applications where it is crucial to reduce weight without compromising strength.

Both aluminum 5052-H32 and 6061-T6 are suitable for custom metal fabrication. That said, aluminum 5052-H32 is a better choice for sheet metal fabrication; here’s why!

Formability

Aluminum 5052-H32 has excellent formability and can be easily bent and drawn (without cracking) to form complex, intricate shapes. Aluminum 6061-T6 has good formability as well, however, it is not as pliable as aluminum 5052-H32 and is, therefore, less suitable for applications that involve creating complex shapes and intricate patterns.

Corrosion Resistance

Aluminum 5052-H32 offers excellent corrosion resistance and is commonly used in marine environments. Aluminum 6061-T6 is also corrosion resistant, but it is not as resistant as aluminum 5052-H32, especially in chloride-rich environments.

Fatigue Strength

Aluminum 5052-H32 has better fatigue strength (the maximum stress a material can withstand without cracking) than aluminum 6061-T6 and is, therefore, better suited for applications subjected to repeated stress cycles.

Weldability

Aluminum 5052-H32 has excellent weldability and can be easily welded using common welding techniques. Welding does not affect its mechanical properties. While aluminum 6061-T6 can be welded, the heat produced during welding can affect its strength in the heat-affected zone unless T6 is re-heat-treated.

Cost

Aluminum 5052-H32 is more cost-effective as the alloy contains only 4% or less of other elements and is easier to fabricate. Because it is cost-effective, 5052-H32 can help reduce overall project costs. 6061-T6 is more expensive than 5052-H32 due to its superior strength and the complex method used to produce the alloy.

Workability

Aluminum 5052-H32 is easy to work with, making it ideal for custom metal fabrication projects. You may need specialized tools and techniques to fabricate aluminum 6061-T6. As a result, fabrication costs can increase.

Aluminum 5052-H32 vs. Aluminum 6061-T6: Applications 

Aluminum 5052-H32 is commonly used for fuel tanks, automotive parts, and marine applications. 6061-T6 is commonly used in applications (such as aircraft structures) where a high strength-to-weight ratio is crucial.

Bayou Metal Supply offers a wide variety of aluminum products. We use advanced CNC routers to cut and bend metals into custom shapes. To learn more, call (985) 643-3340.