November 2025 Volume 7

MATERIALS

4. Bare aluminum – may be used when surface treating would interfere with application, under conditions free of salinity or extended wetness, or when high corrosion resistant alloys are used. Faying edges should be sealed to prevent crevice corrosion. Conclusions • Aluminum is a “light” metal, about one third of the density of steel, copper, and brass. • Aluminum forgings have good corrosion resistance to common atmospheric and marine atmospheres. (Its corrosion resistance and scratch resistance can be enhanced by anodizing or other surface treatments.) • Aluminum has high reflectivity, and the forged surface does not require extensive polishing. • When forged, aluminum alloys demonstrate some mechanical qualities comparable with steel, and the strength to weight ratio of aluminum exceeds that of steel. • Aluminum retains its toughness at very low temperatures, without becoming brittle like carbon steel. • Aluminum forgings can be a good conductor of heat and electricity. • Aluminum is readily worked and formed using ring rolling, open and closed die forging into both small and large sizes. Summary • Aluminum is infinitely recyclable and nearly 75% of all aluminum ever produced is still in use today. • The fastest-growing automotive material, aluminum makes vehicles safer, more energy efficient and better-performing. • Modern air and space flight would not be possible without the development of lightweight but high strength aluminum alloys. • Highly versatile aluminum can be thin or thicker sections than plate, and durable enough to use in military armor plate. • Aluminum forgings are generally cost-effective and attractive in their appearance. Resources and Events Provided by FIA RFQ: If you have a need for a forged aluminum part, you can use FIA’s Request for Quote (RFQ) page for fast access to the many producer members who forge aluminum. Once you answer a few short questions about your component requirements, click submit, and any company subscribed to receive RFQs will automatically be emailed your RFQ. Lightweight Alloys Conference: The 2025 Forging Lightweight Alloys Conference took place September 15-17 at the Hilton Long Beach in Long Beach, California, and began with a plant tour of Weber Metals. The conference covers topics including lightweight materials, OEM needs, advancements in technology, equipment for lightweight forging, post-forging processes and more.

References 1. https://unitedaluminum.com/a-brief-history-of-aluminum/ 2. https://www.usgs.gov/centers/national-minerals information-center/bauxite-and-alumina-statistics-and information#:~:text=Bauxite%20is%20a%20naturally%20 occurring,in%20minor%20or%20trace%20amounts 3. https://pubs.usgs.gov/periodicals/mcs2024/mcs2024-bauxite alumina.pdf 4. https://unitedaluminum.com/the-aluminum-production-process/ 5. https://international-aluminium.org/statistics-overview/ 6. https://www.aluminum.org/product-markets 7. https://www.reliance-foundry.com/blog/aluminum ?srsltid=AfmBOoqSOmfnRQtohsR0Np93IM1Y vg4nCbFyaWXSRY4hmnU7A1fc8CG 8. https://materialsdata.nist.gov/bitstream/handle/11115/223/ Forging%20of%20Aluminum%20Alloys.pdf 9. https://nalcoindia.com/business/operation/aluminium-smelter/ 10. https://www.dropforging.net/forging-of-aluminum-alloys.html 11. https://www.epa.gov/eg/aluminum-forming-effluent-guidelines 12. https://elements.visualcapitalist.com/ 13. https://kdmfab.com/aluminum-alloy/ 14. NASA, MSFC-STD-3029, Guidelines for Selection of Metallic Materials for SCC Resistance in NaCl 15. Dept. of Defense, MIL-STD-889D, GALVANIC COMPATIBILITY OF ELECTRICALLY CONDUCTIVE MATERIALS 16. https://www.lme.com/en/Metals/Non-ferrous/LME-Aluminium premiums/LME-Aluminium-Premium-Duty-Paid-US Midwest-Platts#Price+graph Blake Nelson is a student at the University of Central Florida studying for a master's degree in mechanical engineering where he also earned his bachelor's degree in mechanical engineering. He has career and research interest in aerospace engineering and materials science. Mike Manning serves as a consultant for the FIA for training and magazine contributor. He holds a BS and MS in Materials Engineering from Rensselaer Polytechnic Institute (Troy, NY). Mike has enjoyed a 40 year career with metallurgy roles supporting supply chain, manufacturing, new product Introduction, and quality across the automotive, aerospace and Energy industries.

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