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  1. #1
    Join Date
    Apr 2021
    Location
    NSW
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    3

    Default Aluminium plate - sources, grades and cutting

    Hi everyone, new member here I'm a 'semi-experienced' tinkerer / builder / inventor, jack of all trades and master of none

    I'm currently interested in experimenting with (eg ~3mm) aluminium plate of a decent grade, for light weight and rigidity. The pieces I need are rectangular or square, something in the range of 300mm to 600mm a side, though this is not particularly critical (at least for prototyping). Ideally it would be at least partially punched or drilled to help form a cagelike structure.

    A grille or perforated sheet product was my first quest, but I can't find anything available off the shelf that isn't the usual weak soggy base grade ali. Next I racked my brain (and google skills) trying to identify products that might be a cheap and convenient source of suitable pieces, but with no luck. So my next plan is to buy a sheet and get it cut to my own design.

    Ultimately I want to pulse mig (or tig) the bits together, with supporting gussets etc, to end up with a lightweight but sturdy structure. My last resort would be to mig it all up out of rod, but I'm hoping to avoid this, as I have no experience yet welding ali and will be using borrowed gear with limited time constraints.

    So if it's not too greedy to ask multiple questions in my first post:

    1. Can you think of any products that contain stiff aluminium plates/grilles?

    2. What grade of ali should I be looking for, for rigidity and miggability?

    3. Should I get it laser cut, water cut, plasma cut, cnc cut, or other?

    4. Can I fold 90 degree bends in this stuff, or is this generally done prior to hardening? (This is not critical but it would save some or all of the welding. I could even perforate the folding lines).

  2. #2
    Join Date
    Jan 2004
    Location
    Mackay North Qld
    Posts
    6,446

    Default

    Hello Inigo Montoya,
    Welcome to the MetalWork Forums

    We have some fine folks here who are supportive friendly and helpful.

    Please take the time to navigate around the sub forums to view the varied and interesting subjects.

    To do this, goto the the FORUM box in the top left hand corner of the screen. Then click Forum Home and a scroll down page will come up.

    Scroll down the page and the various help pages and sub forums shall be shown. Many pages also have a sticky at the top.If you post its always a good idea to check the pertinent sticky ,if there is one there.

    Please make sure you read the Terms of Use ( known in the our Forum as TOU,s ) on the very top of the scroll down page - they are our rules.

    To save time here's a link
    https://metalworkforums.com/f90/t197...terms-tou-read

    You might,consider changing your location from NSW to more general one IE. Sydney,or even better a suburb.
    Often when you could be seeking product info, members who know your general area can direct you ( to a previously unknown by you ) to you business location that has a product you may be seeking

    It might well be, that fellow member maybe they are just across in the next suburb and can assist or demonstrate a technique. Many of us are willing to help in this fashion.

    Again, welcome to our forums.

    Grahame

  3. #3
    Join Date
    Sep 2010
    Location
    Lebrina
    Posts
    1,910

    Default

    It would help if you actually came out and said what you are building.
    What do you term the "usual soggy base grades" of aluminium?
    Weldable grades of aluminium that you will commonly find in either sheet or extruded products will come from the 5XXX and 6XXX families of aluminium, with the latter being confined to extrusions. Strength and toughness come at the expense of bendability. For example, grades commonly found in 3mm would be 5005, 5052 and 5356. These are all very workable, but do not have the toughness of 5083. 5083 however is not the best for bending and has a tendency to crack unless radius bends are used.
    All aluminium softens to some degree post welding, so you will also need to consider that.
    You will tend to find that aluminium is supplied in grades that reflect its probable end use. For example 20mm 5083 would be a common item, while 1.6mm 5083 is not.
    In short, your choices are limited.
    As far as profile cutting, avoid water jet cutting if you want to weld the components. My first choice would be CNC router, followed by laser.

  4. #4
    Join Date
    Aug 2008
    Location
    Melbourne
    Age
    34
    Posts
    1,075

    Default

    Quote Originally Posted by Karl Robbers View Post
    It would help if you actually came out and said what you are building.
    I'll never understand all these posts that ask for help and give all the details except for what they're actually trying to do

  5. #5
    Join Date
    Sep 2010
    Location
    Lebrina
    Posts
    1,910

    Default

    It would help if you actually came out and said what you are building.
    What do you term the "usual soggy base grades" of aluminium?
    Weldable grades of aluminium that you will commonly find in either sheet or extruded products will come from the 5XXX and 6XXX families of aluminium, with the latter being confined to extrusions. Strength and toughness come at the expense of bendability. For example, grades commonly found in 3mm would be 5005, 5052 and 5356. These are all very workable, but do not have the toughness of 5083. 5083 however is not the best for bending and has a tendency to crack unless radius bends are used.
    All aluminium softens to some degree post welding, so you will also need to consider that.
    You will tend to find that aluminium is supplied in grades that reflect its probable end use. For example 20mm 5083 would be a common item, while 1.6mm 5083 is not.
    In short, your choices are limited.
    As far as profile cutting, avoid water jet cutting if you want to weld the components. My first choice would be CNC router, followed by laser.

  6. #6
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    71
    Posts
    5,945

    Default

    As Elan suggested, if we knew what you were trying to make, it would be far more helpful in suggesting appropriate materials etc.? Also telling us what equipment you have available helps too.
    As for a solid grille type item, I can only think of Security Mesh being strong enough, it's used a lot in 4WD's for storage of seldom used items, above areas that need quick access, without having to unload everything above it.
    Welcome to a TOP FORUM too.
    HTH
    Kryn
    To grow old is mandatory, growing up is optional.

  7. #7
    Join Date
    Oct 2010
    Location
    NSW
    Posts
    177

    Default

    These people will make anything to a provided drawing. Very versatile.

  8. #8
    Join Date
    Jan 2004
    Location
    Mackay North Qld
    Posts
    6,446

    Default

    Hi Inigo Montoya,
    Please take the following in the spirit it was written. We want to help ,but gee whiz please make it easier for us .

    You are not the first person and will not be the last, to post a question in our Forum and not be specific about what object they propose to make.

    From the point of view of a person attempting to answer your question/s it can be most difficult, as the person replying has to guess what you are making and question you on sets of variables, few of which may be applicable.

    Far better to state what item you hope to make plus the environment the item is expected to operate in and then ask about what materials would be best suited to achieve this and how they can be worked using the available tools /equipment you possess.

    It helps a lot if you tell what gear/tools etc you own that you thing might be useful.

    I am sure many inquiries of a similar type fail to attract all the responses they deserve because it hard to begin this process as there is no point to start from.

    So if you can let us know what you are wanting to build, I do believe you are likely to attract more responses.


    Ok something you may need to know. Some aluminium sheet should not be sharply folded with the grain. It can crack.

    What grade is was I can't remember. Sheet metal guys will know what I speak of and can advise on that.

    It so happened that the fold was the last process after the rest was marked, cut out, drilled etc and the job went in the bin.

    Handy to know or what?

    Cheers
    Grahame

  9. #9
    Join Date
    Apr 2021
    Location
    NSW
    Posts
    3

    Default

    Hi everyone, thanks for the warm welcome and tips, and apologies for my lack of detail. Put simply though, I think I've found a gap in the market and this could potentially be a saleable product, so I'm really reluctant to spell out what I'm working on in a whole lot of detail. I realise that's probably a bit frustrating and I apologise, I'm just feeling a bit coy until I get deeper into what I can and can't achieve and whether it could become an income stream for me.

    By 'soggy' aluminium I meant the extrusions you find at bunnings (I also bought some from Capral many years ago) that just had no strength. They'd bend under very little load, and had no resistance to twisting. In contrast I have some audiovisual gear with aluminium mounting brackets that feel very close to steel - ie, really stiff and strong, so that's what I was seeking.

    I think you've answered my questions though, it seems like what I'm looking for is grade 5xxx plate or 6xxx extrusion, which is ideally already hardened, to make the stiffest structures with the lowest weight. It also sounds like anything stiff enough to be useful will not realistically be bendable without special techniques. I have the usual workshop tools to cut and drill, and I can borrow a pulse mig set up for alloy, so for now I will focus on a simple cut and weld fabrication process.

    Thanks again for your help, and I look forward to spending more time here and sharing what I learn

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