Aluminum Stamping

KDM is your one-stop solution for aluminum stamping processes.

Aluminum Stamping

Metal stamping is a metalworking procedure that is used to shape sheet metal into various parts and products. It can handle a variety of materials, including aluminum.

Due to its strength and workability, aluminum is ideal for stamping operations. Stamped aluminum components are used in a wide range of industries, including marine, aerospace, automotive, building & construction, medical, electronics & appliances, etc.

Pure aluminum is frequently alloyed with several other metals in stamping processes to add or enhance certain material qualities. This improves the end product’s performance. Copper, iron, magnesium, manganese, silicon, and zinc are common alloying elements.

KDM is your one-stop solution for aluminum stamping processes. Using advanced machinery and techniques, we can produce superior quality products suitable for your needs. Contact us immediately!

 

KDM Aluminum Stamping Project

Aluminum Stamping Parts
Automotive Stamping Parts
Automotive Stamping Parts
Electronic Stamping Parts
Electronic Stamping Parts
3 Products Found.

Aluminum Stamping: The Ultimate Guide

In this guide, you will find all information you are looking for about aluminum stamping.

Whether you want to learn about stamping techniques, suitable alloys for stamping or applications of aluminum stamping – read this guide.

What Is Aluminum Stamping?

Sheet Metal stamping

Sheet metal stamping

This is a metal fabrication technique that you can use to transform your flat sheet aluminum metals into a variety of shapes, components, and products.

A stamping press system comprises the hardware and software components.

The hardware component is made up of the press and the tool while the software components comprise the press set-up, material (aluminum sheet), and the lubricant.

You can change the software components from one operation to the other while the hardware components are constant and don’t change between operations.

Aluminum is stamped using a machine known as a stamping press. This machine has the tooling, which moves around per the user fed-in design (Process set-up). You can place a flat aluminum sheet in the machine either as blank form or coil.

The stamping press transforms the aluminum sheet into the desired shape, part, or product through the die surface and tool.

You could achieve the desired shape/part in a single press operation or multiple operations, depending on the complexity of the final shape.

However, you have to first design your tooling before transforming the sheet aluminum into the desired shape.

Computer-Aided Design and Computer-Aided Manufacturing technology offer advanced engineering tools that you can use to design complex parts.

Design precision is mandatory to ensure proper clearance for each punch and bend and overall superior part quality.

The design development can be very difficult and consume a lot of time as a single model can have multiple parts.

Aluminum Alloy Suitable For Metal Stamping

Aluminum and its alloys have enhanced material properties that are ideal for metal stamping operations.

Alloys of aluminum are made from mixing pure aluminum with other metals.

Different alloys have different, four-digit reference numbers.

Some of the aluminum alloys that you can use for metal stamping operations include:

  • 1000 series: These materials comprise 99% pure aluminum and lack alloying elements.
  • 2000 series: These materials are copper alloyed aluminum
  • 3000 series: Aluminum and steel alloys
  • 4000 series: These are silicon alloyed aluminum
  • 5000 series: These are magnesium alloyed aluminum
  • 6000 series: These are magnesium and silicon alloyed aluminum
  • 7000 series: These are aluminum-zinc alloys
  • 8000 series: These are alloys comprising aluminum and other elements

You can also add selected letters to the end of the aluminum reference digit to indicate the temper types used in the process of fabrication.

Letters F, O, and H refer to alloys tempered through fabrication, annealing, and strain hardening respectively.

Letters T and W refer to aluminum alloys that you have subjected to heat and solution heating treatments respectively.

Some of the shared properties which make aluminum stand out as a superior material for metal stamping include:

  • High flexible and malleable: Aluminum alloys have high elasticity than other types of metal, making them an exceptional choice for stamping complex shapes and parts.
  • High corrosion resistance. Your products will be protected with an aluminum oxide layer that forms naturally with exposure to air.
  • Outstanding electrical and heat conductivity: Aluminum alloys are exceptional thermal and electrical conductors making them the ideal materials for use in applications that require lightweight material.
  • Highly resistant to low temperature: The structural integrity of aluminum alloys rarely disintegrate beyond zero degrees Celsius, unlike alternatives that may succumb to such low temperatures.
  • Higher strength-to-weight ratio: Aluminum alloys are strong and yet extremely light, making them a priority material in the fabrication of automotive, aerospace, and construction parts.
  • Supports shiny and smooth surface finishing.
Stamped Aluminum Parts

Stamped aluminum parts

Stamped aluminum parts

You will end up with a stamped aluminum part after subjecting an aluminum sheet metal through the stamping process.

Stamped aluminum parts are ideal for use in industries where strength and light weight are desirable. Specifically, stamped aluminum parts possess the following properties:

  • Low density
  • Exception resistance to corrosion
  • Lightweight
  • More strength-to-weight ratio

Though there are numerous stamped aluminum parts, the following are the commonly used stamped aluminum parts: Subs, connectors, mandrels, bush rings, plugs, end rings, hangers, caps, packers, pistons, spacers, collars, cones, shoes, sleeves, adaptors, housings, shoes, etc.

Advantages Of Stamping Aluminum.

This material will offer you exceptional properties compared to alternatives like steel, zinc, etc.

At present, stamped aluminum alloys are product leaders in diverse industries including; automotive, shipping, aerospace, etc.

The lightweight nature of aluminum makes it desirable, especially in transport industries.

Other than the specific advantages of aluminum as a material for stamping, the following are some of the benefits of stamped aluminum parts.

High Accuracy

Parts produced through stamping are highly identical and detailed. Aluminum stamping is a superior technique for fabricating parts with complex designs in detailed similarity.

Further, you will not need to subject the stamped aluminum part to secondary machining to enhance its tolerance.

Low Cost Of Production

You will incur significantly lower costs of production just by considering aluminum stamping over other alternative methods.

The speed of producing stamped aluminum is very fast. The technique is also ideal for high-density production at a considerably low labor force.

You can cut on costs associated with material acquisition when you use the aluminum stamping technique because it produces minimal scrap.

Process Automation

Automating the aluminum stamping formation process will enable you to incorporate other complementary processes such as welding, nut insertion, and tapping.

As a result, automation helps lower the cost of labor, and fasten production, producing a high-value end product.

Exceptional Properties

Even though the process of aluminum stamping involves a high number of parts cutting, this technique still delivers products of exceptional quality.

Stamping enhances the physical strength of the aluminum part through structural change in the final product. These parts also possess state of art surface finishing that sustains the productive life of your products for an extended period.

Aluminum Stamping Techniques

Some of the most common techniques include:

Blanking Aluminum

This is a metalworks procedure that cuts the workpiece from its base metal sheet. Blanking is the first stage of aluminum stamping because it eases the metalwork steps in subsequent operations.

Fine blanking is a specialized kind of blanking that utilize high pressure and a V-ring to prevent the outward flow of metal when punched downwards.

It also prevents excessive aluminum plasticity and results in fully sheared, smooth edges.

Blanking vs piercing

Blanking vs piercing

Bending Aluminum

Aluminum bending is a type of metal formation that uses a combination of tensile and compression forces to reform its shape.

You can induce a plastic deformation to bend an aluminum sheet by applying force to the workpiece’s forming die. The opposing bottom die of the workpiece must be fixed in position.

You will achieve the desired curvature by subjecting the workpiece to a downward punch. You can perform the following bending methods in aluminum stamping:

Bottom Pressing

In bottom pressing, you have to subject the workpiece to the punching force until it comes into contact with the U or V-shaped die or the bottom of the die surface. The die also determines the final curvature angle.

Bottom bending applies more force to the workpiece to produce precise bends with little to no probability of spring back.

Air Bending

This technique is also known as partial bending. In contrast to bottom pressing, the workpiece is only bent partially without any contact between the punch press and the die’s bottom surface.

The bending precision of air bending is less accurate than that of bottom bending. However, you can apply more force if you desire to make sharper bends.

Aluminum Metal Coining

Coining compresses the workpiece between die and punch. The desired angle of the workpiece arises from the internal dimensions of the die and the punch which complement each other.

Coining yields a comprehensive force that is 30 times more powerful than other metal bending methods. As a result, it produces precise angles and accurate bending with zero probabilities of spring back.

Sheet metal coining

Sheet metal coining

Wipe Bending/Flanging

In this aluminum bending method, you hold your workpiece between the upper-pressure pad and the bottom die and then push down a protruding material using the forming punch.

The metal flanging technique compensates for potential spring back by modifying the angles of the punch and the die. It is ideal for perpendicular bends.

Forming Aluminum

Aluminum forming closely resembles bending and is useful for economically producing workpieces with complex sections.

You can use aluminum forming to manufacture aluminum parts and products with multiple bends while maintaining a uniform material thickness

Piercing Aluminum

Metal piercing is also referred to as metal punching. Piercing shear the aluminum plate or sheet by creating/boring small shapes such as holes in the workpiece using a die and punch.

The process of aluminum shearing closely resembles tooling and processes used in blanking. You can combine the two steps in one downward punch stroke.

The final step also scraps the unused parts.

Stamping Operations On Aluminum Sheet Metal

There are four main types of stamping operations as described below:

Progressive Die Stamping

progressive die stamping

Progressive die stamping

This technique hosts several workstations with distinct tasks. Consequently, you will first unroll the aluminum sheet and then feed it into the stamping press.

The aluminum sheet proceeds to different stations where the sheet is subject to distinct operations including cutting, bending, and punching. These operations occur either in isolation or in combination.

During this process, the base strip of the part stays connected and the sheet stays in the conveyor belt throughout the process.

The workpiece is pressed down and transformed as it moves from one workstation to the next. As the press withdraws, the workpiece moves horizontally to the next station for succeeding operations.

The sheet proceeds through to the next station as the parts gradually form into the desired shape/product. subsequently, the workpiece proceeds to the final stage where the finished component detaches and exits the process.

You can progressively die stamp aluminum parts and products requiring high repeatability. This technique is exceptionally suited for the high throughput production of complex components and parts at a reduced cost.

Transfer Die Stamping

Transfer die stamping process

Transfer die stampig process

Contrary to progressive die stamping, the workpiece is separated from the aluminum sheet before it is transferred into successive stamping stations.

You can simultaneously produce parts using the transfer die stamping technique as the separated workpieces find their way into different presses.

This technique is ideal for stamping large parts that require deep drawing. Separation of the workpiece in the initial stage disassociates parts conjoining at the base metal sheets. Therefore, you can still perform deep punching without interfering with stamping operations for other parts.

You can also this technique with a process having intermediate steps that would otherwise efficiently operate with early parts separation.

Four-slide Stamping Aluminum

This technique is also known as multi-slide stamping and deviates from traditional aluminum stamping techniques.

Consequently, you align the aluminum rams/slide horizontally and move them toward the workpiece. Four or more tools simultaneously shape the workpiece.

It is ideal for the fabrication of very complex designs as it allows you to perform complex bends and intricate cuts. The individual slides are then either cut, bent, twisted, or formed in horizontal strokes.

Four-slide stamping is highly flexible and allows you to incorporate changes you make in your original design. Its versatility also sets it above traditional stamping techniques in the accommodation of complex parts in the design.

You can use the four-slide stamping technique to fabricate cylindrical parts and parts that require more than 900 bends.

Its initial cost is low compared to other stamping techniques. It is quick and also ideal for cost-saving for raw materials as it will significantly reduce scraps.

Fine Blanking Aluminum

Fine blanking aluminum is a specialized stamping process that you can use to shape your workpiece design that would otherwise be impossible while using a conventional stamping process.

This technique also allows you to pierce very tiny holes which may be near each other in the workpiece.

It uses three high-pressure pads to keep the aluminum sheet stable and restrain it from excessive plasticity while cutting and punching.

Fine blanking operations usually incorporate an impingement/stringer, a V-ring, in the process of punching to reduce outwards movement. The result is a reduced cut edge rollover.

You can use this technique for the production of parts that are completely shared. This is enabled by the high pressure and small clearance capabilities of this technique.

You can run the parts progressively in the press machine and embed other processes such as coining and embossing alongside fine blanking. In addition, fine blanking is a relatively fast process.

Surface Finishing For Stamped Aluminum Parts

To furnish the stamped aluminum with an ideal surface finishing, first, you have to treat your parts with a physical barrier before applying a surface finish of your choice.

Surface finishing for stamped aluminum parts helps protect the parts from corrosion, wear, tear, and other related environmental hazards.

Your product will also have improved physical appearance, durability, thermal and electrical properties as well as resistance to tarnishing.

Surface finishing options for the stamped aluminum parts include:

Electroplating

This is a chemical process that entails coating the stamped aluminum surface with a thin metallic layer using an electric current.

You can use this technique to coat products of extended size variation, from tiny to large-sized products. For this reason, the majority of stamped aluminum products have this type of coating.

It significantly improves the aesthetic appearance and surface value of your product as well as protects it from corrosion.

Electroless Plating

This technique of surface finishing coats your stamped aluminum with a thin metallic film through chemical reaction and not electric current.

Coating your stamped aluminum parts with electroless coating offers even superior properties compared to electroplated products. This method of surface finishing delivers smoother products with outstanding uniformity compared to the electroplating surface finishing method.

Electroless plating is less costly and produces smoother components compared to the former technique.

Powder Coating/Chemical Coating

Chemical coating applies powder to the material’s surface through a compressed air system and then later melts it.

This coating technique is preferably used for coating stamped aluminum parts in the automotive industry.

Powder-coating stamped aluminum parts are ideal for products that are to be color painted. Products subjected to this type of surface finishing exhibit high-level resistance to scratches, cracks, and corrosion.

Metal Anodizing

You can also create an oxide protective film on your stamped aluminum surface through electrolytic oxidation.

This particular surface finishing option can only be used with aluminum metals. However, you have to ensure that the surface of the component you intend to furnish is smooth because you cannot apply metal anodizing on an irregular /rough surface.

It significantly minimizes wear and tear, protects against corrosion, and enhance the strength of your metal parts.

Vacuum Metalizing

The vacuum metalizing process helps with smothering your stamped aluminum parts and products by applying protective metal barriers. You have to insert the part inside a container and apply the treatment through spraying.

This technique is ideal for treating stamped aluminum components and possesses a characteristic mirror-like appearance suitable for great aesthetic designs.

Painting

Painting improves the aesthetic appearance of your products and offers protection against corrosion.

You can either use electrostatic painting, spray painting, electric-conductive paintings, lubricant coating, etc.

Thermal Spraying

You can use thermal spraying for large stamped aluminum parts. This surface treatment option is ideal for reducing surface cracking, peeling, and scratching.

Aluminum Stamping Applications

Aluminum and its alloys are widely used in diverse metal stamping applications and industries, primarily because of their workability and strength.

You can use stamped aluminum in applications where strength and weight are critical factors. Aluminum alloys are some of the lightest among metal alloys and are widely used in metal stamping.

You can use stamped aluminum in the following industries:

  • Aerospace
  • Construction
  • Marine
  • Automotive
  • Medical
  • Electronics
  • Military and defense
  • Food and beverage
  • Lighting, etc.

For all your aluminum stamping needs, contact us now.

Send Your Inquiry Today
Scroll to Top