What Is Aircraft Grade Aluminum?

Aluminum has been a game-changer in the aerospace industry for over a century. Its unique combination of light weight, strength, corrosion resistance, and workability makes it ideal for aircraft manufacturing. But not all aluminum is the same. Only certain high-performance alloys meet the demanding requirements of the aviation world. These specialized materials are commonly known as aircraft grade aluminum.

In this SEO-focused article from sasaalloy, we explore what aircraft grade aluminum is, the most common grades used, their key properties, and why this material is critical to modern aviation and advanced engineering projects.

1. What Is Aircraft Grade Aluminum?

Aircraft grade aluminum refers to high-strength, lightweight aluminum alloys specifically designed to meet the rigorous demands of aerospace applications. These alloys offer excellent strength-to-weight ratios, fatigue resistance, corrosion resistance, and formability, making them ideal for aircraft structures, fuselages, wing components, and more.

Unlike general-purpose aluminum used in construction or packaging, aircraft grade aluminum is engineered and certified to comply with aerospace industry standards such as those from AMS (Aerospace Material Specifications) and MIL (Military Standards).

2. Why Use Aluminum in Aircraft?

The key reason aluminum is favored in aircraft design is its low density and high strength.

Key advantages:

• Lightweight: Reduces fuel consumption and improves payload capacity

• Strong: Withstands high stress loads during flight

• Corrosion-resistant: Suitable for changing altitudes and harsh environments

• Malleable: Easy to form into aerodynamic shapes

• Weldable and machinable: Simplifies manufacturing and repair

Aircraft grade aluminum provides the balance of durability and weight reduction that no other material can match at a competitive cost.

3. Common Aircraft Grade Aluminum Alloys

Several specific aluminum alloys have become standards in the aerospace industry. These are mainly from the 2xxx, 6xxx, and 7xxx series.

1. 2024 Aluminum

• Primary alloying element: Copper

• Strength: Very high

• Corrosion resistance: Fair (often clad for protection)

• Uses: Fuselages, wing skins, and structural components

2. 6061 Aluminum

• Primary alloying elements: Magnesium and silicon

• Strength: Moderate to high

• Corrosion resistance: Excellent

• Workability: Very good

• Uses: Aerospace fittings, fuel lines, and structural tubing

3. 7075 Aluminum

• Primary alloying elements: Zinc, magnesium

• Strength: Extremely high

• Corrosion resistance: Moderate (improved in 7075-T73)

• Uses: Wing spars, aircraft frames, landing gear

These grades are often supplied in T6 or T73 tempers, which offer excellent hardness and mechanical stability.

sasaalloy provides all major aircraft-grade aluminum alloys with certifications for aerospace and industrial applications.

4. Chemical Composition of Aircraft Grade Alloys

Let’s take a quick look at the general chemical makeup of some key aircraft-grade aluminum alloys:

2024 Aluminum

• Copper: ~4.4%

• Magnesium: ~1.5%

• Manganese: ~0.6%

• Balance: Aluminum

6061 Aluminum

• Magnesium: ~1.0%

• Silicon: ~0.6%

• Copper: ~0.28%

• Balance: Aluminum

7075 Aluminum

• Zinc: ~5.6%

• Magnesium: ~2.5%

• Copper: ~1.6%

• Balance: Aluminum

These alloying elements are carefully chosen to maximize tensile strength, fatigue resistance, and heat treatability.

5. Mechanical Properties of Aircraft Grade Aluminum

Aircraft grade aluminum offers exceptional mechanical strength. Below are typical ranges for 7075-T6:

• Ultimate tensile strength: 570–620 MPa

• Yield strength: 500–540 MPa

• Elongation: ~11%

• Hardness: ~150–160 Brinell

• Modulus of elasticity: ~71 GPa

This level of performance, combined with low density (2.8 g/cm³), makes these alloys ideal for high-strength, weight-critical components.

6. Heat Treatment and Tempers

Aircraft-grade aluminum alloys are often heat treated to improve mechanical properties. The most common tempers include:

• T3: Solution heat-treated, cold worked

• T6: Solution heat-treated, aged for hardness

• T73: Over-aged temper for stress corrosion resistance

• O: Annealed for maximum softness and formability

Each temper provides a different balance of strength, ductility, and corrosion resistance, depending on the intended application.

7. Applications of Aircraft Grade Aluminum

Aircraft-grade aluminum is not just limited to planes. Its unique properties make it suitable for:

1. Aerospace Components

• Fuselages

• Wings and spars

• Cockpit frames

• Engine cowlings

2. Defense and Military Use

• Fighter jets

• UAVs

• Missile structures

• Transport aircraft

3. Automotive and Motorsport

• Chassis components

• Roll cages

• High-performance frames

4. Marine and Industrial Equipment

• High-strength fittings

• Lightweight platforms

• Portable structural assemblies

At sasaalloy, we supply certified aircraft-grade aluminum to OEMs, MROs, and manufacturers worldwide.

8. Corrosion Resistance and Surface Protection

Some aircraft-grade aluminum alloys like 2024 and 7075 are not naturally corrosion-resistant. To protect them, they are often:

• Alclad: Coated with a thin layer of pure aluminum

• Anodized: Enhanced corrosion resistance and surface hardness

• Painted or sealed: For long-term protection

sasaalloy offers pre-treated or coated aircraft aluminum for immediate use in structural and exposed applications.

9. Fabrication and Machining

Aircraft grade aluminum is:

• Easily machinable in T6 condition

• Weldable (6061 is preferred for welding)

• Formable in annealed or O-temper

• Compatible with riveting, bolting, and mechanical fasteners

It is essential to choose the right alloy and temper for the fabrication method to avoid cracking or reduced mechanical performance.

10. Why Aircraft Grade Aluminum Matters Today

As industries aim to build lighter, safer, and more fuel-efficient systems, aircraft-grade aluminum is becoming more relevant—not just in aerospace, but also in:

• Electric vehicle frames

• Lightweight rail systems

• Spacecraft and satellites

• Next-generation drones

Aluminum remains a strategic metal, balancing performance and cost-effectiveness in advanced engineering.

11. Why Choose Aircraft Grade Aluminum from sasaalloy

sasaalloy is your trusted global supplier of certified aircraft-grade aluminum products. We offer:

• Wide selection of 2024, 6061, 7075, and other aerospace-grade alloys

• Mill certifications and AMS-compliant products

• Sheet, plate, bar, rod, tube, and extrusion forms

• Custom cutting, machining, and logistics support

• Fast delivery and global export capability

Whether you are manufacturing structural airframes or high-performance vehicles, sasaalloy delivers consistent quality you can rely on.

12. Conclusion: What Is Aircraft Grade Aluminum?

Aircraft grade aluminum refers to a class of high-strength, lightweight aluminum alloys developed for demanding aerospace applications. Alloys such as 2024, 6061, and 7075 offer a blend of mechanical strength, corrosion resistance, and low density, making them ideal for both air and land use.

Understanding the properties and differences between aircraft-grade alloys helps engineers and manufacturers choose the right material for their high-performance projects.