A practical comparison of the most common CNC aluminum grades — strength, machinability, corrosion resistance, and cost.
Aluminum is the most popular material for CNC machining. It is lightweight, easy to machine, and relatively inexpensive. But not all aluminum is the same. The three most common grades for CNC machining are 6061, 7075, and 5052.
Quick Comparison Table
| Property | 6061-T6 | 7075-T6 | 5052-H32 |
|---|---|---|---|
| Tensile Strength | 310 MPa | 572 MPa | 228 MPa |
| Yield Strength | 276 MPa | 503 MPa | 193 MPa |
| Hardness (Brinell) | 95 | 150 | 60 |
| Machinability | Excellent | Good | Excellent |
| Corrosion Resistance | Very Good | Good | Excellent |
| Weldability | Good | Fair (with heat treat) | Excellent |
| Cost | Low | Medium-High | Low |
6061-T6: The General-Purpose Workhorse
6061-T6 is the most widely used aluminum alloy for CNC machining. It offers an excellent balance of strength, machinability, corrosion resistance, and cost.
- Best for: General structural parts, brackets, enclosures, automotive components, recreational equipment
- Why choose it: Easy to machine, welds well, anodizes beautifully, widely available at low cost
- Not ideal for: Extremely high-stress applications where 7075 would be needed
7075-T6: The High-Strength Option
7075-T6 is one of the strongest aluminum alloys available. It rivals many steels in strength-to-weight ratio.
- Best for: Aerospace components, high-stress brackets, bicycle frames, firearm parts, high-performance automotive
- Why choose it: Highest strength among common aluminum grades
- Considerations: More expensive, slightly harder to machine, less corrosion resistant than 6061 — often requires anodizing for protection
5052-H32: The Corrosion-Resistant Choice
5052 is known for excellent corrosion resistance, especially in marine environments. It is also highly formable.
- Best for: Marine hardware, sheet metal parts, fuel tanks, signage, outdoor enclosures
- Why choose it: Best corrosion resistance among these grades, excellent for forming and bending
- Considerations: Lower strength than 6061 or 7075, not ideal for high-stress structural parts
Other Aluminum Grades Worth Knowing
- 2024: High strength, poor corrosion resistance — aerospace structural parts
- 3003: Pure aluminum, excellent formability — cooking utensils, chemical equipment
- 6082: European equivalent to 6061, slightly higher strength
How to Choose the Right Aluminum Grade
Ask yourself these questions:
- How much strength do I need? — 7075 for high stress, 6061 for general, 5052 for low stress
- Will it be exposed to moisture or chemicals? — 5052 for marine/chemical, 6061 for general outdoor
- Will it be welded? — 6061 and 5052 weld well, 7075 is trickier
- What is my budget? — 6061 and 5052 are most cost-effective
- Does it need anodizing? — All three anodize well; 6061 produces the most attractive clear anodize
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