Aluminium (5052, 5754, 6061, 7075)
Which aluminium alloy to specify for laser cutting, bending, CNC machining and anodising in the MENA climate
Aluminium weighs 2.7 g/cm3, one third of steel, and forms a self-healing oxide layer that resists corrosion without paint. For sheet parts choose EN AW-5754 or 5052 (bendable, weldable, marine grade); for machined parts choose 6061-T6 (strong, anodisable, easy to mill); for high-load parts choose 7075-T6 (strength close to structural steel, not weldable). CutLinq suppliers in Egypt, the UAE and Saudi Arabia laser cut aluminium to 15 mm, bend to 6 mm and machine billets to 300 mm. Upload a DXF or STEP file and receive a binding quote within 12 hours.
Aluminium costs roughly 2.5 to 3 times more per kilogram than mild steel, but a part of equal stiffness weighs about half as much, and it needs no galvanising or powder coating for indoor use. In the Gulf, the choice of alloy and finish matters more than in temperate climates: salt air attacks 6xxx and 7xxx alloys faster than 5xxx, and 45-50°C surfaces accelerate any coating failure.
Alloy selection at a glance
The first digit of the alloy number gives the main alloying element: 5xxx is magnesium, 6xxx is magnesium and silicon, 7xxx is zinc. The temper suffix matters as much as the alloy: 6061-O bends easily but is soft, 6061-T6 is strong but cracks at a tight bend radius.
| Alloy | Temper | Yield strength | Tensile strength | Best for | Weldable | Bendable |
|---|---|---|---|---|---|---|
| EN AW-5052 | H32 | 195 MPa | 230 MPa | Sheet parts, enclosures, tanks | Yes | Excellent, 1 x t radius |
| EN AW-5754 | H22 / H111 | 130-190 MPa | 220-250 MPa | Marine, sheet, tread plate | Yes | Excellent, 1 x t radius |
| EN AW-5083 | H111 | 125 MPa | 275 MPa | Marine, pressure vessels | Yes | Good, 2 x t radius |
| 6061 | T6 | 240 MPa | 290 MPa | Machined parts, frames, anodised | Yes, loses 30-40% strength | Poor, 3-4 x t radius |
| 6082 | T6 | 260 MPa | 310 MPa | Structural extrusions, machined parts | Yes | Poor, 3-4 x t radius |
| 7075 | T6 | 460 MPa | 540 MPa | High-load machined parts, tooling | No | Not recommended |
Process capabilities by thickness
Aluminium is cut with nitrogen on a fiber laser; edge quality is good to 8 mm and acceptable to 15 mm. Bending needs a larger radius than steel and the springback is 2 to 4 degrees, which the press brake operator compensates. Machining is fast: 6061 removes at 3 to 5 times the rate of stainless steel, so complex milled parts are cheaper in aluminium than in any other metal.
| Process | Range | Standard tolerance | Notes |
|---|---|---|---|
| Fiber laser cutting | 0.5-15 mm | ±0.1 mm to 3 mm, ±0.2 mm above | Nitrogen, burr-free to 8 mm |
| Waterjet cutting | 3-150 mm | ±0.1 to ±0.5 mm | For plate over 15 mm |
| Press brake bending | 0.5-6 mm | ±0.5° angle, ±0.2 mm flange | Inner radius 1 x t (5xxx), 3 x t (6061-T6) |
| CNC milling | Billet to 300 mm | ±0.05 mm, ±0.01 mm achievable | Ra 0.8-1.6 µm as milled |
| CNC turning | Bar to 200 mm diameter | ±0.02 mm | 6061, 6082, 2011 free-machining |
| TIG welding | 1-12 mm | - | AC TIG, 5356 or 4043 filler |
| Anodising | Any | Type II 5-25 µm, hard 25-50 µm | 6xxx best colour, 5xxx grey tone |
Corrosion in heat, sand and salt air
Untreated 5754 and 5052 survive outdoors in Cairo and Riyadh for decades with only a dull grey surface. Within 5 km of the coast in Alexandria, Dubai, Jeddah or Dammam, 6061 and 7075 show pitting within a year unless anodised or powder coated. Anodising type II at 15-25 µm is the standard exterior finish; hard anodising at 25-50 µm is used where sand abrasion is expected, such as solar tracker bearings and outdoor equipment housings.
Galvanic corrosion is the most common failure in the region: aluminium bolted directly to stainless or galvanised steel corrodes at the joint when wet. Use isolating washers, nylon sleeves or a zinc-plated fastener and keep the contact dry.
Surface finishes for aluminium
Aluminium is delivered mill finish with a slight roll pattern and possible handling marks. Sheet can be ordered with a protective PE film for parts where the visible face matters, such as signage and interior panels.
- Mill finish: as delivered, Ra 0.4-1.0 µm on sheet, suitable for hidden parts
- Brushed: grain 180-240, Ra 0.6-1.2 µm, used for panels and fascias
- Bead blasted: uniform matte, hides machining marks before anodising
- Anodised type II, natural or black: 15-25 µm, indoor and outdoor
- Hard anodised type III: 25-50 µm, 400-500 HV, wear surfaces
- Powder coated: 60-120 µm, any RAL colour, requires chromate-free pretreatment
Availability in Egypt, the UAE and Saudi Arabia
Sheet in 5052 and 5754 from 1 to 6 mm is stocked in all three countries in 1250 x 2500 and 1500 x 3000 mm formats. 6061-T6 plate from 6 to 100 mm and 6082 extrusions are widely available in the UAE and Saudi Arabia; in Egypt, 6061 plate over 30 mm may add 5 to 10 working days for import. 7075 is stocked by a few suppliers in Dubai and Riyadh in round bar and plate to 60 mm.
Design tips
- Use inner bend radius equal to thickness for 5052 and 5754, and 3 times thickness for 6061-T6 to avoid cracking on the outside of the bend.
- Bend 5xxx alloys with the grain direction crossed at 90° where possible; bending along the rolling direction raises the risk of cracks by roughly a third.
- Keep milled wall thickness at 1 mm or more for walls up to 20 mm tall; thinner walls deflect and chatter.
- Allow 0.02-0.03 mm per side for anodising growth on tight-tolerance bores; hard anodising grows the part by half the coating thickness.
- Specify 6061-T6 rather than 7075 unless yield strength above 250 MPa is required; 7075 costs roughly twice as much and cannot be welded.
- For welded frames, place welds away from load-bearing sections; 6061 loses 30-40% of its strength in the heat-affected zone.
- Order sheet with PE protective film for visible faces; handling scratches on bare aluminium cannot be hidden by anodising.
Applications
| Industry | Example parts | Typical material |
|---|---|---|
| Signage and facades | Letter faces, cladding panels, louvres | EN AW-5754 2-3 mm, anodised or powder coated |
| Solar | Module frames, tracker brackets, cable clips | 6063-T6 extrusion, 6061-T6 plate 4-8 mm |
| Electronics and electrical | Heat sinks, enclosures, control panels | 6061-T6 machined, 5052 2 mm bent |
| Automotive | Brackets, spacers, intake parts | 6061-T6, 6082-T6 billet |
| Food and pharma | Trays, guides, machine covers | 5754 3 mm, anodised 6061 |
| Marine and coastal | Deck fittings, hatches, ladders | 5083-H111 4-8 mm |
| Machinery | Fixture plates, gantry parts, jigs | 6082-T6 plate 10-50 mm, 7075 for high load |
Pricing and lead time
Three factors drive the price of an aluminium part: material grade and thickness (7075 costs roughly twice 6061, and 6061 plate over 25 mm costs 20-30% more per kilogram than sheet), machining or cutting time, and the finish (anodising typically adds 15-30% to a small machined part). Laser cut and bent sheet parts ship in 3 to 5 working days from Cairo, Dubai, Riyadh or Jeddah; CNC machined parts in 5 to 8 working days; anodised or powder coated parts add 3 to 5 working days. Local courier delivery is same or next day for parts under 20 kg.
Frequently asked questions
EN AW-5754 or 5083. Both are marine grades that resist salt air without coating. Avoid bare 6061 and 7075 within a few kilometres of the coast, or anodise them at 20-25 µm.
Upload your DXF or STEP file to CutLinq and receive a binding quote for aluminium parts within 12 hours.