Forming Tolerance
Aluminum Tube Tolerances
A question we get asked a lot at Aircraft Extrusion Company, "what is the bend tolerance for aluminum sheet and why is my material 2024-T42 instead of 2024-T3 or 7075-T62 instead of 7075-T6.". Basically, aircraft sheet bend tolerance that are detailed in Boeing data release specification BAC5300. The difference between 2024-T3 v's 2024-T42, and 7075-T6 v's 7075-T62 is that in the case of both 2024-T3 and 7075-T6 whether it is bare or alclad material, the temper is referred to as a "mill temper" which means that the manufacturer (mill) heat treated material when it was produced to the desired temper. In situations where the sheet material is unable to be formed in the T3 or T6 temper due to the bend radius being too tight, then material will either have to be annealed to the "0" temper or the "W" condition. After forming material in the "0" or "W" condition material is then aged to the desired temper. The mechanical properties of T3 v's T42 and T6 v's T62 are the same, the "2" on the end denotes that material has received additional heat treatment. The bend tolerance is basically the allowable radius you can form aircraft sheet before it starts to crack. In most cases if you are unable to form in the original temper you will have to anneal to the O temper, form your parts then re-heat treat.
Table of Extrusion Tolerances
| Diameter | ||||
|---|---|---|---|---|
| Specified Diameter Inches | Deviation Of Mean From Specified* | Maximum Deviation At Any Point From Specified† | ||
| Inches - Plus and Minus | Inches - Plus and Minus | |||
| Alloys 5083 5086 5454 | All Other Alloys | Alloys 5083 5086 5454 | All Other Alloys | |
| 0.500 - 0.999 | .015 | .010 | .030 | .020 |
| 1.000 - 1.999 | .018 | .012 | .038 | .025 |
| 2.000 - 3.999 | .023 | .015 | .045 | .030 |
| 4.000 - 5.999 | .038 | .025 | .075 | .050 |
| 6.000 - 7.999 | .053 | .035 | .113 | .075 |
| 8.000 - 9.999 | .068 | .045 | .150 | .100 |
| 10.000 - 11.999 | .083 | .055 | .188 | .125 |
| 12.000 - 13.999 | .098 | .065 | .225 | .150 |
| 14.000 - 15.999 | .113 | .075 | .263 | .175 |
| 16.000 - 17.999 | .128 | .085 | .300 | .200 |
†Not applicable in the annealed (0) temper or if wall thicknesa ia lean than 21/2% of the OD.
Seamless Extruded Round Tubing
| Wall Thickness | |||||||||
|---|---|---|---|---|---|---|---|---|---|
| Specified Wall Thickness Inches | Deviation Of Mean From Specified | Maximum Deviation At Any Point | |||||||
| Under 1.250 OD | 1.250-2.999 OD | 3.000-4.999 OD | 5.000 & Over | ||||||
| Alloys 5083 5086 5456 | All Other Alloys | Alloys 5083 5086 5456 | All Other Alloys | Alloys 5083 5086 5456 | All Other Alloys | Alloys 5083 5086 5456 | All Other Alloys | All Alloys | |
| Under 0.047 | .009 | .006 | - | - | - | - | - | - | Plus and Minus 10% of mean thickness Max. ±.060 Min. ±.010 |
| 0.047 - 0.061 | .011 | .007 | .012 | .008 | .012 | .008 | .015 | .010 | |
| 0.062 - 0.077 | .012 | .008 | .012 | .008 | .014 | .009 | .018 | .012 | |
| 0.078 - 0.124 | .014 | .009 | .014 | .009 | .015 | .010 | .023 | .015 | |
| 0.125 - 0.249 | .014 | .009 | .014 | .009 | .020 | .013 | .030 | .020 | |
| 0.250 - 0.374 | .017 | .011 | .017 | .011 | .024 | .016 | .038 | .025 | |
| 0.375 - 0.499 | - | - | .023 | .015 | .032 | .021 | .053 | .035 | |
| 0.500 - 0.749 | - | - | .030 | .020 | .042 | .028 | .068 | .045 | |
| 0.750 - 0.999 | - | - | - | - | .053 | .035 | .083 | .055 | |
| 1.000 - 1.499 | - | - | - | - | .068 | .045 | .098 | .065 | |
| 1.500 - 2.000 | - | - | - | - | - | - | .113 | .075 | |
Seamless Extruded Square & Rectangular Tubing
| Diameter (Width or Depth) | ||||
|---|---|---|---|---|
| Specified Width or Depth Inches | Deviation of Width or Depth at Corners From Specified* | Deviation of Width or Depth Not At Corners From Specified† | ||
| Inches - Plus and Minus | Inches - Plus and Minus | |||
| Alloys 5083 5086 5454 | All Other Alloys | Alloys 5083 5086 5454 | All Other Alloys | |
| 0.500 - 0.749 | .018 | .012 | .030 | .020 |
| 0.750 - 0.999 | .021 | .014 | .030 | .020 |
| 1.000 - 1.999 | .027 | .018 | .038 | .025 |
| 2.000 - 3.999 | .038 | .025 | .053 | .035 |
| 4.000 - 4.999 | .053 | .035 | .068 | .045 |
| 5.000 - 5.999 | .068 | .045 | .083 | .055 |
| 6.000 - 6.999 | .083 | .055 | .098 | .065 |
| 7.000 - 7.999 | .098 | .065 | .108 | .075 |
| 8.000 - 8.999 | .113 | .075 | .123 | .085 |
| 9.000 - 9.999 | .128 | .085 | .143 | .095 |
| 10.000 - 10.999 | .143 | .095 | .158 | .105 |
| 11.000 - 12.000 | .158 | .105 | .173 | .115 |
†Not applicable in the annealed (0) temper or if wall thickness is less than 2 1/2% of the OD.
Seamless Drawn Round Tubing
| Diameter | |||
|---|---|---|---|
| Specified Diameter Inches | Deviation Of Mean From Specified | Maximum Deviation At Any Point From Specified | |
| Inches - Plus and Minus | Inches - Plus and Minus | ||
| All Alloys | Alloys 1100 5052 3003 5086 | Alloys 2014 6061 2024 6063 7075 | |
| Less Than 0.500 | .003 | .003 | .006 |
| 0.501 - 1.000 | .004 | .004 | .008 |
| 1.001 - 2.000 | .005 | .005 | .010 |
| 2.000 - 3.000 | .006 | .006 | .012 |
| 3.001 - 5.000 | .008 | .008 | .016 |
| 5.001 - 6.000 | .010 | .010 | .020 |
| 6.001 - 8.000 | .015 | .015 | .030 |
| 8.001 - 10.000 | .025 | .020 | .040 |
| 10.001 - 12.000 | .025 | .025 | .050 |
Seamless Drawn Round Tubing
| Wall Thickness | |||
|---|---|---|---|
| Specified Wall Thickness, Inches | Tolerance - Inches, Plus And Minus | ||
| Deviation of Mean From Specified | Max Deviation At Any Point | ||
| 1100 3033 5052 5086 | 2024 6061 6063 7075 |
||
| 0.010 - 0.035 | .002 | .002 | Plus and minus 10% of specified wall thickness. mm. ± 0.003 |
| 0.036 - 0.049 | .003 | .003 | |
| 0.050 - 0.083 | .004 | .004 | |
| 0.084 - 0.120 | .005 | .006 | |
| 0.121 - 0.203 | .006 | .008 | |
| 0.204 - 0.300 | .008 | .012 | |
| 0.301 - 0.375 | .015 | .020 | |
| 0.376 - 0.500 | .020 | .030 | |
Quality
Our AS9100 certified quality management system allows us to provide the consistency and traceability required in the aviation industry. We pride ourselves on our document control procedures which ensure all required documentation is controlled, distributed, and maintained appropriately. Our planning and scheduling department ensures that projects flow smoothly through the shop and all required materials are available when needed.
In-House Design Team
We are proficient in SolidWorks and Autocad and can translate engineering drawings and designs. We work with designers, engineers and buyers daily. Provide cost analysis and feasibility studies for commercial and aerospace grade aluminum. Providing over the phone quotes on most custom from simple to complex. We can discuss feasibility, die charges and lead times for Extrusions and tubes.
We talk Extrusion
The worlds largest dedicated company of aluminum profiles in 2024 and 7075. At Aircraft Extrusion Company, extruded shapes profiles and tubes is our focus. With over the past 15 years of over consolidation of metal companies the experts have gone. With no clear leader in aerospace profiles, no company specializing in the design, manufacture and supplier of aerospace extrusions and special shapes. We offer design information, tolerance, specifications and heat treating information, forming and bending capabilities to a wide range of customers ranging from Boeing, Airbus, Spacex to vintage aircraft groups building B-17 or experimental aircraft.
Custom Design
We work with you to develop the most cost-effective and optimal design for your product with our design engineers and with custom-made dies.
Rolled Extrusions
New advanced equipement and design development aircraft extrusion company can now offer rolled extrusions.
CNC Machining
CNC Milling up to 4ft x 12ft parts, including seat tracks and secondary oporations aluminum profiles in 7075 and 2024
Seat Tracks
Standard and none-standard types of seat tracks in stock. We also provide milling services for the round slots on the tracks.
Roll-Form Stringers
A great selections of formed angles, channels, hats and tee's in both 2024 Clad and 7075 Clad. In addition, we also have forming capabilities
Cutting
We cut to size 7075 and 2024 extruded profiles, sheet, plate and form section. In-house cutting ops help reduce time, cost and shipping weights