Forming Tolerance

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Forming and Bend Tolerances for 2024 and 7075

We supply airrcaft quality tubing from all area's of the aerospace industries including such companies like Embraer and Spacex.

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

Minimum Standard
Bend radius requirements for aluminum alloy sheet
Thickness in inches 2219-0, 5052-0, 6061-0 2219-T42, 2024-0, 6061-T4 2219-T31, 2219-T34 7075-0, 7178-0 2219-T62, 2219-T81, 2024-T3, 2024-T4, 6061,T6 7075-T6, 7178-T6, 2024-T36 2219-T87, 2024-T85
0.016 0.030 0.030 0.030 0.030 0.060 0.090 0.250
0.020 0.030 0.030 0.060 0.030 0.060 0.090 0.250
0.025 0.030 0.060 0.060 0.060 0.090 0.120 0.310
0.032 0.030 0.060 0.060 0.060 0.120 0.160 0.440
0.036 0.030 0.060 0.090 0.060 0.160 0.190 0.500
0.040 0.060 0.060 0.090 0.060 0.160 0.190 0.560
0.045 0.060 0.090 0.090 0.090 0.190 0.250 0.620
0.050 0.060 0.090 0.120 0.090 0.190 0.250 0.620
0.056 0.060 0.120 0.120 0.120 0.220 0.280 0.620
0.063 0.060 0.120 0.160 0.120 0.220 0.310 0.750
0.071 0.090 0.120 0.160 0.120 0.280 0.380 0.880
0.080 0.090 0.160 0.190 0.190 0.340 0.440 1.120
0.090 0.090 0.190 0.190 0.190 0.380 0.500 1.250
0.100 0.120 0.220 0.250 0.220 0.440 0.620 1.750
0.112 0.120 0.250 0.340 0.280 0.500 0.750 -
0.125 0.120 0.250 0.500 0.280 0.560 0.880 -
0.140 0.120 0.340 0.560 0.380 0.620 1.000 -
0.160 0.160 0.380 0.620 0.440 0.750 1.120 -
0.180 0.190 0.440 0.690 0.500 0.880 1.250 -
0.190 0.280 0.500 0.750 0.560 0.880 1.250 -
+/- 0.01 for 0.03 to 0.06 | +/- 0.030 for 0.090 and larger

Quality

widerOur 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.