Aluminum Tube Tolerances

Why our rejection rate is so low.

Understanding how companies inspect, pack and ship aerospace profiles is very important. Structural ships that are transported in flimsy tubes or cardboard is a recipe for disaster and the risk of exposure to damage is high. Aircraft Extrusion Company not only understands this concept, but aggressively addresses the task with a solution to fit all of our customers needs.



PLACEHOLDER

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
*Except for T3510, T4510, T6510 and T8510 tempers.
†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
*Except for T3510, T4510, T6510, and 18510 tempers.
†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

Seamless Drawn Round Tubing

Straightness*
Specified Outside Diameter Or Width Allowable Deviation From Straight, Inches
In Each Foot Of Length In Total Length Of Piece
Under 0.375 .500 .500 x length, ft
0.375 - 5.999 .010 .010 x length, ft
6.000 & larger .020 .020 x length, ft
Not applicable to annealed (-0) temper tube.
Not applicable to lengths under 10 feet.

Seamless Drawn Square & Rectangular Tubing

Corner Radii
Specified Radius Allowable Deviation
From Specified Inches
Sharp corners ±1/64
Under 0.188 ±1/64
0.188 and over ±10%

Seamless Drawn 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
All Alloys All Alloys
Less Than 0.500 .003 .006
0.501 - 1.000 .004 .008
1.001 - 2.000 .005 .010
2.001 - 3.000 .006 .012
3.001 - 5.000 .008 .016
5.001 - 6.000 .010 .020
6.001 - 8.000 .015 .030
8.001 - 10.000 .025 .040
10.001 - 12.000 .025 .050
*Example: The width tolerance of a 1x3 inch rectangle is plus and minus .008 inch and the depth tolerance is plus and minus .012 inch.
See notes under round extruded.

Seamless Drawn Square & Rectangular Tubing

Diameter
Specified Wall
Thickness Inches
Deviation Of Mean
From Specified
Maximum Deviation
At Any Point
1100 5052
3003 5086
2014 6061
2024 6063
7075
0.010 - 0.035 .002 .002 Plus and
minus 10%
of mean wall
thickness
Min. ± .003
0.036 - 0.049 .003 .003
0.050 - 0.083 .004 .004
0.084 - 0.120 .005 .006
0.121 - 0.202 .006 .008
0.204 - 0.300 .008 .012
0.301 - 0.375 .015 .020
0.376 - 0.500 .020 .030

Seamless Pipe

Nominal Pipe Size Inches Diameter Tolerances Wall Thickness Tolerances
Deviation Of Mean From Nominal Maximum Deviation At Any Point Maximum Deviation At Any Point
Percent of Nominal Wall
Schedules 5 & 10 Schedules 20 & Over Schedules 5 & 10 Schedules 20 & Over
Plus Minus Plus Minus Plus Minus Plus Minus
1/8 - 1 1/2 IPS .015" .031" .015" .031" 12.5% 12.5% 8% (WT) 12.5%
2 - 4 IPS .031" .031" 1% 1% 12.5% 12.5% 8% (WT) 12.5%
5 - 8 IPS .062" .031" 1% 1% 12.5% 12.5% 8% (WT) 12.5%
10 - 12 IPS .093" .031" 1% 1% 12.5% 12.5% 8% (WT) 12.5%

How We Inspect

All material is fully inspected for dimensional correctness prior to stocking including a visual acceptance for dings, scratch or dents. The certification is also inspected to ensure that material meets the requested specification, with no exceptions, and that the heat lot and specification on material also conforms with the mill test report.


How We Pack

We take pride in our extruded shapes and tubes, and the way we pack them. Bad packing is one of the most common area for damage. It benefits no one and everyone loses. All our extrusions are packed in either a sturdy .180" thick tube for short length up to 6ft. Longer pieces are shipped in either our 5" flex-form packaging or our larger 4 x 8 packaging.

Flex-form is densely laminated paperboard panels with paper separations allowing the panels to be folded to create a finished product. Flex-form comes in varying dimensions including squares, rectangles, L-shapes, U-shapes, and triangles.

The material is packed suitable for both domestic and international shipments. For larger orders over 150Lbs. we export in wood crates.


How We Ship

Flex-form containers are a superior alternative to wood crates, tri-wall boxes, spiral wound tubes and other solid fiber packaging products. Over 40,000 Flexform containers have been shipped worldwide without a single freight issue.


Our Flex-Form Cartons

Flex-form containers are a superior alternative to wood crates, tri-wall boxes, spiral wound tubes and other solid fiber packaging products. Over 40,000 Flexform containers have been shipped worldwide without a single freight issue.

  1. Stronger and more dense than other flat sheet packaging products
  2. Stronger hinge does not tear or break during packaging or shipping
  3. Has greater beam strength than tri-wall boxes or spiral wound tubes
  4. Superior puncture resistance
  5. Not brittle under stress, like wood
  6. Are exempt from IPPC rules and regulations for exportation
  7. Environmentally friendly and can be disposed of in standard refuse or recycled

Our Capabilities


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

Some of Our Clients