Aluminium Fabrications

Aluminium is the most abundant metal in the Earth's crust, and the third most abundant element therein, after oxygen and silicon. It makes up about 8% by weight of the Earth’s solid surface. Aluminium is too reactive chemically to occur in nature as a free metal. Instead, it is found combined in over 270 different minerals. The chief source of aluminium is bauxite ore. Aluminium is remarkable for its ability to resist corrosion (due to the phenomenon of passivation) and its low density. Structural components made from aluminium and its alloys are vital to the aerospace industry and very important in other areas of transportation and building. Its reactive nature makes it useful as a catalyst or additive in chemical mixtures, including being used in ammonium nitrate explosives to enhance blast power.

Corrosion resistance can be excellent due to a thin surface layer of aluminium oxide that forms when the metal is exposed to air, effectively preventing further oxidation. The strongest aluminium alloys are less corrosion resistant due to galvanic reactions with alloyed copper. This corrosion resistance is also often greatly reduced when many aqueous salts are present however, particularly in the presence of dissimilar metals.

Although aluminium is an extremely common and widespread element, the common aluminium minerals are not economic sources of the metal. Almost all metallic aluminium is produced from the ore bauxite (AlO_x(OH)_3-2x). Bauxite occurs as a weathering product of low iron and silica bedrock in tropical climatic conditions. Large deposits of bauxite occur in Australia, Brazil, Guinea and Jamaica but the primary mining areas for the ore are in Ghana, Indonesia, Jamaica, Russia and Surinam. Smelting of the ore mainly occurs in Australia, Brazil, Canada, Norway, Russia and the United States.

Pure aluminium has a low tensile strength, but when combined with thermo-mechanical processing, aluminium alloys display a marked improvement in mechanical properties, especially when tempered. Aluminium alloys form vital components of aircraft and rockets as a result of their high strength-to-weight ratio. Aluminium readily forms alloys with many elements such as copper, zinc, magnesium, manganese and silicon (e.g., duralumin). Today, almost all bulk metal materials that are referred to loosely as "aluminium," are actually alloys. For example, the common aluminium foils are alloys of 92% to 99% aluminium.