Aluminum has always been considered the leading material for prototype tooling because of cost and availability, ease of machining and dependability for several thousand shots.

Now aluminum has penetrated into production tooling for cost savings benefits in cycle time improvements, improved machining and polishing performance and better process efficiency. Most moldmakers and molders have limited experience with aluminum tooling—some favorable and some not. Those who have enjoyed the success of aluminum tooling are reaping its benefits.

Several important facts about aluminum need to be conveyed for the moldmaking process.

When compared to P20 steel, aluminum:

Has four to five times better thermal heat transfer. With better thermal conductivity, the position and number of water lines is less critical, allowing for the placement of additional ejector pins where needed.

Has demonstrated productivity improvement of 20 to 30 percent in cycle time savings.

Has outstanding machining and polishing characteristics. With some high strength aluminum alloys, machining ratings are as high at eight times faster than steel.

Does not have to be sent out for heat treating or stress relieving. All of that is done during its manufacturing process.

It needs to be stated that while aluminum is lighter in weight and faster machining than steel, all aluminum alloys are not created equal. This article is to help differentiate several aluminum alloys used in today’s moldmaking shops and assist toolmakers in selecting the appropriate aluminum for their production tool requirements.