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The Difference Between Aluminum Thin Wall Pipe and Thick Wall Pipe

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Aluminum alloy pipes are widely used in industry and construction, and there are obvious differences between thin-walled pipes and thick-walled pipes in terms of wall thickness, strength, weight, cost, performance and use.

Understanding the different characteristics of aluminum alloy thin-walled and thick-walled pipes can help you make informed decisions when designing and selecting materials to meet project needs and achieve optimal performance.

thin wall vs thick wall

Definition of thin wall pipe and thick wall pipe

  • Aluminum thin wall pipe
    Aluminum thin wall pipe
    • Aluminum alloy thin-walled pipes refer to aluminum alloy pipes with relatively thin wall thickness, and usually the ratio of wall thickness to pipe diameter is small. This type of pipe is suitable for applications that require light weight and low strength requirements, and can effectively reduce the weight of the structure.
    • Minimum wall thickness: 0.25mm.
  • Aluminum thick wall pipe
    Aluminum thick wall pipe
    • Refers to aluminum alloy pipes with relatively thick wall thickness, and the ratio of wall thickness to pipe diameter is large. This type of pipe is usually used in situations that require higher strength and pressure resistance, and can withstand greater external pressure and load.
    • Maximum wall thickness: 100-250mm.

The difference in alloy selection

Alloy
series
Commonly used
alloy grades
thin wall
tube
thick wall
tube
Features
10001050, 1100Better ductility and formability
20002024, 2014High strength, excellent fatigue
strength and processability
30003003, 3004Good corrosion resistance and
weldability
50005052, 5083High strength and good corrosion
resistance
60006061, 6063Excellent mechanical properties and
strength
70007075Extremely high strength and
hardness

Performance differences

Features and
performance
Thin wall tube Thick wall tube
Strength and stiffnessLower strength and stiffness, suitable
for lightweight structures or
applications with higher weight
requirements
High strength and stiffness, suitable
for occasions that need to bear
larger loads or provide structural
support.
Flexibility and
deformation
More flexible, more prone to
deflection and deformation,
providing greater flexibility and
adaptability in certain applications.
It has higher stiffness, stronger
resistance to flexibility and
deformation, and is more suitable
for occasions requiring stability and
support.
Pressure
resistance
Generally has a low pressure-
bearing capacity and is not suitable
for withstanding high-pressure
liquids or gases.
Able to withstand greater pressure,
suitable for high-pressure liquid or
gas transmission systems.
Corrosion
resistance
Because the material is thin, it may
perform poorly in corrosive
environments and requires
additional protection.
Because the material is thicker, it
generally has better corrosion
resistance and is suitable for harsh
environments.
manufacturing
cost
Thin-walled tubes use relatively less
material and generally have lower
production costs.
The production cost of thick-walled
pipes is relatively high because
more material is required, but in
some specific engineering
situations, thick-walled pipes may
provide a more economical
solution.

Manufacturing process difference

Thick-walled pipes are relatively easy to process, but the influence of wall thickness also needs to be considered and appropriate processing techniques selected to ensure their internal and external quality.

Thin-walled tubes are more difficult to process because they are easily deformed due to their thin walls. Higher-precision processing equipment and technology are required in processes such as extrusion and stretching to ensure their dimensional accuracy and surface quality.

Application areas and aluminum tube selection

Thin-walled tubes generally have a high strength-to-weight ratio and are suitable for applications requiring lightweight design, such as in the aerospace and automotive industries. Its lightweight characteristics enable it to meet structural strength requirements while reducing the overall weight.

Application areas and aluminum tube selection

Thick-walled pipes are usually used in engineering structures because of their large load-bearing capacity and are suitable for applications that require higher strength and pressure resistance, such as building support structures, mechanical equipment and other fields.

Thick-walled pipes

Application
areas
Application site thin wall
tube
thick wall
tube
Commonly used
alloys
Aerospaceaircraft frame2024, 7075
landing gear6061, 7075
tank3003, 5052,
carSuspension parts6061, 6063
engine parts5083, 5052
heat exchanger1100, 3003
shipmast5083, 6061
railing5052
architecturetruss frame6061
scaffold6063
furnitureframe6061, 6063
Bracket6061, 6063
leg6061, 6063,
heat sinkElectronic component1050, 1220
Bus pipe1060, 6101
heat exchanger3003, 6063
pipelineirrigation pipes-
oil and gas pipeline-
pressure vessel piping-

※ 8 Tips for the production of thin wall aluminum tube pipe

  • When sampling, it is necessary to check according to the drawing size, strictly control the wall thickness of the aluminum profile, and use a vernier caliper to check whether it is qualified.
  • The molds are polished and improved to improve the surface quality of the aluminum profiles, and nitriding treatments are performed regularly to ensure sufficient preparation for the next production.
  • Adjust the level of the discharging table and cooling bed before production to prevent the aluminum profiles from being scratched during movement and ensure product quality.
  • Control the temperature during the extrusion process, including the temperature of the aluminum billet, container and mold, and adjust the speed according to the extrusion surface quality and process progress to ensure a smooth product surface.
  • Pay attention to the surface quality and initial runout from the discharge port to the cooling bed to avoid defects such as scratches on the bottom surface, and adjust the height of the support wheel to prevent deformation of the aluminum profile.
  • Reasonably arrange the spacing between aluminum profiles on the cooling bed to avoid collisions and scratches and ensure product quality.
  • Control the straightening and sawing processes to avoid deformation and surface defects of aluminum profiles, and pay attention to cleaning aluminum chips to keep the product surface clean.
  • Use special lifting tools to install the profile frame, keep intervals and observe the end quality to improve surface quality and avoid scratches, and ensure ventilation and aging conditions of the aluminum profile.