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Home Xometry Community Industrial Design Switch 6061-T6 for 5052-H32 (bending), weight vs strength

Switch 6061-T6 for 5052-H32 (bending), weight vs strength

0
K
2

Hi everyone –

I’m evaluating the feasibility of bending a 5 mm thick 6061-T6 aluminium sheet into tie-off points for tensioned stabilizing lines, considering a bending radius of 15 mm. Given the known challenges of bending 6061-T6 without compromising its strength, especially at critical points where the material is under tension, I’m contemplating switching to a 6 mm thick 5052-H32 sheet. This change aims to enhance bendability and durability but raises concerns about the weight impact. How significantly does bending with a 15 mm radius affect the structural integrity of 6061-T6, and does a transition to 5052-H32, considering its thickness, offer a balanced solution in terms of maintaining strength while managing weight considerations? 

Thank you in advance!

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Solved by Greg Paulsen

6061-T6 is an excellent material with a high-performance strength-to-weight ratio, but it's not ideal for forming because it can crack in that condition and break at the bend. 5052-H32 is better suited for forming because of its higher fatigue strength and malleability. It will have different properties, so you may look into designing other features like gussets or putting a weld in at the joints for additional strength.

Even with a 3x radius to thickness this part may have risk and requires review if you choose to stay with 6061-T6. I recommend speaking with an Xometry team member once you have your quote in place so they can review the design and feedback.

    • K

      Hi everyone –

      I’m evaluating the feasibility of bending a 5 mm thick 6061-T6 aluminium sheet into tie-off points for tensioned stabilizing lines, considering a bending radius of 15 mm. Given the known challenges of bending 6061-T6 without compromising its strength, especially at critical points where the material is under tension, I’m contemplating switching to a 6 mm thick 5052-H32 sheet. This change aims to enhance bendability and durability but raises concerns about the weight impact. How significantly does bending with a 15 mm radius affect the structural integrity of 6061-T6, and does a transition to 5052-H32, considering its thickness, offer a balanced solution in terms of maintaining strength while managing weight considerations? 

      Thank you in advance!

      0
      Reply
    • Xometry Engineer

      6061-T6 is an excellent material with a high-performance strength-to-weight ratio, but it’s not ideal for forming because it can crack in that condition and break at the bend. 5052-H32 is better suited for forming because of its higher fatigue strength and malleability. It will have different properties, so you may look into designing other features like gussets or putting a weld in at the joints for additional strength.

      Even with a 3x radius to thickness this part may have risk and requires review if you choose to stay with 6061-T6. I recommend speaking with an Xometry team member once you have your quote in place so they can review the design and feedback.

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      Reply
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      • K
        Greg Paulsen

        Thank you!

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Switch 6061-T6 for 5052-H32 (bending), weight vs strength
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