With completely new metal products, the design choices are often governed by the choice of manufacturing technology. Extrusions are particularly important in this regard, owing to the ease with which aluminium alloys, particularly the Al–Mg–Si series, can be extruded to form complex profiles.
An important structural limitation of aluminium alloys is their lower fatigue strength compared to steel. In controlled laboratory conditions, steels display a fatigue limit, which is the stress amplitude below which no failures occur – the metal does not continue to weaken with extended stress cycles. Aluminium alloys do not have this lower fatigue limit and will continue to weaken with continued stress cycles. Aluminium alloys are therefore sparsely used in parts that require high fatigue strength in the high cycle regime (more than 107 stress cycles).
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Suggested Reading: Aluminium alloys versus types of steel(1)
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