Aluminum Alloys
5052 aluminum is a popular choice for FTC teams fabricating custom metal parts, especially with laser cutting. What sets 5052 apart from other aluminum alloys—like 6061—is its superior corrosion resistance and excellent bendability without cracking. While 6061 may be stronger in some applications, 5052 is easier to form and better suited for parts that require tight bends, curves, or precision tabs and slots.
Its high fatigue strength and moderate-to-high strength make it ideal for structural brackets, chassis panels, and load-bearing supports. Additionally, 5052 performs exceptionally well in environments where moisture or oxidation may be a concern—an advantage over more brittle or corrosion-prone alloys. For teams looking for a balance of strength, formability, and durability, 5052 is one of the most versatile and cost-effective choices available.
Physical Properties of 5052 Alloys
Density
0.098 lb/in3
0.098 lb/in3
0.098 lb/in3
Ultimate Tensile Strength
28 ksi
33 ksi
38 ksi
Yield Tensile Strength
13 ksi
28 ksi
31 ksi
Fatigue Strength
16 ksi
17 ksi
18 ksi
Shear Strength
18 ksi
20 ksi
21 ksi
6061 aluminum is one of the most widely used aluminum alloys in the world—and for good reason. It offers an excellent balance of strength, corrosion resistance, and machinability, making it ideal for structural components in FTC robots. Unlike 5052, 6061 can be heat-treated through a process called precipitation hardening, which significantly increases its strength while preserving its other valuable properties.
In FTC applications, laser-cut 6061 aluminum excels in load-bearing structures such as drivetrains, arms, and lift systems. It handles high-impact forces well and has strong fatigue resistance, making it a smart choice for parts exposed to vibration or repeated stress.
Another advantage of 6061 is its excellent weldability and compatibility with post-processing methods like anodizing, which adds a protective layer to the metal surface. While it’s less formable than 5052, 6061’s superior rigidity and versatility make it the go-to alloy for custom frames, brackets, and mounting plates.
If your team needs durable, high-performance parts that can withstand competition wear and tear, 6061 is a top-tier material to consider.
Physical Properties of 6062
Density
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
Ultimate Tensile Strength
18 ksi
35 ksi
45 ksi
46 ksi
42 ksi
Yield Tensile Strength
8 ksi
21 ksi
40 ksi
39 ksi
40 ksi
Fatigue Strength
9 ksi
14 ksi
14 ksi
14 ksi
15 ksi
Shear Strength
12 ksi
24 ksi
30 ksi
30 ksi
25 ksi
7075 aluminum is one of the strongest aluminum alloys available and is often referred to as “aircraft grade.” Its high strength comes from its zinc and copper content, which give it mechanical properties comparable to, or even exceeding, some mild steels—especially in the T6 temper.
7075 is ideal for FTC teams building components that must handle extreme loads with minimal flex, such as arms, structural brackets, or drivetrain elements where rigidity is critical. While it doesn’t match the weldability or formability of 5052 or 6061, its strength-to-weight ratio is among the best of any aluminum alloy used in robotics.
Although its corrosion resistance and machinability are rated as average to good, 7075 is not recommended for welded parts. It can be anodized, though with less consistency than 6061. Its lack of weldability makes it more suitable for bolted or riveted assemblies rather than fully custom-welded structures.
Physical Properties of 6062
Density
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
Ultimate Tensile Strength
max. 40 ksi(bare); max. 39 ksi(clad)
83 ksi(bare); 76 ksi (clad)
80 ksi
72.2 ksi
73.2 ksi
Yield Tensile Strength
max. 21 ksi
73 ksi(bare); 67 ksi(clad)
67 ksi
63.1 ksi
63.1 ksi
Fatigue Strength
18 ksi
23 ksi
23 ksi
20.8 ksi
21.8 ksi
Shear Strength
22 ksi
48 ksi(bare); 46 ksi(clad)
48 ksi
42.5 ksi
43.5 ksi
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