Comparing Different Types of Aluminum Extrusions Used in Automotive Industry

Aluminum extrusions are a vital component in the automotive industry, offering a lightweight, durable, and versatile material for various applications. By understanding the different types of aluminum extrusions used in the automotive industry, engineers and manufacturers can optimize vehicle performance and efficiency.

Types of Aluminum Extrusions

Aluminum extrusions used in the automotive industry can be classified based on their shape, size, and alloy composition.


– Standard shapes: Rectangular, square, round, and oval extrusions are widely used for structural components, such as beams and frames.

– Custom shapes: Complex shapes can be designed to meet specific functional and aesthetic requirements, such as curved extrusions for body panels.


– Small extrusions: Extrusions with diameters or widths less than 100 mm are suitable for small-scale components, such as trim and fasteners.

– Medium extrusions: Extrusions with sizes between 100 mm and 250 mm are used for structural components, such as door frames and window surrounds.

– Large extrusions: Extrusions with diameters or widths exceeding 250 mm are employed in high-strength applications, such as chassis components and bumpers.

Alloy Composition

– 6000 series: Aluminum alloys in this series, such as 6061 and 6063, offer a good combination of strength, corrosion resistance, and weldability.

– 7000 series: 7000 series alloys, such as 7075 and 7050, provide superior strength and hardness, making them suitable for high-performance components.

– Other alloys: Other aluminum alloys, such as 5000 and 8000 series, may be used for specific applications based on their unique properties.

Applications of Aluminum Extrusions in Automotive Industry

Body Panels

Aluminum extrusions are extensively used for body panels, such as hoods, doors, and fenders. Their lightweight and high strength contribute to reduced vehicle weight and improved fuel efficiency.

Structural Components

Extrusions serve as structural components, including chassis rails, bumper reinforcements, and impact beams. They provide rigidity and crashworthiness to the vehicle.

Interior Components

Aluminum extrusions are used in interior components, such as dashboard frames, seat frames, and decorative trim. Their corrosion resistance and aesthetic appeal enhance the vehicle’s interior design.

Advantages of Using Aluminum Extrusions

– Lightweight: Aluminum extrusions significantly reduce vehicle weight compared to traditional materials like steel.

– Durability: Aluminum alloys are inherently corrosion-resistant and can withstand harsh environmental conditions.

– Strength: Aluminum extrusions offer comparable strength to steel while being significantly lighter.

– Versatility: Custom shapes and complex profiles can be produced through extrusion, meeting various design and engineering requirements.

– Cost-effectiveness: Aluminum extrusions are cost-effective, especially when produced in high volumes.


Understanding the different types of aluminum extrusions used in the automotive industry enables engineers and manufacturers to select the optimal materials for specific applications. By leveraging the advantages of aluminum extrusions, the automotive industry can enhance vehicle performance, safety, and efficiency while reducing weight and improving cost-effectiveness.