Forming Taps for Aluminum
Aluminum is one of the best materials for thread forming taps. Its ductility and low forming force make it ideal for chipless threading. This guide covers everything you need to know about forming threads in aluminum.
Why Forming Taps Are Perfect for Aluminum
- Low hardness – aluminum easily flows into thread profile
- No chip issues – aluminum chips are sticky and can clog flutes in cutting taps
- Stronger threads – work-hardened aluminum threads have better fatigue resistance
- High speed capable – run at 30-60 m/min
Recommended Parameters
| Parameter | Value |
|---|---|
| Cutting speed | 30-60 m/min (100-200 SFM) |
| Lubrication | Light cutting oil or tapping fluid |
| Tap material | HSSE recommended |
| Hole tolerance | H7 recommended |
Best Practices for Aluminum Forming
- Use correct tap drill size – aluminum flows easily, so precise hole preparation is critical
- Apply liberal lubrication – reduces friction and heat
- Run at higher speeds – aluminum tolerates fast forming well
- Consider oxide treatment – helps with aluminum’s tendency to gall
Common Aluminum Alloys
- 6061-T6 – Most common, excellent for forming taps
- 7075-T6 – Harder, still suitable with HSSE taps
- 2024-T3 – Good forming characteristics
- 5052-H32 – Soft, very easy to form
Conclusion
Aluminum and forming taps are a perfect match. With the right HSSE tap, correct drill size, and proper parameters, you’ll produce strong, precise threads with zero chip issues.