Aluminum Bar Cross Sectional Shape

Aluminum rod bars can be categorized into various types based on their cross-sectional shape, commonly including round, square, hexagonal, flat (aluminum busbars), and irregularly shape bars.

• Round aluminum bars are the most widely used, offering uniform stress distribution and ease of machining. They are frequently used for shafts, fasteners, and structural supports.
• Square aluminum bars are easy to position and assemble, commonly found in frames, brackets, and decorative components.
• Hexagonal aluminum bars are convenient for wrench operation and are often used for bolts, nuts, and transmission components.
• Flat aluminum bars (aluminum busbars) offer good rigidity and a large cross-sectional area, suitable for conductive busbars, heat sinks, and large structural components.
• Irregularly shaped aluminum bars are designed with elliptical, trapezoidal, and T-shaped cross-sections to meet specific needs, reducing subsequent processing and enabling one-piece molding. They serve in specialized fixtures, special fasteners, and decorative components.

Different shapes of aluminum rod bars offer advantages in machinability, assembly convenience, and mechanical properties, allowing for flexible selection based on specific applications.

Features	Geometric Advantage: No sharp corners, low stress concentration; uniform force distribution during rotational machining (turning, milling, drilling), ideal for shaft parts. Comprehensive Properties: Lightweight yet strong, corrosion resistant, non‑magnetic, good thermal & electrical conductivity. Machining Friendly: Easy to turn, tap, and polish; can achieve high dimensional accuracy and smooth surface finish.
Common Alloys	6061 / 6063: General structural parts, frames, brackets. 2011 / 2024 / 7075: High‑strength fasteners, aerospace structural parts. 1100 / 3003: Conductive parts, corrosion‑resistant components.
Typical Applications	Mechanical / Automotive: Drive shafts, guide shafts, fasteners, pins. Fluid / Piping: Pneumatic/hydraulic lines, conveying tubes. Construction / Home: Handrails, railings, decorative rods.

Features	Strong Support: One large flat face provides a wide support or connection surface, ideal for backing plates and clamps. Forming Flexibility: Easy to bend and stamp; also simple to drill and tap, offering high material utilization. Efficient Machining: Commonly used as “blank” in machining for mass production of brackets, mounting plates, etc.
Common Alloys	6061: General structural parts, brackets, fixtures. 3003 / 5052: Corrosion‑resistant parts such as architectural fittings, containers. 1100: Conductive parts, decorative strips.
Typical Applications	Structural Support: Equipment brackets, backing plates, guides, bases. Construction / Decoration: Door/window frame profiles, curtain wall pressure strips, decorative strips. Electrical / Electronics: Ground busbars, heat sink substrates, signage backplates.

Features	Structural Stability: 90° right‑angle cross section gives better bending & torsional stiffness than round bar of same cross‑sectional area, suitable for beams and columns. Easy Connection: Can be easily joined by corner welding or bolts into frames with high space efficiency. Good Machinability: Can be extruded into complex sections; easy to cut, drill, bend, and apply surface treatments.
Common Alloys	6061 / 6082: High‑strength structural parts, frames, machine bases. 5052 / 5083: Highly corrosion‑resistant parts such as marine and offshore platform components. 2024: High‑strength aerospace structural parts.
Typical Applications	Structural Frames: Equipment frames, shelf uprights, display rack skeletons. Machine Parts: Bases, support blocks, guides. Construction / Decoration: Door/window frames, curtain wall mullions, decorative strips.

Features	Clamping & Anti‑Rolling: Hexagonal cross section fits wrenches securely without slipping, and is easy to clamp on machine tools. Torque Transmission: Often used for bolts, nuts, and other parts that must withstand torque. Excellent Performance: Certain alloys (e.g., 6262‑T6511) offer high strength, wear resistance, and dimensional precision.
Common Alloys	6061: General structural parts, fasteners. 6262: High‑strength, wear‑resistant parts such as valve stems, precision shafts. 2024 / 7075: High‑strength aerospace fasteners, shafts.
Typical Applications	Fastening & Transmission: Bolts, nuts, valve stems, drive shafts. Machine Parts: Connectors, locating pins, fixture positioning blocks. Decorative Hardware: High‑end decorative bolts, pull handles.

Quick Selection Guide

• Shafts / Pins / Fasteners​ → Prefer Round Bar​ or Hex Bar.
• Frames / Beams / Columns / Supporting Structures​ → Prefer Square Bar​ or Flat Bar.
• Mounting Plates / Backing Plates / Guides / Heat Sinks​ → Prefer Flat Bar.
• Bolts / Nuts / Valve Stems / Parts Requiring Wrench Assembly​ → Prefer Hex Bar.

About Us

Shandong Heshengtaifu Aluminum Group Co., Ltd. is a leading aluminum bar producer and supplier in China. And has been recognized as a “China Integrity Enterprise” for many consecutive years. We specialize in the production, processing, and trading of aluminum rod. With over 18 years of experience in the aluminum industry, we can provide a full range of high-quality aluminum rod at competitive prices.

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