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or extruded and a host of other questions Extruded geometries include angle-shaped bars, tee-shaped bars, I-beams, C-channels, and square and rectangular tubing You can choose from among at least nine common aluminum alloys: 1100, 2011, 2017, 2024, 3003, 5052, 6061, 6063, and 7075 If that list makes your head spin, add to that numerous tempers for each of the alloys Don t despair, for even though each of these alloys has an application where it fits best, we ll discuss only the few that seem to be best for robots considering just how well you can machine it, its cost, and its availability Alloy 6061 at a temper of T6 seems to be one of the most versatile and readily available aluminum types for sheet stock This popular aluminum alloy comes in sheets from 1/32 inch (0032 inch) to several inches in thickness (the thicker version is called plate rather than sheet) and can be up to 48-by-144 inches in size This alloy is available at aerospace surplus yards, metal supply houses, and the better specialty hardware stores, and it is fairly good for robot skin covering and excellent for internal structures It welds, drills, and taps well Alloy 6061 also comes in extruded angle stock, which is useful for fastening two pieces of sheet stock together at right angles for structures Alloy 6063 is similar to 6061, yet it offers better corrosion resistance for wet applications Alloy 7075 is one of the hardest aluminum alloys and is an ideal material for machining high-stress parts It is popular in aircraft and aerospace production It also comes in sheet stock tempered at T6 and makes good robot skin 7075 can be found at most metal houses and aerospace surplus yards Alloy 2024 is another aircraft-grade alloy that offers high strength and is fairly machinable 2024-T3 (T3 is a temper number) comes in extruded stock such as rounds and squares Alloy 2011 is also easy to machine and comes in rounds and hexagonal stock It is probably the best for threading and machining on a lathe and milling machine Robot hubs, shafts, and similar items can be easily made from this alloy Aluminum alloys are easy to mill, cut, and drill, but the careful application of cutting fluid to these operations will greatly assist your machining operations This is especially important in tapping aluminum Tapping fluids used for drilling and tapping of steels should not be used AlumiTap and special compounds designed for aluminum should be the only types used This also applies to cutting large holes with a fly cutter or in sawing with a band saw As always, use a good pair of goggles or a face-mask when machining any material Aluminum, as well as stainless steel, requires special talents and equipment to weld properly Both require what are commonly referred to as wirefeed welders, also called MIG (metal inert gas) welders, or TIG (tungsten inert gas) welders You might have seen cheaper varieties of these types of welders in cut-rate tool catalogs or stores This is an area where more money means a better job, and cutting corners just to own a MIG welder will cost you in the end with poor and weak welds If you want to save money, go to a welding shop that specializes in aluminum and stainless steel welding and have a professional do it right the first time.

Cell loss ratio (CLR) Maximum cell transfer delays (maxCTD) Cell delay variations (CDV)