Billet aluminum is valuable in many industries thanks to its ready availability, strength, durability and relatively low cost. However, many myths about billet, billet aluminum, cast aluminum and alloy billet continue to cause confusion around these materials and their uses. Understanding billet aluminum and how it differs from other materials, including cast aluminum, can give crucial insight into billet’s value and utility in numerous capacities and industries.
This brief guide to billet aluminum will highlight what it is, its uses, how it compares to other materials, current price trends and other aluminum industry insights.
WHAT IS BILLET ALUMINUM?
Most billet aluminum definitions found in dictionaries describe billet as “a bar of metal,” which, though brief, is accurate. Some people call billet “bar stock” because it can create bars, tubes and rods, among other items. With that in mind, understand that billet itself is not a type of metal. Instead, it is a term used to define a state of metal that has undergone specific manufacturing processes. For example, there can be billet steel, billet aluminum and others.
Once a foundry successfully creates a billet aluminum block from the metal and its alloys, workers can shape products into various forms and formats, including finely wrought items, such as a wire. In particular, billet engineering can transform aluminum into automotive parts, electronics, appliances and construction materials. Thanks to their prevalence, quality and adaptability, aluminum billets are in high demand in numerous industries and manufacturing ventures throughout the global market.
HOW IS BILLET ALUMINUM MANUFACTURING DIFFERENT FROM CAST ALUMINUM MANUFACTURING?
Cast and billet are two of the most common forms of aluminum and its alloys. While similar, these two have some notable differences. Comparing and contrasting each metal type is crucial to understanding how each works and how they apply to different industries.
Cast aluminum: To create cast aluminum, heat raw aluminum or alloy past its melting point. Then, pour it into a mold — using techniques such as gravity or high-pressure die casting — to form the desired shape. Casting is highly versatile and can accommodate low quantities and high-volume needs. Cast aluminum is excellent for detailed items and applying various finishes.
Billet aluminum: To form billet aluminum, heat and pressurize aluminum or its alloys. This process will result in dense billets, or metal blocks. Aluminum alloy billet is prevalent in a variety of industries due to its strength and durability. Billet aluminum is used in construction projects, machinery, electronics and appliances.
Billet vs. cast aluminum has been an ongoing debate for years, and deciding which is better for your company, your industry and your needs will depend on various factors — including cost, strength, availability, durability and malleability, among others.
How Is Billet Aluminum Made?
Billet aluminum is made by turning raw aluminum or its alloys into a semi-finished form ready for further processing. The manufacturing process follows several steps:
- Selecting raw materials: Aluminum scraps or ingots are common raw materials used in making billet aluminum. Which raw materials to use will depend on factors such as material availability, cost and the desired alloy composition.
- Melting and alloying: The raw aluminum materials are melted in a large, high-temperature furnace until they become liquid. If the desired alloy composition requires additional alloying elements, these elements can be added when the aluminum reaches its liquid state.
- Degassing and purifying: The molten aluminum is transferred to a degassing section to remove hydrogen. It is also passed through powerful filters to remove impurities.
- Casting or extrusion: Aluminum billets are formed either through casting or extrusion. The casting process requires the aluminum to be poured into a mold, while the extrusion process forms the billet by using extreme pressure and forcing aluminum through a die.
- Cooling: Once the billet is formed, it must cool and solidify. The billets can cool through various methods, including natural air cooling or water quenching.
Common Types of Aluminum Billets
Aluminum billet is available in several types and grades to offer different benefits depending on the application. The International Alloy Designation System has created a naming scheme that gives each alloy a four-digit number to specify the major alloying element and the series to which it belongs.
Common aluminum billet types include:
- Aluminum Billet Series 1000: Billets in the 1000 series are essentially pure aluminum.
- Aluminum Billet Series 2000: Aluminum billets in the 2000 series are alloyed with copper to provide additional strength.
- Aluminum Billet Series 3000: The 3000 series billets are alloyed with manganese, offering moderate strength, corrosion resistance and good formability.
- Aluminum Billet Series 4000: The 4000 series billets are alloyed with silicon for optimal wear resistance and high-temperature performance.
- Aluminum Billet Series 5000: Alloyed with magnesium, 5000 series billets provide excellent corrosion resistance and moderate strength ideal for marine applications.
- Aluminum Billet Series 6000: Aluminum billets from the 6000 series are alloyed with magnesium and silicon, serving as a reliable general-purpose aluminum alloy.
- Aluminum Billet Series 7000: The 7000 series billets are alloyed with zinc to deliver high strength, toughness and fatigue resistance.
Applications of Aluminum Billets
Since aluminum billets can be extruded into various shapes and sizes, they are a versatile material for a wide range of applications. Billet parts are made from a single block of aluminum or its alloys, so they can precisely and consistently match product design specifications while offering exceptional strength and durability.
They can be shaped through various machining methods to meet the needs of several industries, including:
CURRENT PRICE TRENDS FOR ALUMINUM BILLETS
Aluminum’s price has experienced a general downward trend throughout 2023. Even with slight price increases throughout Q4, the outlook remains bearish for 2024. Given aluminum prices’ historical pattern of moving in long-term trends, our market experts predict aluminum demand will continue to contract throughout 2024.
STAY INFORMED BY SUBSCRIBING TO HARBOR ALUMINUM INTELLIGENCE
With aluminum prices fluctuating daily, tracking this material’s price and availability is crucial for anyone who works in industries that rely on it to create products. HARBOR Aluminum Intelligence is a trusted industry source for the most up-to-date, actionable aluminum billet price trends. We assess more than 150 aluminum prices and product premiums worldwide. With access to more aluminum product price information than any other consulting or journalistic group, HARBOR is the most reliable and comprehensive source.
At HARBOR Aluminum, we offer valuable information to meet our clients’ needs. Some of our most frequently requested reports include P1020, which tracks aluminum pricing by country and geographic markets. The Scrap report includes pricing on scrap aluminum in several markets, while the Billet report is an excellent guide to billet aluminum pricing and availability.
Contact us today for subscription options and price information. We also offer aluminum billet consulting services and serve as expert witnesses in arbitration and legal disputes.