A practical comparison page for aluminum materials used in motor conductors, busbars, rotor cages, housings, end covers, heat sinks, cooling plates, brackets and lightweight structural parts.
Aluminum selection should be connected to function. Conductive parts need electrical performance, housings and heat sinks need thermal path and dimensional stability, while cast or machined structures need strength, process capability and cost control.
Different aluminum families are optimized for different priorities. Electrical aluminum, extrusion aluminum, casting aluminum and high-strength aluminum should be selected according to the part function and process route.
Used where conductivity and stable current carrying capacity are more important than high mechanical strength.
Balanced aluminum alloys for extruded profiles, heat sinks, motor housings and CNC machined structural parts.
Used for high-volume motor housings, end covers, brackets and integrated structures with complex shapes.
Selected when casting quality, mechanical property and heat-treatment response are more important than lowest cost.
Used for lightweight structures where strength is important, but corrosion protection and cost should be reviewed.
Useful for rapid prototypes, complex cooling channels and low-volume special motor parts.
Use this table for early-stage material screening. Actual values depend on alloy standard, temper, wall thickness, casting quality, extrusion condition and supplier process.
| Aluminum Type | Typical Grades | Density | Strength Direction | Conductivity / Thermal Behavior | Typical Motor Use | Key Risk |
|---|---|---|---|---|---|---|
| Electrical Pure Aluminum | 1050, 1060, 1070, 1350 | Approx. 2.70 g/cm3 | Low to moderate strength | High electrical and thermal conductivity | Busbars, conductors, rotor cages, current-carrying parts | Mechanical strength, creep, joint resistance and surface oxidation |
| Electrical Extrusion Aluminum | 6101, 6101-T6, 6063 conductive temper | Approx. 2.70 g/cm3 | Moderate strength with useful conductivity | Good balance of conductivity and extrusion performance | Busbar profiles, conductor rails, electrical connection parts | Conductivity variation after temper and forming |
| General Extrusion Alloy | 6063, 6061, 6082 | Approx. 2.70 g/cm3 | Moderate to good strength after T5 / T6 | Good thermal path for housings and heat sinks | Motor housings, heat sinks, frames, brackets, cooling profiles | Flatness, profile tolerance, anodizing appearance, thermal contact |
| Machining Aluminum | 6061-T6, 6082-T6, 7075-T6 | Approx. 2.70-2.81 g/cm3 | Good to high strength depending on grade | Lower conductivity than pure aluminum but acceptable for structures | Prototype housings, fixtures, precision brackets, rotor support parts | Residual stress, machining deformation, corrosion protection |
| Die Casting Aluminum | ADC12, A380, A383 | Approx. 2.65-2.75 g/cm3 | Good casting strength for complex parts | Moderate thermal performance | High-volume motor housings, end covers, brackets, integrated castings | Porosity, sealing leakage, machining exposure, coating adhesion |
| Heat-Treatable Casting Aluminum | A356-T6, ZL101, AlSi7Mg | Approx. 2.68 g/cm3 | Better strength and ductility after T6 | Good for structural cooling castings | Structural housings, cooling plates, load-bearing cast components | Heat treatment distortion, casting quality, shrinkage and lead time |
| High-Strength Aluminum | 7075, 7050, 2024 | Approx. 2.78-2.85 g/cm3 | High strength and fatigue capability | Lower corrosion resistance and moderate conductivity | Lightweight high-load brackets, special rotor or fixture parts | Corrosion, cost, stress corrosion cracking and process availability |
| 3D Printed Aluminum | AlSi10Mg | Approx. 2.67 g/cm3 | Depends on print direction and heat treatment | Useful for complex thermal channels | Rapid prototypes, cooling structures, special low-volume parts | Anisotropy, roughness, fatigue, porosity and post-machining |
This matrix connects material choice with part function, manufacturing route and inspection focus.
| Motor Part | Recommended Aluminum Direction | Design Driver | Common Process | Inspection Focus |
|---|---|---|---|---|
| Busbar / Conductor | 1050, 1060, 1070, 1350, 6101 | Conductivity, temperature rise, joint resistance | Extrusion, stamping, bending, machining, plating | Conductivity, burrs, plating thickness, contact surface, insulation distance |
| Rotor Cage | Pure aluminum or die-cast aluminum system | Conductivity, fill quality, rotor balance | Die casting, pressure casting, machining, balancing | Porosity, fill integrity, runout, balance, resistance consistency |
| Motor Housing | 6063 / 6061 extrusion, ADC12 / A380 die casting, A356 casting | Thermal path, stiffness, cost, sealing | Extrusion, die casting, sand casting, CNC machining | Flatness, porosity, leak test, coating adhesion, bearing-seat tolerance |
| Heat Sink / Cooling Profile | 6063-T5, 6061-T6, AlSi10Mg for special channels | Thermal conductivity, fin geometry, surface area | Extrusion, CNC machining, brazing, additive manufacturing | Fin thickness, thermal contact, flatness, pressure drop if liquid cooled |
| End Cover | ADC12, A380, 6061, A356-T6 | Assembly accuracy, strength, sealing, cost | Die casting, machining, surface treatment | Bearing bore, hole position, flatness, leak test, surface defects |
| Bracket / Frame | 6061, 6082, 7075 when high strength is needed | Weight reduction, stiffness, load path | Extrusion, CNC machining, welding, anodizing | Dimensional tolerance, weld quality, deformation, surface treatment |
| Prototype Structure | 6061-T6, 6082-T6, AlSi10Mg | Fast iteration, machining stability, assembly proof | CNC machining, 3D printing, finishing | Fit, tolerance, roughness, threaded inserts, design update feedback |
Aluminum material selection is reliable only when alloy, temper, process route, surface treatment and inspection are considered together.
Confirm whether the part is conductive, thermal, structural, cast, machined, sealed or corrosion-exposed.
Choose candidate alloys according to conductivity, thermal path, strength, casting or extrusion route and supply availability.
Define extrusion, die casting, CNC machining, forging, welding, brazing, anodizing, coating or plating route.
Check certificate, dimensions, conductivity, porosity, coating, sealing, flatness and assembly fit before release.
For busbars and conductors, specify alloy, temper, minimum conductivity, joint area and surface treatment.
For housings and heat sinks, review wall thickness, contact flatness, fin geometry and coating influence.
For die-cast parts, define porosity limit, leakage requirement, machining allowance and critical sealing zones.
Control residual stress, clamping deformation, bearing-seat tolerance, thread strength and surface roughness.
Choose anodizing, passivation, chromate-free conversion coating, powder coating or plating according to environment.
Check galvanic corrosion with steel or copper parts, fastener torque, inserts, welding distortion and sealing surfaces.
1050, 1060, 1070, 1350 and 6101 are common choices. The final decision should consider conductivity, mechanical strength, bending, joint method, plating and temperature rise.
6063 and 6061 are common for extruded or machined housings. ADC12 / A380 are common for high-volume die-cast housings, while A356-T6 is useful when better casting strength and heat-treatment response are required.
7075 can be used for lightweight high-strength brackets or special mechanical parts, but it is usually not the first choice for general motor housings because of cost, corrosion sensitivity and process considerations.
Check conductivity, strength, temper, corrosion protection, thermal path, machining stability, casting or extrusion feasibility, supplier availability and inspection method.