Aluminum Roll Forming Material Guide: Coil Sizes, Alloys, Properties & Applications

Aluminum Roll Forming Material

1. Overview of Aluminum in Roll Forming

Aluminum is one of the most widely used non-steel materials in roll forming due to its lightweight nature, excellent corrosion resistance, and high formability.

Unlike steel, aluminum does not require protective coatings like zinc for corrosion resistance, making it ideal for outdoor, marine, and architectural applications.

In roll forming, aluminum is commonly used for roofing panels, façade systems, trims, gutters, and lightweight structural components. It is especially popular in regions where corrosion resistance and weight reduction are critical.

2. Material Composition & Structure

Aluminum roll forming material consists of:

Aluminum alloy base metal
Optional surface treatments or coatings

Common Alloy Series:

1000 Series (Pure Aluminum) – High corrosion resistance
3000 Series (Al-Mn) – Most common for roll forming
5000 Series (Al-Mg) – Marine-grade corrosion resistance
6000 Series (Al-Mg-Si) – Structural applications

Structure:

Homogeneous metal (no layered coating like steel unless painted)

3. Available Coil Specifications

Thickness Range

0.3mm – 3.0mm

Coil Width

600mm – 1500mm

Coil Weight

2 tons – 8 tons

Coil ID / OD

ID: 508mm / 610mm
OD: up to 1400mm

Tolerance

Excellent flatness
Tight thickness tolerances

4. Mechanical Properties

Typical values (depending on alloy):

Yield Strength: 80 – 300 MPa
Tensile Strength: 120 – 350 MPa
Elongation: 10% – 35%
Hardness: 40 – 100 HB

Common Tempers:

H14 / H24 (half hard)
H32 / H34 (strain hardened)

5. Coating Types (IF APPLICABLE)

Aluminum can be supplied as:

Mill Finish

Natural aluminum surface

Painted Aluminum (Color Coated)

PE, SMP, PVDF coatings
Thickness: 20–35 microns

Anodized Aluminum

Enhanced corrosion resistance
Decorative finish

Cost Level

Medium to high

6. Surface Finishes

Mill finish (raw aluminum)
Painted (gloss, matte, textured)
Brushed aluminum
Anodized finish
Embossed aluminum

7. Common Roll Forming Applications

Aluminum is used in:

Roofing panels (standing seam, corrugated)
Wall cladding systems
Gutters and downpipes
Flashing and trims
Curtain wall systems
Marine applications
Transportation components

8. Advantages of Aluminum

Excellent corrosion resistance
Lightweight (approx. 1/3 weight of steel)
High formability
Non-magnetic
Recyclable
Ideal for coastal environments

9. Disadvantages / Limitations

Higher cost than steel
Lower strength (depending on alloy)
Prone to denting
Thermal expansion higher than steel
Requires careful handling

10. Roll Forming Machine Considerations

Roll Tooling

Highly polished rollers required
Aluminum is softer — surface protection critical

Speed

15–60 m/min

Lubrication

Often required

Cutting

Flying shear preferred
Sharp blades required

Common Issues

Surface scratching
Material marking
Springback
Coil camber

11. Common Problems in Production

Surface scratching
Roller pickup (material sticking)
Springback affecting profile accuracy
Oil canning
Edge cracking (in harder tempers)

12. Pricing Guide

Typical global pricing:

Low: $1800–$2500 per ton
Medium: $2500–$3500 per ton
High: $3500–$5000+ per ton

Factors affecting price:

Alloy type
Thickness
Coating (painted or anodized)
Global aluminum prices

13. Comparison with Other Materials

Aluminum vs Steel

Aluminum = lighter, corrosion resistant
Steel = stronger, cheaper

Aluminum vs Stainless Steel

Aluminum = lighter and cheaper
Stainless = stronger and more durable

Aluminum vs Galvanized Steel

Aluminum = no rust coating required
GI = cheaper alternative

14. Best Industries Using Aluminum

Construction
Marine industry
Transportation
Aerospace (special applications)
Architectural design

15. How to Choose Aluminum

Choose Aluminum When:

Corrosion resistance is critical
Weight reduction required
Coastal or marine environment
High-end architectural applications

Avoid When:

Budget is limited
High structural strength required
Heavy load applications

16. FAQ Section

What aluminum is best for roll forming?

3000 and 5000 series are most common.

Is aluminum better than steel?

Depends — aluminum is lighter, steel is stronger.

Does aluminum rust?

No, it naturally resists corrosion.

Can aluminum be roll formed easily?

Yes, it has excellent formability.

Is aluminum good for roofing?

Yes, especially in coastal areas.

17. Machine Matcher Section

We supply roll forming machines for all material types including aluminum.

Custom-built machines to your profile
New machines built to specification
Global delivery available
UK and USA technical support

Contact:
Machine Matcher
Sales & Technical Team

Quick Specs

Thickness
0.3–3.0mm

Yield Strength
80–300 MPa

Coil Width
600–1500mm

Coil ID
508 / 610mm