Understanding aluminum alloy series is fundamental to material selection. The Aluminum Association registers over 530 active compositions, organized into series based on primary alloying elements. For clipboard manufacturing and general sheet metal applications, three alloys dominate: 5052 (Al-Mg series), 6061 (Al-Mg-Si series), and 7075 (Al-Zn series) [2].
Aluminum Alloy Grade Comparison for Clipboard Manufacturing
| Property | 5052-H32 | 6061-T6 | 7075-T6 |
|---|
| Tensile Strength | 228 MPa (33 ksi) | 310 MPa (45 ksi) | 572 MPa (83 ksi) |
| Yield Strength | 193 MPa (28 ksi) | 276 MPa (40 ksi) | 503 MPa (73 ksi) |
| Elongation at Break | 12% | 17% | 11% |
| Formability | Excellent | Excellent | Poor/Low |
| Weldability | Excellent | Excellent | Poor (cracks after welding) |
| Corrosion Resistance | Excellent (marine grade) | Good | Fair |
| Machinability | Good | Good | Fair |
| Cost Relative to 6061 | ~90% | Baseline | ~150-200% |
| Best For | Forming, welding, marine environments | Versatile structural applications | High-stress, weight-critical applications |
Data compiled from Approved Sheet Metal, Protolabs, and SendCutSend technical specifications
[2][4][5]5052 Aluminum Alloy belongs to the 5xxx series (aluminum-magnesium), known for excellent corrosion resistance and formability. With tensile strength of 228 MPa, it's the weakest of the three but offers superior weldability and resistance to saltwater corrosion, making it ideal for marine applications. For clipboards, 5052 is best suited for complex formed parts requiring extensive bending or welding [2].
6061 Aluminum Alloy is the most versatile and widely used structural aluminum alloy. Part of the 6xxx series (aluminum-magnesium-silicon), it offers an excellent balance of strength (310 MPa tensile), formability, weldability, and corrosion resistance. 6061-T6 is the default choice for most CNC machining and sheet metal applications because it's cheaper, more forgiving, and easier to finish than 7075. For clipboards, 6061 provides the best all-around performance for general office, medical, and field use [2][4].
In most cases 6061 is the better default because it's cheaper, more forgiving, and easier for finishing. I usually only see 7075 make sense when the part is truly strength-limited and weight matters. [4]
7075 Aluminum Alloy belongs to the 7xxx series (aluminum-zinc), offering the highest strength-to-weight ratio among common aluminum alloys. With tensile strength of 572 MPa—nearly 1.5x that of 6061—it's used extensively in aerospace and defense applications. However, 7075 has poor weldability (tends to crack after welding) and limited formability, making it unsuitable for complex formed parts. For clipboards, 7075 is overkill unless targeting extreme durability requirements (military, heavy industrial jobsites) [2][4].
Density and Weight: All three alloys have similar density (~2.68-2.81 g/cm³), approximately 60% lighter than steel. A 5mm aluminum sheet weighs ~25kg per square meter vs ~70kg for steel, offering significant weight savings for portable equipment like clipboards [6].
