1000 series (1xxx) are the “commercially pure” wrought aluminums (≥99.0% Al). They deliver top electrical/thermal conductivity, excellent corrosion resistance and formability, but low strength compared with alloyed families. Great for busbar, foil, chemical equipment, reflectors, fins—not for structural loads.
What is 1000 series aluminum?
The 1xxx family contains ≥99.0% aluminum with only trace elements (Si, Fe, Cu, Mn, Zn, Ti). They are non-heat-treatable; strength increases only by cold work (H-tempers). Because they’re so pure, they offer:
- Very high conductivity (electrical & thermal)
- Excellent corrosion resistance in neutral environments
- Outstanding formability for deep drawing, spinning, bending
- Low to very low strength vs 3xxx/5xxx/6xxx families
Which grades are in 1xxx?
Common grades and where they fit:
| Grade | Min. Al (%) | What it’s known for | Typical forms | Typical uses |
|---|---|---|---|---|
| 1050 | 99.5 | High reflectivity, easy forming | Sheet, coil | Reflectors, fins, signage |
| 1060 | 99.6 | Conductivity with easy fabrication | Sheet, strip, wire | Busbar, foil, wire, tabs |
| 1070 | 99.7 | Very high conductivity | Wire, strip | Cable sheathing, electronics |
| 1100 | 99.0 | Workhorse 1xxx grade | Sheet, plate, tube | Chemical equipment, cookware, tanks |
| 1200 | 99.0 | General-purpose pure Al | Sheet, roofing | Roofing, cladding |
| 1350 | 99.5 | Electrical conductor grade | Rod, wire | Transformer windings, conductors |
(Values are minimum Al by spec; choose temper for strength level.)
1000 Series Aluminum & Die Casting?
No. 1xxx alloys are wrought grades for sheet, foil, wire, and plate. Die casting relies on cast alloys with silicon and other additions for fluidity and casting performance. In production we use cast families such as A380, ADC12, AlSi10Mg for die-cast parts.
How we bridge the gap: Many assemblies use die-cast housings (A380/ADC12/AlSi10Mg) together with 1xxx busbar, foil, or shields. We handle the die casting and advise on joining/clearances so your wrought and cast parts fit cleanly.
How strong is 1xxx by temper (O/H14/H18)?
- O (annealed): softest, best for deep draw/spin; lowest strength.
- H12/H14: lightly to moderately work-hardened; a good balance for formed sheet with a little strength.
- H18: heavily work-hardened; highest strength for 1xxx, lowest elongation.
Rule of thumb: more “H”, more strength, less ductility—conductivity stays high.
How does 1xxx weld and braze?
- Welding: GTAW/GMAW are straightforward. For 1xxx-to-1xxx joints you can use 1100 filler. For joints to 6xxx or cast 3xx alloys, 4043 is commonly chosen to improve crack resistance.
- Brazing: Good brazeability with appropriate flux/fillet design.
- Tip: Because 1xxx is soft, design joints to avoid peel loads and use broad lap areas.
Where is 1xxx used (busbar, foil, equipment)?
- Electrical: 1350/1060 busbar, transformer windings, battery tabs
- Thermal: Foil and fins for HVAC/heat exchangers, heat spreaders
- Process & consumer: 1100 for chemical equipment, tanks, cookware, signage, reflectors
- Packaging: Household and industrial foil, lidding, barrier layers
1xxx vs 3xxx/5xxx/6xxx — how to choose?
- Pick 1xxx when you need maximum conductivity, best formability, bright finish, and only low loads.
- Pick 3xxx (Mn) for better strength/formability with good corrosion resistance (tanks, cookware).
- Pick 5xxx (Mg) for higher strength and marine corrosion resistance (sheet structures).
- Pick 6xxx (Mg-Si) when you need heat-treatable strength, machining, and extrusion (frames, heatsinks, general structures).
Does 1xxx anodize to a bright finish?
Yes. High-purity aluminum can yield excellent bright or mirror-like anodized finishes. Appearance depends on surface prep, trace elements, and anodizing parameters. For mirror parts, specify mill-bright or chemically brightened surfaces before anodize.
How to specify 1xxx for purchasing?
Include the full callout: Grade + Temper + Form + Thickness/Width + Surface + Tolerances + Standards.
Example: Aluminum sheet, 1060-H14, 1.0 mm × 1,250 mm, one side bright, EN/ASTM standard, ±0.05 mm thickness tolerance.
Add: packaging, paper interleaf, and test certs (chemistry/mech/cond).
Design tips for low-strength, high-conductivity 1xxx
- Use geometry for stiffness: ribs, hems, flanges, beads.
- Laminate or stack sheets for busbars to reduce eddy losses while keeping section.
- Keep bend radii generous (especially in H18).
- Combine with die castings: let the die-cast housing carry loads; let 1xxx conduct heat/electricity.
1000 series aluminum FAQs
Is 1xxx heat-treatable? No—only cold-work strengthens it.
Which is stronger: 1100 or 6061? 6061 by a wide margin; choose 1xxx for conductivity/forming.
What is 1350 used for? Electrical conductors and transformer windings.
Can I weld 1xxx to die-cast A380/ADC12? Yes—4043 filler is commonly used; design joints for shear/lap, not peel.
Marine use? Prefer 5xxx for loaded marine structures; 1xxx is fine for non-structural components and liners.
Need cast parts that work with 1xxx sheet or busbar?
We produce aluminum die castings in A380, ADC12, and AlSi10Mg, and we support mixed assemblies (cast housings + 1xxx conductors/foils). Share your drawing and we’ll review DFM, joining method, and tolerances to ensure a clean fit.
