The 8000 series (“8xxx”) groups special-purpose wrought alloys that don’t fit into the 1/2/3/5/6/7 series. In practice it covers Fe–Si foil & container grades (8006/8011/8014/8025), electrical-conductor wire (8030/8176), and aluminum–lithium aerospace alloys (8090/8091/8093). These are not die-casting alloys—but they often work with die-cast housings in one assembly.
8000 Series Aluminum Quick selector
| Alloy | Sub-family | Typical forms | Strength vs 6xxx | Key advantage | Typical uses |
|---|---|---|---|---|---|
| 8006 | Fe–Si foil/container | Foil, light sheet | Low | Clean surface, good deep-draw | Food & pharma foil, container stock |
| 8011 | Fe–Si foil/container | Foil, sheet | Low–mid (work-hard.) | Formability + barrier performance | Household & pharma foil, heat-exchanger fins |
| 8014/8025 | Fe–Si foil/container | Foil | Low–mid | Surface quality, ductility | Ultra-thin packaging foils |
| 8030 | AA-8000 conductor | Rod, wire | Low–mid | Better creep strength than 1xxx at similar conductivity | Building wire & cable |
| 8176 | AA-8000 conductor | Wire | Low–mid | Electrical wire with drawability | Electrical wiring |
| 8090/8091/8093 | Al-Li aerospace | Plate, sheet (wrought) | Mid–high (heat-treatable) | Lower density, higher stiffness, fatigue resistance | Aircraft structures, space components |
What is 8000 series aluminum?
The 8xxx series is a catch-all family for aluminum alloys where the principal additions are not Mn (3xxx), Mg (5xxx), Mg-Si (6xxx), or Zn (7xxx). Because the use cases diverge—packaging foil, electrical conductors, and lightweight aerospace—8xxx is best understood as three sub-families with very different behaviors and specs.
Which alloys are in 8xxx?
- Fe–Si container/foil grades: 8006, 8011, 8014, 8025. Designed for formability, cleanliness, barrier performance, and work-hardening response.
- Electrical conductors: 8030, 8176 (often referred to as AA-8000 electrical conductor alloys). Tuned for conductivity + creep resistance in building wire.
- Aluminum–lithium (Al-Li): 8090, 8091, 8093. Heat-treatable wrought alloys that trade lower density and higher modulus for more demanding processing and joining.
Where does 8xxx fit vs 1xxx/3xxx/5xxx/6xxx?
- 1xxx (commercially pure): maximum conductivity, very low strength → foil, busbar.
- 3xxx (Mn): cookware, tanks—better strength than 1xxx.
- 5xxx (Mg): sheet structures, marine—high strength + corrosion resistance.
- 6xxx (Mg-Si): extrusions/plate—heat-treatable strength + machinability.
- 8xxx: niche performance—foil/container, electrical wire, or Al-Li aerospace.
Think of 8xxx as the specialist when generic families don’t hit the spec.
Why choose 8011/8006 for foil and packaging?
- Formability: Excellent for deep drawing and press forming of containers and lids.
- Barrier & hygiene: Thin-gauge foils with good barrier to moisture and gases; widely used in food and pharmaceutical lines.
- Work-hardening: Available in tempers that balance ductility (for forming) and handling strength.
- Surface quality: Clean, even surfaces that accept lubricants, coatings, and lacquers used in packaging.
Buyer tip: When ordering foil/container stock, specify alloy + temper + gauge + surface (one/both sides), coil ID/OD, oil/contamination limits, and pinhole limits.
When to use AA-8000 electrical-conductor wire?
- Why not 1xxx? Pure aluminum (1xxx) conducts well but creeps and relaxes under sustained temperature/load.
- 8030/8176 improve creep strength and bend durability while holding useful conductivity—ideal for building wire and cable.
- Processing: Delivered as rod/wire for drawing, stranding, and insulation lines.
Design note: Compare ampacity and connector compatibility with local codes; use proper termination hardware for AA-8000 conductors.
How do Al-Li 8xxx grades reduce weight in aerospace?
- Lower density than conventional Al alloys → weight savings at the structure level.
- Higher stiffness and good fatigue → efficient panels, skins, stringers.
- Heat-treatable → strength comparable to selected 2xxx/7xxx use cases.
- Cautions: Welding/processing demand tight controls; distortions and anisotropy must be managed. Typically used as wrought plate/sheet, not castings.
Is 8xxx weldable and formable?
- Foil/container grades: outstanding formability (drawing, stamping). Welds are uncommon on thin foil; for sheet, GTAW/GMAW are workable with appropriate filler (often 4xxx when joining to 6xxx or cast 3xx).
- Conductor grades: primarily drawn and crimped, not welded in service; welding is process-specific.
- Al-Li: weldable with expertise; many programs opt for friction stir welding or designed fasteners to control distortion and properties.
Does 8xxx anodize and resist corrosion well?
- Fe–Si foil/container: generally good atmospheric corrosion resistance; cosmetic anodizing is not the primary goal—coatings and lacquers are common.
- Conductor grades: focused on electrical performance; surface treatments depend on cable design.
- Al-Li: can be anodized, but appearance and film properties are alloy/process-dependent; follow aerospace finishing specs.
Can 8xxx be die cast?
No. 8xxx alloys are wrought (rolled, drawn, extruded). Die casting relies on cast alloys—e.g., A380, ADC12, AlSi10Mg—for fluidity, filling, and shrink control.
How we combine them in production:
- Die-cast housing (A380/ADC12/AlSi10Mg) for structure + threads.
- 8xxx inserts/liners for foil barriers, thermal shields, or AA-8000 leads passing through the casting.
- We support DFM, fixture design, joint selection (braze/adhesive/mechanical), and tolerances so the wrought 8xxx piece mates cleanly with the casting.
How to specify 8xxx for purchasing
- Alloy + temper (e.g., 8011-H14 foil, 8030 wire, 8090 plate).
- Form + size (gauge/width for foil; rod/wire diameter; plate thickness).
- Surface/cleanliness (oil content, pinhole rating, lacquer/coating requirements).
- Mechanical/electrical targets (tensile, elongation; conductivity for conductors).
- Standards (EN/ASTM/IEC, aerospace specs).
- Packaging (core size, coil weight, wrap type; spool/take-up for wire).
- Certificates & tests (chemistry, mechanical, conductivity, pinholes/leaks for foil).
FAQs
What is 8000 series aluminum used for?
Foil and container stock (8006/8011/8014/8025), electrical wire (8030/8176), and Al-Li aerospace structures (8090/8091/8093).
Is 8000 series aluminum weldable?
Foil grades are rarely welded; sheet can be welded with suitable filler. Al-Li is weldable with controlled processes (FSW/TIG). Conductors are typically crimped/terminated, not welded in service.
8000 vs 6000— which is stronger?
6xxx (heat-treatable Mg-Si) is stronger and widely used for structural extrusions. 8xxx targets special properties (foil formability, electrical performance, or Al-Li weight savings).
Can you bend 8000 series aluminum?
Yes—foil/container grades are highly formable. Conductor wire is designed for drawing and bending. Al-Li sheet/plate requires engineering bend radii and tight process control.
Which 8xxx grade is for electrical wire?
8030 and 8176 (AA-8000 electrical conductor alloys).
Is 8011 suitable for food/pharma foil?
Yes. It’s widely used for household and pharmaceutical packaging—confirm cleanliness and pinhole specs with your supplier.
Need Build a mixed assembly?
We die cast parts in A380, ADC12, AlSi10Mg and support assemblies that include 8xxx foil liners, shields, or AA-8000 leads. Send your drawing—we’ll review DFM, joining method, and tolerances and quote fast.
