The Aluminum Association Tolerances For Aluminum Extrusions...

Cross-Sectional Dimesion Tolerances - Profiles

EXCEPT FOR T3510, T4510, T6510, T73510, T76510 AND TB510 TEMPERS
Image 306

Specified Dimension

In.		 TOLERANCE (2)(3) in. plus and minus
Metal Dimensions Space Dimensions
ALLOWABLE DEVlATlON FROM
SPECIFIED DIMENSION WHERE
75 PERCENT OR MORE OF
THE DlMENSlON IS METAL(9) (18)		 ALLOWABLE DEVIATION FROM SPECIFIED
DIMENSION WHERE MORE THAN 25 PERCENT OF
THE DIMENSION IS SPACE (6) (8)
All
Except Those
Covered
by Column 3

Wall Thickness(4) Completely(5) Enclosing Space 0.11 sq. in. and Over (Eccentricity)

At Dimensioned Points 0.250-0.624 inches from Base of Leg

 At Dimensioned Points 0.625-1.249 inches from base of leg At Dimensioned Points 1.250-2.499 inches from Base of Leg At Dimensioned Points 2.500-3.999 inches from base of leg At Dimensioned Points 4.000-5.999 inches from base of leg At Dimensioned Points 6.000-8.000 inches from base of leg
Col. 1 Col. 2 Col. 3 Col. 4 Col. 5 Col. 6 Col. 7 Col. 8 Col. 9
Standard Tolerance, All Except 5XXX Alloys (11) Precision Tolerance, All Except 5XXX Alloys Standard Tolerance, All Except 5XXX Alloys (11) Precision Tolerance, All Except 5XXX Alloys Standard Tolerance, All Except 5XXX Alloys (11) Precision Tolerance, All Except 5XXX Alloys Standard Tolerance, All Except 5XXX Alloys (11) Precision Tolerance, All Except 5XXX Alloys Standard Tolerance, All Except 5XXX Alloys (11) Precision Tolerance, All Except 5XXX Alloys Standard Tolerance, All Except 5XXX Alloys (11) Precision Tolerance, All Except 5XXX Alloys Standard Tolerance, All Except 5XXX Alloys (11) Precision Tolerance, All Except 5XXX Alloys Standard Tolerance, All Except 5XXX Alloys (11) Precision Tolerance, All Except 5XXX Alloys
CIRCUMSCRIBING CIRCLE SIZES LESS THAN 10 INCHES IN DIAMETER

Up thru 0.124

0.125-0.249

0.250-0.499

0.500-0.749

0.750-0.999

 0.006
0.007
0.008
0.009
0.010		 0.004
0.005
0.005
0.006
0.007		 +- 15% of specified dimension, +-.060 max +- .015 min. +- 10% of specified dimension, +-.060 max +- .010 min.

0.010

0.012

0.014

0.016

0.018

0.007

0.008

0.009

0.011

0.012

0.012

0.014

0.016

0.018

0.020

0.008

0.009

0.011

0.012

0.013

..

0.016

0.018

0.020

0.022

..

0.011

0.012

0.013

0.015

..

..

0.020

0.022

0.025

..

..

0.013

0.015

0.017

..

..

..

..

0.030

..

..

..

..

0.020

..

..

..

..

..

..

..

..

..

..

1.000-1.499

1.500-1.999

2.000-3.999

4.000-5.999

6.000-7.999

8.000-9.999

 0.012
0.014
0.024
0.034
0.044
0.054		 0.008
0.009
0.016
0.022
0.029
0.036

0.021

0.024

0.034

0.044

0.054

0.064

0.014

0.016

0.022

0.029

0.036

0.042

0.023

0.026

0.038

0.050

0.062

0.074

0.015

0.017

0.025

0.033

0.041

0.049

0.026

0.031

0.048

0.064

0.082

0.100

0.017

0.020

0.032

0.042

0.054

0.066

0.030

0.036

0.057

0.078

0.099

0.120

0.020

0.024

0.038

0.051

0.065

0.079

0.035

0.042

0.068

0.094

0.120

0.145

0.023

0.028

0.045

0.062

0.079

0.096

..

0.050

0.080

0.110

0.140

0.170

..

0.033

0.053

0.073

0.092

0.112
CIRCUMSCRIBING CIRCLE SIZES 10 INCHES IN DIAMETER AND OVER
Up thru 0.124
0.125-0.249
0.250-0.499
0.500-0.749
0.750-0.999		 0.014
0.015
0.016
0.017
0.018		 0.009
0.010
0.011
0.011
0.012		 +- 15% of specified dimension, +-.060 max +- .015 min. +- 10% of specified dimension, +-.060 max +- .010 min. 0.018
0.019
0.020
0.022
0.023		 0.012
0.013
0.013
0.015
0.015		 0.020
0.022
0.024
0.027
0.030		 0.013
0.015
0.016
0.018
0.020

..

0.028
0.030
0.040
0.050

..

0.018
0.020
0.026
0.033

..

. .
0.050
0.060
0.070

..

..

0.033
0.040
0.046

..

..

..

..

0.090

..

..

..

..

0.059

..

..

..

..

..

..

..

..

..

..
l.000-1.499
1.500-1.999
2.000-3.999
4.000-5.999
6.000-7.999		 0.019
0.024
0.034
0.044
0.054		 0.013
0.016
0.022
0.029
0.036		 0.024
0.034
0.044
0.054
0.064		 0.016
0.022
0.029
0.036
0.042		 0.034
0.044
0.054
0.064
0.074		 0.022
0.029
0.036
0.042
0.049		 0.060
0.070
0.080
0.090
0.100		 0.040
0.046
0.053
0.059
0.066		 0.080
0.090
0.100
0.110
0.120		 0.053
0.059
0.066
0.073
0.079		 0.100
0.110
0.120
0.130
0.140		 0.066
0.073
0.079
0.086
0.092

..

0.170
0.180
0.190
0.200

..

0.112
0.119
0.125
0.132
8.000-9.999
10.000-11.999
12.000-13.999
14.000-15.999
16.000-17.999		 0.064
0.074
0.084
0.094
0.104		 0.042
0.049
0.055
0.062
0.069		 0.074
0.084
0.094
0.104
0.114		 0.049
0.055
0.062
0.069
0.075		 0.084
0.094
0.104
0.114
0.124		 0.055
0.062
0.069
0.075
0.082		 0.110
0.120
0.130
0.140
0.150		 0.073
0.079
0.086
0.092
0.099		 0.130
0.140
0.150
0.160
0.170		 0.086
0.092
0.099
0.106
0.112		 0.150
0.160
0.170
0.180
0.190		 0.099
0.106
0.112
0.119
0.125		 0.210
0.220
0.230
0.240
0.250		 0.139
0.145
0.152
0.158
0.165
18.000-19.999
20.000-21.999
22.000-24.000		 0.114
0.124
0.134		 0.075
0.082
0.088		 0.124
0.134
0.144		 0.082
0.088
0.095		 0.134
0.144
0.154		 0.088
0.095
0.102		 0.160
0.170
0.180		 0.106
0.112
0.119		 1.800
0.190
0.200		 1.188
0.125
0.132		 0.200
0.210
0.220		 0.132
0.139
0.145		 0.260
0.270
0.280		 0.172
0.178
0.185

Footnotes for Tables 11.2 through 11.4


(1) These Standard and Precision Tolerances are applicable to the average profile. The extrusion conditions required to produce the wide variety of alloy-temper and profile combinations require close review between customer and producer to determine critical characterislics and tolerance capability, Agressive profile characteristics may require wider than standard tolerance and closer than precision tolerance may be feasible for other characleristics.


(2) The tolerance applicable to a dimension composed of two or more component dimensions is the sum of the tolerances of the component dimensions if all of the component dimensions are indicated.

 

(3) When a dimension tolerance is specified other than as an equal bilateral tolerance, the value of the standard tolerance is that which applies to the mean of the maximum and minimum dimensions permissible under the tolerance for the dimension under consideration.

 

(4) Where dimensions specified are outside and inside, rather than wall thickness itself, the allowable deviation (eccentricity) given in Column 3 applies to mean wall thickness. (Mean Wall thickness is the average of two wall thickness measurements taken at opposite sides of the void.)


(5) In the case of Class 1 Hollow Profiles the standard wall thickness tolerance for
extruded round tube is applicable. (A Class 1 Hollow Profile is one whose void is round
and one inch or more in diameter and whose weight is equally distributed on opposite
sides of two or more equally spaced axes.)

Table 11.5 Length(1) - Wire, Rod, Bar, and Profiles


SPECIFIED DIAMETER (WIRE AND ROD):
SPECIFIED WIDTH (BAR):
CIRCUMSCRIBING
CIRCLE DIAMETER @:
(PROFILES)
in.		 TOLERANCE - in. plus
ALLOWABLE DEVIATION FROM SPECIFIED LENGTH
SPECIFIED LENGTH-ft.
Up thru 12 Over 12 thru 30 Over 30 thru 50 Over 50

Up thru 2.999

3.000-7.999

8.000 and over

1/8

3/16

1/4

1/4

5/16

3/6

3/8

7/16

1/2

1

1

1


Table 11.6 Straightness (1) - Rod, Bar and Profiles

Product Temper SPECIFIED DIAMETER
(ROD):
SPECIFIED WIDTH
(BAR):

CIRCUMSCRIBING
CIRCLE DIAMETER (4):
(PROFILES)
 SPECIFIED
THICKNESS
(RECTANGLES):
MINIMUM
THICKNESS:
(PROFILES)
in.		 Tolerance (3) - in.
INTOTAL LENGTH OR IN ANY
MEASURED
SEGMENT OF ONE FT.
OR MORE OF TOTAL LENGTH
Rod and Square,
Hexagonal
and Octagonal
Bar

All except O

TX510(2)

TX511(2)

 All ..
 .0125 x Measured length, ft.
O .500 and over .. .050 x Measured length, ft.
TX510(2) .500 and over .. .050 x Measured length, ft.
TX511(2) .500 and over .. .0125 x Measured length, ft.
Rectangular Bar

All except O

TX510(2)

TX511(2)		 Up thru 1.499 Up thru 0.094 (7)
0.095 end over		 .050 x Measured length, ft.
.0125 x Measured length, ft.
1.500 and over All .0125 x Measured length, ft.
O Over 0.500 0.500 and over .050 x Measured length, ft.
TX510(2) Over 0.500 0.500 and over .050 x Measured length, ft.
TX511(2) Over 0.500 0.500 and over .0125 x Measured length, ft.
Profiles

All except O

TX510(2)

TX511(2)		 Up thru 1.499 Up thru 0.094 (7)
0.095 end over		 .050 x Measured length, ft.
.0125 x Measured length, ft.
1.500 and over All .0125 x Measured length, ft.
O .500 and over Up thru 0.094 (7)
0.095 end over		 .200 x Measured length, ft.
.050 x Measured length, ft.
TX511(2) .500 and over Up thru 0.094 (7)
0.095 end over		 .050 x Measured length, ft.
.0125 x Measured length, ft.


Image 308

Footnotes for Tables 11.5 through 11.8

(1) These Standard Tolerances are applicable to the average profile; wider tolerances may be required for some profiles, and closer tolerances may be possible for others.


(2) TX510 and TX511 are general designations for the following stress relieved tempers: T3510, T4510, T61510, T6510, T8510, T73510, T76510 and T3511, T4511, T61511. T6511, T8511, T73511, T76511, respectively.


(3) When weight of piece on the flat surface minimizes deviation.


(4) The circumscribing circle diameter is the diameter of the smallest circle that will completely enclose the cross section of the extruded product.


(5) Tolerances for T3510,T4510,T6510,T73510,T76510, andT8510 tempers shall be as agreed upon between purchaser and vendor at the time the contract or order is entered.


(6) Twist is normally measured by placing the extruded section on a flat surface and at any point along its length measuring the maximum distance between the bottom surface of the extruded section and the flat surface. From this measurement, the actual deviation from straightness of the
extruded section at that point is subtracted. The remainder is the twist. To convert the standard twist tolerance (degrees) to an equivalent linear value, the sine of the standard tolerance is multiplied by the width of the surface of the section that is on the flat surface. The following values are used to convert angular tolerances to linear deviation:


Maximum allowable


Tolerance, Degrees Maximum allowable linear deviation inch per inch of width
1/4 0.004
1/2 0.009
1 0.017
1 1/2 0.026
3 0.052
5 0.087
7 0.122
9 0.156
15 0.259
21 0.358













(7) Applies only if the thickness along at least 1/3 of the total perimeter is 0.094 or less. Otherwise use the tolerance shown for 0.095 and over.


(8) Tolerance for "O" temper material is four times the standard tolerances shown.


(9) Straightness must be met in all orientations, including orientations which are not self-supporting.

TABLE 11.7 Twist (1) (6) - Bar and Profiles

Product Temper

Specified Width(Bar):

CIRCUMSCRIBING
CIRCLE DIAMETER (4):
(PROFILES) in.

 SPECIFIED
THICKNESS
(RECTANGLES):
MINIMUM
THICKNESS:
(PROFILES) in.		 Tolerance (3) - Degrees
IN TOTAL LENGTH OR IN
ANY MEASURED SEGMENT
OF ONE FT. OR MORE FOR
OF TOTAL LENGTH		 Maxiumum For Total Length
Bar

All except O

TX510 (2)

TX511 (2)		 Up thru 1.499
1.500-2.999
3.000 and over		 All
All
All		 1 x Measured length, ft.
1/2 x Measured length, ft.
1/4 x Measured length, ft.

7

5

3
O 0.500-1.499
1 500-2.999
3.000 and over		 0.500 and over
0.500 and over
0.500 and over		 3 x Measured length, ft.
1 1/2 x Measured length, ft.
3/4 x Measured length, ft.

21

15

9
TX510 (2) 0.500-2.999
3.000 and over		 0.500 and over
0.500 and over		 1 1/2 x Measured length, ft.
1/2 x Measured length, ft.

7

5
TX511 (2) 0.500-1.499
1 500-2.999
3.000 and over		 0.500 and over
0.500 and over
0.500 and over		 1 x Measured length, ft.
1/2 x Measured length, ft.
1/4 x Measured length, ft.

7

5

3
Profiles

All except O

TX510 (2)(5)

TX511 (2)		 Up thru 1.499
1.500-2.999
3.000 and over		 All
All
All		 1 x Measured length, ft.
1/2 x Measured length, ft.
1/3 x Measured length, ft.

7

5

3
O 0.500 and over
0.500-1.499
1.!500-2.999
3.000 and over		 Up thru 0.094 (7)
0.095 and over
0.095 and over
0.095 and over

3 x Measured length, ft.
3 x Measured length, ft.
1 1/2 x Measured length, ft.

3/4 x Measured length, ft.

21

21

15

9
TX511(2) 0.500 and over
0.500-1.499
1.500-2.999
3.000 and over		 Up thru 0.094 (7)
0.095 and over
0.095 and over
0.095 and over

1 x Measured length, ft.
1 x Measured length, ft.
1/2 x Measured tength, ft.

1/4 x Measured tength, ft.

7

7

5

3
Image 309

TABLE 11.8 Flatness (Flat Surfaces)(1) - Bar, Solid Profiles and Semihollow Profiles

EXCEPT FOR PROFILES IN O(8), T3510. T4510, T6510, T73510. T76510 and T851O TEMPERS (5)
  SURFACES WIDTHS UP THRU 1 INCH OR ANY 1 INCH INCREMENT OF
WIDER SURFACES

Maximum Allowable Deviation D =TOLERANCE (in.)

WIDTHS OVER 1 INCH

Maximum Allowable Deviation D = TOLERANCE x W (in.)
MINIMUM THICKNES OF METAL FORMING THE SURFACE in. Surface With - in.
Up To 5.999 6.000 To 7.999 8.000 To 9.999 10.000 To 11.999 12.000 To 13.999 14.000 To 15.999 16.000 To 17.999 18.000 To 19.999 20.000 To 23.999 22.000 To 23.999 24.000 And Up
Tolerance
Up thru 0.124 .004 .006 .010 .014 .. .. .. .. .. .. ..
0.125-0.187 .004 .006 .008 .012 .014 .014 .014 .. .. .. ..
0.188-0.249 .004 .006 .008 .010 .012 .012 .012 .014 .014 .. ..
0.250-0.374 .004 .006 .006 .008 .010 .010 .012 .012 .012 .014 ..
0.375-0.499 .004 .004 .006 .008 .008 .008 .010 .010 .010 .012 .014
0.500-0.749 .004 .004 .006 .006 .008 .008 .008 .008 .010 .010 .012
0.700-0.999 .004 .004 .006 .006 .008 .008 .008 .008 .008 .008 .010
1.000-1.499 .004 .004 .004 .006 .006 .008 .008 .008 .008 .008 .008
1.500-1.999 .004 .004 .004 .004 .006 .006 .006 .008 .008 .008 .008
2.000 and up .004 .004 .004 .004 .004 .006 .006 .006 .008 .008 .008
Image 310

Table 11.9 Flatness (Flat Surfaces) (1) - Hollow Profiles (Except for Profiles in O(10), T3510, T4510, T6510, T73510, T76510 and T8510 Tempers (4)

 

SURFACES WIDTHS UP THRU 1 INCH OR ANY 1 INCH INCREMENT OF WIDER SURFACES

Maximum Allowable Deviation D = Tolerance (in.)

Widths over 1 inch

Maximum Allowable Deviation D = Tolerance X W (in.)
Minumum Thickness of metal forming the surface in. Surface width - in.
Up To 5.999 6.000 To 7.999 8.000 To 9.999 10.000 To 11.999 12.000 To 13.999 14.000 To 15.999 16.000 To 17.999 18.000 To 19.999 20.000 To 21.999 22.000 To 23.999 24.000 And Up
Tolerance
Up thru 0.124 .006 .008 .012 .016 .. .. .. .. .. .. ..
0.125-0.187 .006 .008 .010 .014 .016 .. .. .. .. .. ..
0.188-0.249 .004 .006 .010 .012 .014 .014 .014 .016 .. .. ..
0.250-0.374 .004 .006 .008 .010 .012 .012 .012 .014 .014 .016 ..
0.375-0.499 .004 .006 .008 .010 .010 .010 .012 .012 .012 .014 .016
0.500-0.749 .004 .004 .006 .008 .008 .008 .010 .010 .012 .012 .014
0.750-0.999 .004 .004 .006 .006 .008 .008 .008 .008 .010 .010 .012
1.000 and up .004 .004 .004 .006 .006 .008 .008 .008 .008 .008 .008
Image 311

Table 11.10 Surface Roughness (1) (8) - Extruded Wire, Rod, Bar and Profiles

Specified Section Thickness in. Allowable Depth of Conditions (2) in. max.
Up thru 0.063 0.0015
0.064-0.125 0.002
0.126-0.188 0.0025
0.189-0.250 0.003
0.251-0.500 0.004
0.501 and over 0.008

TABLE 11.11 Contour (Curved Surfaces) (1) (3) - Extruded Profiles

 Image 312
Temper
All except O, TX510 (4) Allowable deviation from specified contour: 0.005 inch per inch of chord length; 0.005 inch minimum. Not applicable to contours with chord length 6 inch and over.
O Allowable deviation from specified contour: 0.015 inch per inch of chord length; 0.015 inch minimum. Not applicable to contours with chord length 6 inches and over.

Table 11.12 Squareness of Cut Ends (1) - Extruded Rod, Bar and Profiles

Allowable devation from square: 1 degree

Table 11.13 Corner and Fillet Raddi (1) - Extruded Bar and Profiles

Specified Radius (9) in. Tolerance - in.
Sharp corners +- 1/64
0.016-0.187 +- 1/64
0.188 and over +- 10%
Image 313

TABLE 11.14 Angularity (1)(5) - Extruded Bar and Profiles

Temper Minimum Specified Leg Thickness in.

Tolerance

Degrees plus and minus
Allowable deviation from specified angle
Ratio: (6) (7) Leg or Surface length to leg or metal thickness
1 and less Over 1 thru 40
  Col. 1 Col. 2 Col. 3
All except O, TX510 (4)

Up thru 0.187

0.188-0.749

0.750 and over

1

1

1

2

1 1/2

1
O

Up thru 0.187

0.188-0.749

0.750 and over

3

3

3

6

4 1/2

3
Image 314