Aluminum alloy quirks (welding, built-up edge, chips)

?Likely causes

• It is soft and ductile, so chips become long and welding tends to roughen the finished surfaceAgreed by 2+ makers^[1][2]
• Welding and built-up edge occur easily (sticky material)Agreed by 2+ makers^[3][1][4]
• Elastic deformation causes welding on the flank as wellOne maker^[5]
• Alloys with high Si content have hard particles that worsen machinabilityOne maker^[1]
• Internal threads tend to shrink from elastic recovery (a material with little enlargement allowance)One maker^[6][7]
• Aluminum tends to weld to thread gaugesOne maker^[8]

✓Fixes

Cutting conditions

• Break long chips with step cycles (G73, etc.)One maker^[2][9]

Tool

• Use a cutter with a large rake angle and a sharp tool made for aluminumAgreed by 2+ makers^[4][9][1]
• Use a larger clearance angle than for steel and a tool with a mirror-finished rake faceOne maker^[5]
• For reamers, consider cutting part materials with low affinity, such as diamondOne maker^[10]
• For taps, consider an oversize (higher accuracy class) tapOne maker^[6][7]

Coolant

• Use enough cutting fluid concentration and supply (to prevent tearing)One maker^[9]

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