CNC Machining 7075 Aluminum Services | Aerospace-Grade Quality

Generally, no. 7075 aluminum is considered unweldable for structural applications due to its high zinc content. Welding causes micro-cracking in the heat-affected zone, significantly reducing the part's strength and fatigue resistance.

If your design requires welded assemblies, we strongly recommend switching to 6061 aluminum or using mechanical fasteners (bolts/rivets) for 7075 parts.

7075-T6 has much higher tensile strength and hardness compared to 6061, rivaling some soft steels. This makes it more abrasive on cutting tools, generating higher heat. It requires specialized tool paths, slower feeds, and rigid setups to maintain precision tolerance without causing thermal distortion or tool wear.

For maximum durability, Type III Hard Anodizing is best, creating a wear-resistant, ceramic-like surface. For corrosion protection and aesthetics, Type II anodizing is common, though colors may appear duller due to zinc. If electrical conductivity needs to be maintained, Chromate Conversion (Alodine) is the ideal choice.

Typically, raw 7075-T6 material costs about 2 to 3 times more than standard 6061-T6 due to its complex alloying elements and processing. Machining costs are also slightly higher due to slower cutting speeds. We recommend choosing 7075 only when its superior strength-to-weight ratio is absolutely necessary for your application's performance.

Aluminum doesn't "rust" like steel, but 7075 has lower natural corrosion resistance than alloys like 6061 or 5052 because of its high zinc and copper content. It is susceptible to stress corrosion cracking in harsh environments. We highly recommend applying a protective finish, such as anodizing, for any parts exposed to the elements.

Despite the material's hardness, RALLY’s advanced CNC equipment and experienced operators routinely achieve tight tolerances of ±0.01mm (±0.0004”) on critical features. We utilize temperature-controlled machining environments and in-process probing to ensure consistent accuracy across production runs, from complex prototypes to high-volume orders.

The difference is chemical. 7075 has a high concentration of zinc, which reacts differently during the electrochemical anodizing process compared to 6061. This often results in colors (especially black or clear coats) appearing slightly more matte, greyish, or "earthy" on 7075, rather than the vibrant, shiny finish typical of 6061.

No, 7075 aluminum is not magnetic. Like almost all aluminum alloys, it is a non-ferrous metal. This property makes it an excellent material choice for aerospace components, electronic enclosures, or medical devices where magnetic interference must be avoided near sensitive instrumentation.