In large-scale projects such as aerospace, shipbuilding and offshore engineering, energy and power, rail transit, and heavy equipment, conventional aluminum sizes often cannot meet the design requirements of large structures, integral forming, fewer welded joints, and heavy-duty components. These projects therefore require large aluminum products with greater width, thickness, diameter, cross-section, or length.
Manufacturing becomes significantly more difficult as product size increases. In addition to equipment capacity limits, large aluminum products require careful control of microstructural uniformity, forming stability, dimensional tolerances, internal quality, and deformation during machining and transportation. Different product forms also require different production routes, such as rolling, extrusion, forging, and cutting. They are not simply enlarged versions of conventional products.
With large-scale aluminum processing equipment, multiple forming processes, and supporting machining, inspection, and quality control capabilities, Chalco can produce ultra-wide aluminum plate, ultra-thick aluminum plate, large-diameter aluminum tube, large-diameter aluminum bar, large-section aluminum extrusions, and large aluminum forgings. Production and supply plans can be developed according to specific requirements for alloy, temper, dimensions, tolerances, and application.
If your project specifications exceed conventional size ranges, you can provide the required dimensions, alloy, quantity, application, or drawings. We can assess manufacturing feasibility based on the actual requirements and recommend a suitable product form and production route.
Large Aluminum Products Chalco Can Supply
Large structures often aim to create bigger integral components with fewer material joints. Wider plate can reduce welds, larger tubes and bars can meet the size requirements of integral cylinders and large machined parts, and large-section or long extrusions can integrate multiple structural functions into a single component.
For these large-scale engineering requirements, Chalco can supply ultra-wide aluminum plate, ultra-thick aluminum plate, large-diameter aluminum tube, large-diameter aluminum bar, large-section aluminum extrusions, and large aluminum forgings. Large sizes are produced through rolling, extrusion, forging, and subsequent processing as appropriate. The actual manufacturable range can be further evaluated according to alloy, temper, dimensions, tolerances, and end use.
Ultra-Wide and Ultra-Thick Aluminum Plate
Aluminum plate for large structures often exceeds conventional width or thickness limits. Ultra-wide aluminum plate provides a larger integral plate area to reduce joints and welding, while ultra-thick aluminum plate provides greater section size and machining allowance for large load-bearing components and deeply machined parts.
Ultra-Wide Aluminum Plate and Coil
Maximum stretched width for T651 plate:4350 mm
Maximum hot-rolled plate/coil width:2650 mm
Supply forms:Aluminum plate, aluminum coil
Maximum thickness:Up to 600 mm
Main applications:Large molds, equipment bases, load-bearing structures, and heavy-duty CNC-machined parts
Supply forms:Ultra-thick aluminum plate, sawn aluminum blocks, cut-to-size blanks
Large-Diameter Aluminum Tube
Large-diameter aluminum tube provides a large hollow cross-section while helping reduce structural weight. It is suitable for large cylinders, load-bearing structures, piping systems, and large machined components. Requirements for outside diameter, wall thickness, length, cross-sectional shape, and dimensional accuracy vary by project, so the manufacturing method should be selected according to the end use.
Chalco can provide forged tubes, extra-large seamless tubes, high-precision tubes, and large square and rectangular tubes. These products are supported by extrusion, forging, vertical extrusion, forming, and precision machining capabilities for different large-scale engineering requirements.
Popular large-diameter aluminum tube types from Chalco include:
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Maximum diameter: Φ1000 mm
Wall thickness: 20–100 mm
Length: ≤6000 mm or customized as required
Applications: Suitable for large mechanical structures, piping, and projects requiring large-diameter tube as a machining blank.
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Outside diameter: 200–1320 mm
Wall thickness: 18–220 mm
Length: 4–12 m
Manufacturing method: 500MN vertical hot extrusion
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Dimensional tolerance: Some products can reach ±0.05 mm
Surface roughness: Some products can reach Ra 0.4 μm
Applications: Suitable for tube projects with demanding requirements for dimensional accuracy, surface quality, and subsequent precision machining.
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Square tube size: 300×300–1200×1200 mm
Rectangular tube size: 300×400–1000×1200 mm
Wall thickness: 6–120 mm
Length: 4–12 m
Large-Diameter Aluminum Bar
For large shafts, flanges, round structural parts, and heavy-duty machined components, large-diameter aluminum bar provides a full solid cross-section and sufficient machining allowance. It reduces the need for joined structures and provides an integral starting blank for turning, milling, and deep machining of large components.
Chalco can supply large-diameter aluminum bars, billets, and round blanks sawn to finished-size requirements for aerospace, marine, heavy machinery, and large structural applications.
- Maximum diameter: Φ1350 mm
- Common diameters: Φ600–700 mm
- Length: Customizable as required
- Popular alloys: 2014, 2024, 2219, 2524, 2618, 3104, 5182, 5083, 6061, 7050, 7055, 7075, 7175
- Supply forms: Full-length aluminum bar, cut-to-length bar, sawn discs, round blanks
- Processing services: Saw cutting, turning, milling, drilling, and machining to drawings
- Typical applications: Aerospace, marine, heavy machinery, and large structural components
Learn more about Chalco large-diameter aluminum bar →
Large-Section Aluminum Extrusions
In rail transit, vehicles, aerospace, energy equipment, and industrial structures, more components are being designed as large integral extrusions. Integrating ribs, hollow chambers, mounting slots, and connection features into one cross-section can reduce part count and welded joints while increasing structural integration.
Chalco can produce large, long, and complex-section aluminum extrusions and customize alloy, cross-sectional design, wall thickness, length, and subsequent processing according to customer drawings. The overall manufacturing capability stated on the current product page is: width up to 750 mm, minimum wall thickness 0.3 mm, and length up to 26 m.
Specifications:
| Maximum width | 750 mm |
| Minimum wall thickness | 0.3 mm |
| Maximum length | 26 m |
| Alloys | 2024, 5083, 6060, 6005, 6061, 6063, 6082, 7075, 7005 |
| Product forms | Solid sections, hollow sections, complex custom sections |
| Processing services | CNC machining, surface treatment, bending, welding, assembly |
| Typical applications | Aerospace, rail transit, automotive, battery trays, containers, bridges, heat sinks, and large industrial structures |
For large-section or extra-long extrusions approaching equipment limits, the actual manufacturable size must be evaluated based on alloy, wall thickness, cross-sectional design, and die design. See large custom aluminum extrusions for more information on manufacturing capabilities, or submit a cross-section drawing for a feasibility assessment.
Large Aluminum Forgings
For large load-bearing parts, connectors, and structures with complex loading, aluminum forgings provide integral blanks for critical components while maintaining the lightweight advantage of aluminum. Compared with assemblies made by welding or joining multiple parts, large integral forgings are more suitable for projects with demanding requirements for structural integrity, internal material quality, and subsequent heavy machining.
Typical alloys:6061, 7050, 7075, 2219
Open-die forging diameter capability:Aluminum alloy up to Ø3000 mm
Ring-rolling capability:Aluminum alloy up to Ø3500 × 1200 mm
Chalco can provide large open-die forgings and ring-rolled forgings according to customer drawings, including forged rings, shafts, blocks, discs, flanges, forged tubes, forged bars, and custom-shaped components. Custom supply plans can also include heat treatment, rough machining, inspection, and subsequent machining.
If your part is a large load-bearing structure, forged ring, flange, shaft, or another heavy blank made to drawing, see Chalco large forging products and manufacturing capabilities for more information on forging forms, manufacturing processes, and project customization ranges.
Large Plate-Cut Aluminum Busbar
When conventional extruded aluminum busbar cannot meet ultra-wide, ultra-thick, extra-long, or large-section requirements, large conductive busbars can be produced by cutting thick aluminum plate, followed by hole and slot machining, end processing, bending, and flexible connection features.
- Typical large-size project: 120 × 600 × 10,000 mm
- Typical material: A1070 H112
- Applicable sizes: Projects with widths of 500–600 mm, thicknesses around 100 mm, and lengths in the 8–10 m range can be evaluated
- Processing services: Cutting, drilling, slotting, end processing, bending, and flexible connections
- Typical applications: Large rectifier systems, electrolysis equipment, transformers, generators, and high-current connections in heavy industry
Learn more about Chalco large plate-cut aluminum busbar →
Ultra-Wide Thin-Wall Microchannel Aluminum Tube
Chalco ultra-wide thin-wall microchannel aluminum tube is integrally extruded through a flat die to form a wide, multi-channel thin-wall structure. This can reduce conventional assembly welding while combining lightweight design, structural integrity, and heat-transfer efficiency. It is suitable for EV battery cooling, energy-storage thermal management, 5G heat dissipation, and large heat-exchange systems.
| Width capability | Up to 550 mm |
| Wall thickness | 0.3–3.0 mm |
| Height | 1.5–70 mm |
| Product forms | Water-cooling plates, base plates, multi-channel cooling profiles, integrated modules |
| Typical alloys | 3003, 6005, 6061, 6063 |
| Inspection support | Dimensional inspection, air-tightness testing, pressure testing, and leak testing |
If your project requires ultra-wide, ultra-thick, extra-large-diameter, or extra-long aluminum products, Chalco can provide a suitable large-size aluminum solution based on the actual requirements.
Advantages of Large Aluminum Products for Major Projects
In large structures for marine, aerospace, rail transit, energy equipment, and heavy machinery, material dimensions affect not only the component itself but also welding, assembly, machining, and overall structural design. Using wider, thicker, larger-diameter, or longer aluminum products creates more opportunities to manufacture large components as integral parts.
Reduce Joints and Welding
Larger plate sizes, lengths, and cross-sections can reduce welds and connection points created by joining multiple pieces, allowing large structures to be manufactured from more integral material.
Increase Structural Integration
Large aluminum plate, large-section extrusions, seamless tubes, and integral forgings can consolidate structures that would otherwise require multiple parts into larger single components.
Retain the Lightweight Advantage of Aluminum
For ships, rail vehicles, aerospace structures, and large transportation equipment, material weight becomes more significant as structure size increases. Large aluminum products make it possible to create large integral structures while retaining the low-density advantage of aluminum.
Provide Integral Blanks for Large-Scale Machining
Ultra-thick aluminum plate, large-diameter aluminum bar, large-diameter tube, and large forgings can be used directly as integral machining blanks for large components, providing sufficient material size and machining allowance for turning, milling, drilling, and deep-cavity machining.
Provide More Design Flexibility for Complex Large Structures
Large extrusions, microchannel profiles, and custom forgings can use complex sections, hollow chambers, ribs, or integral forming to combine structural, connection, and functional features in one large component.
Reduce Manufacturing Steps in Large Projects
When the material is closer to the final component size and shape, intermediate joining, welding, pre-assembly, and some rough-machining steps can be reduced.
Main Applications of Large Aluminum Products
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AerospaceLarge aluminum plate, seamless aluminum tube, and large aluminum forgings can be used for aircraft fuselages, frames, cylindrical structures, and integrally machined structures, combining large load-bearing requirements with lightweight design.
Lightweight designintegral structureshigh reliability -
Marine and Offshore EngineeringUltra-wide aluminum plate, long extrusions, and large-diameter tubes are suitable for hulls, decks, superstructures, and offshore engineering structures, helping reduce material joints and welding in large structures.
Seawater corrosion resistancereduced welding -
Rail TransitLarge-section and long aluminum extrusions are widely used in car bodies, underframes, and sidewall structures for high-speed trains, metro vehicles, and large transport vehicles, supporting more integrated and lightweight body structures.
Integrated car bodieslightweight transportation -
Energy and PowerLarge aluminum busbars can be used in power generation, transmission and distribution, electrolysis, and rectifier equipment to meet material requirements for large equipment structures and high-current conductive components.
High-current transmissionlarge conductors -
Heavy Machinery and Industrial EquipmentUltra-thick aluminum plate, large-diameter aluminum bar, thick-wall aluminum tube, and large forgings can serve as integral machining blanks for equipment bases, shafts, flanges, cylinders, and large CNC-machined parts.
Heavy-duty structuresintegral machining -
New Energy and Thermal ManagementUltra-wide microchannel profiles, large water-cooling plates, and large-section aluminum extrusions can be used in traction batteries, energy-storage systems, and large liquid-cooling structures, integrating cooling channels, load-bearing, and mounting functions.
Lightweight designlarge liquid-cooling structures
If your project involves aerospace, marine, rail transit, energy equipment, or other large structural applications, contact Chalco for product and manufacturing support tailored to your project.
Why Choose Chalco?
Chalco has an equipment system covering large-scale rolling, pre-stretching, vertical extrusion, high-tonnage extrusion, open-die forging, and ring rolling. Equipment with different tonnages and forming methods works together to support large aluminum products including plate, tube, extrusions, and forgings, providing a manufacturing base for major engineering projects.
Rather than relying on a single type of equipment, Chalco combines large-scale forming with heat treatment, machining, and quality inspection capabilities. This allows large products to be manufactured and quality-controlled within a complete production system.
Large Rolling and Pre-Stretching Equipment
- Core equipment: 1+4 hot rolling line, 125MN pre-stretching machine
- Equipment capabilities: Large plate rolling, wide plate stretching, residual stress control
- Production support: Melting and casting, hot rolling, heat treatment, stretching, straightening, and inspection
Large aluminum plate requires not only sufficient effective rolling width but also adequate stretching capacity. After rolling and heat treatment, high-strength plate requires high-tonnage stretching equipment for stress relief and dimensional stability control.
Chalco large hot rolling line is paired with a 125MN pre-stretching machine to support continuous production from large slab rolling through plate stretching, providing an equipment base for plate used in large integral structures.
500MN Vertical Hot Extrusion Equipment
- Core equipment: 500MN vertical hot extrusion press
- Equipment capabilities: Ultra-high extrusion force, vertical forming, production of large thick-wall hollow components
- Production support: Billet heating, extrusion forming, heat treatment, straightening, and subsequent inspection
As aluminum alloy product diameter, wall thickness, and individual part size increase, conventional horizontal extrusion equipment is limited by extrusion force and available equipment space.
The 500MN vertical hot extrusion equipment provides greater forming capability, allowing Chalco to produce extra-large, thick-wall, integral seamless structures. For aerospace, large equipment, and important hollow structures, this high-tonnage equipment provides the capacity needed for large integral forming.
High-Tonnage Forging and Ring-Rolling Equipment
- Core equipment: 800-ton open-die forging hammer, 6000–12000-ton hydraulic presses, large ring-rolling equipment
- Equipment capabilities: High-tonnage pressing, integral forging, continuous rolling of large rings
- Production support: Forging, ring rolling, heat treatment, machining, and nondestructive testing
Large aluminum forgings require sufficient equipment tonnage and working space to achieve effective deformation through the full cross-section. Large forged rings also require dedicated ring-rolling equipment for integral continuous forming.
Chalco large hydraulic forging and ring-rolling equipment covers both open-die forging and ring rolling. It can support integral production of large load-bearing structures and critical components while providing suitable blanks for subsequent heat treatment and machining.
Quality Control for Chalco Large Aluminum Products
Chalco applies quality control throughout raw material preparation, production, and final inspection of large aluminum products, with a focus on dimensional accuracy, internal quality, and material properties.
Dimensional and Geometric Control
Depending on the product form, key dimensions and geometric characteristics such as width, thickness, diameter, wall thickness, flatness, straightness, roundness, and concentricity are inspected.
Material Property Testing
Testing can include chemical composition analysis, tensile testing, yield strength, elongation, and hardness to verify the material and heat-treatment condition against specified requirements.
Nondestructive Testing
For thick plate, large-diameter tubes and bars, and large forgings, nondestructive testing such as UT ultrasonic testing, RT radiographic testing, and PT penetrant testing can be provided as required.
Final Inspection and Quality Documentation
Final inspection of appearance, dimensions, and order requirements is completed before shipment. Material certificates, test reports, and third-party inspection support can also be provided.
Certifications and Quality Systems
Chalco has established quality management, production control, and inspection systems. Relevant certifications and quality documents can be provided according to product and project requirements for major engineering projects.
- ISO 9001: Quality management system certification
- AS9100: Aerospace quality management system certification
- GJB 9001: Quality management system for demanding manufacturing sectors
- ISO/IEC 17025: Laboratory testing and calibration competence accreditation
- Nadcap: Special-process certification for forging, heat treatment, nondestructive testing, and related processes
- ISO 14001: Environmental management system certification
- ISO 45001: Occupational health and safety management system certification
- EN 10204 3.1: Material certification and traceability documentation can be provided according to order requirements.
FAQ
What Are Large Aluminum Products?
Large aluminum products generally refer to aluminum plate, tube, bar, extrusions, and forgings whose width, thickness, diameter, cross-section, or length significantly exceeds conventional commercial sizes. They are mainly used for large integral structures, heavy-duty components, and large machining blanks.
What Large Aluminum Products Can Chalco Supply?
Chalco can supply ultra-wide aluminum plate, ultra-thick aluminum plate, large-diameter aluminum tube, large-diameter aluminum bar, large-section and extra-long aluminum extrusions, large aluminum forgings, and special products such as ultra-wide microchannel aluminum tube and extra-large aluminum busbar.
Can Large Aluminum Products Be Made to Drawings?
Yes. Customers can provide product drawings or detailed dimensional requirements. Chalco can evaluate a production plan based on alloy, temper, structural dimensions, tolerances, properties, and processing requirements.
How Is the Quality of Large Aluminum Products Controlled?
Chalco applies quality control from raw materials and forming through heat treatment and final inspection. Available inspection can include dimensional and geometric checks, chemical composition analysis, mechanical property testing, and nondestructive testing such as UT, RT, and PT.
How Are Extra-Long or Oversized Aluminum Products Transported?
Chalco selects packaging and transportation methods according to product length, width, weight, and destination. Options can include reinforced wooden cases, supports, steel frames, containers, open-top containers, or other oversized-cargo solutions to reduce the risk of deformation and surface damage during lifting and transportation.
What Information Is Needed to Request a Quote for Large Aluminum Products?
Please provide the product form, alloy, temper, dimensions, quantity, tolerances, applicable standard, application, and delivery location. For non-standard parts or complex cross-sections, drawings are also recommended so manufacturing capability and quotation can be evaluated more accurately.
