Aluminium stands out for its light weight, machinability and corrosion resistance. It is a chemical element with atomic number 13 and the symbol Al. It is a silver-coloured, ductile metal and is generally found in nature in the form of bauxite ore. According to information published in the MTA Natural Resources and Economy Bulletin, Türkiye’s total bauxite reserves, the main ore used in aluminium production, are stated to be approximately 422 million tonnes, of which approximately 63 million tonnes are considered exploitable.
Aluminium is a metal that can be shaped to meet the needs of different industries and therefore has a very wide range of applications. Thanks to its low density, it offers lighter solutions than steel, while different mechanical properties can be achieved through the choice of alloy and temper. These characteristics make aluminium suitable not only for sheet and cast products, but also for products such as aluminium profiles and tubes. In this article, drawing on the industry experience of ÖZAK Aluminium Extrusion, we will answer the questions of what an aluminium tube is and where it is used.
Aluminium tube is a type of hollow-section profile manufactured from aluminium alloys. The tube geometry may be round, square, rectangular or customised for a specific project. For this reason, the term “aluminium tube” in the market may refer not only to a conventional round metal tube, but also to hollow aluminium profile solutions in different cross-sections. However, the alloy and temper used in production directly affect the mechanical behaviour of the tube. What does this mean in practice? For example, 6063 alloy is frequently preferred in architectural and general profile applications because of its extrudability and surface quality, while alloys such as 6061 may be considered for certain applications requiring higher strength. The right choice should therefore be based not only on where the product will be used, but also on the loads and operating conditions to which it will be exposed. Aluminium’s low density is particularly advantageous in systems where weight is critical.
What Are the Types of Aluminium Tubes?
When selecting aluminium tube types, considering dimensions alone is not sufficient. The area of use, the load to be carried, the installation method and the expected surface properties also play a decisive role in product selection. For this reason, aluminium tubes are manufactured in a variety of cross-sections and technical specifications to meet different requirements. The main types of aluminium tubes that can be considered according to project needs are as follows:
Round Aluminium Tube:
Thanks to its circular cross-section, it is used in mechanical systems, non-load-bearing structures, railings, furniture applications and various machine parts. Outer diameter, inner diameter and wall thickness should be evaluated together
Square and Rectangular Aluminium Tube:
Its flat surfaces provide advantages for connection and installation. It may be preferred for chassis, frames, stands, machine structures and furniture applications.
Industrial Aluminium Tube:
These tubes are considered for applications requiring higher mechanical performance, dimensional precision or a specific alloy-temper combination. Depending on the use case, wall thickness and tolerances become critical.
Custom-Section Aluminium Tubes:
For projects where standard dimensions are insufficient, application-specific cross-sections can be produced by extrusion. This approach makes it possible to combine parts into a single profile and integrate certain connection details into the profile geometry.
Aluminium Tube Dimensions and Technical Specifications
When determining aluminium tube dimensions, the inner diameter, wall thickness, length, tolerance and alloy information should be specified in addition to the outer diameter or outer dimension. For round products, aluminium tube diameters are generally stated based on the outer diameter. For example, of two tubes with an outer diameter of 40 mm, one may have a wall thickness of 2 mm and the other 4 mm. Even though the outer diameter is the same, their weight, rigidity and intended use will differ.
The table below summarises the key technical criteria to consider when selecting an aluminium tube, including dimensions, wall thickness, alloy, temper, tolerance, length and surface treatment.
Technical Criterion
What Does It Mean?
Why Is It Important in Selection?
Outer diameter / outer dimension
The overall cross-sectional dimension of the tube.
Determines installation and system compatibility.
Inner diameter
The dimension of the internal hollow section of the tube.
Important for applications involving cables, fluids or connection elements.
Wall thickness
The material thickness between the outer and inner sections.
Affects rigidity, weight and strength.
Alloy
The chemical composition of the material.
Affects strength, extrudability and surface properties.
Temper
Indicates the heat-treatment and mechanical-property condition.
Used to determine mechanical performance.
Tolerance
The permitted deviation range of a dimension.
Becomes critical in precision assemblies.
Length
The cut length of the profile.
Affects transport, installation and scrap calculations.
Surface treatment
Refers to anodising, painting and similar applications.
Evaluated according to appearance and operating conditions.
Small-Diameter Aluminium Tubes (Ø8–Ø25 mm)
Small-diameter aluminium tubes are preferred for more compact applications where light weight and ease of machining are important. Wall thickness and alloy selection should also be evaluated according to the intended use.
- Ø8–10 mm aluminium tube: May be used in hobby and model-making applications, RC model vehicles, lightweight structures and some lighting fixtures.
- Ø16 mm aluminium tube: May be preferred for curtain mechanisms, furniture details and light mechanical applications.
- Ø25 mm aluminium tube: May be used in furniture and retail equipment, hanging systems, shelving applications and various decorative structures.
Medium-Diameter Aluminium Tubes (Ø30–Ø45 mm)
Tubes in the medium-diameter range stand out in applications that require greater rigidity but do not fall into the heavy-structure category. They can be considered in different dimensions for furniture, retail, architectural applications and lightweight railing systems.
- Ø30–32 mm aluminium tube: May be used in display and retail systems, lightweight railings, furniture and decorative structures.
- Ø35 mm aluminium tube: May be preferred for furniture legs, office partition systems and various frame applications.
- Ø40 mm aluminium tube: One of the commonly used diameters for handrails, railings, grab bars and similar applications. However, the appropriate diameter should be determined according to ergonomics and design requirements.
Large-Diameter and Industrial Aluminium Tubes (Ø50 mm and Above)
As the diameter increases, the tube’s cross-sectional geometry and wall thickness become more decisive in terms of rigidity and load-carrying capacity. Products in this group may be used in structures, pole systems, industrial equipment and applications with higher mechanical requirements.
- Ø50 mm aluminium tube: May be considered for pole systems, advertising and signage applications, railings and various structures. Different wall thicknesses may be selected according to the requirement.
- Ø60 mm aluminium tube: May be used for billboard poles, industrial railings and structures requiring greater rigidity.
- Ø100 mm aluminium tube: May be preferred for non-load-bearing structures requiring a large diameter, or structures determined by engineering calculations, as well as machinery and industrial applications.
Applications of Aluminium Tubes
Thanks to aluminium’s light weight, machinability and suitability for different surface treatments, tube profiles can be used across many industries. However, each application may require a different alloy or wall thickness. The main areas in which aluminium tubes are used include:
- Machinery and equipment manufacturing
- Automotive and transportation applications
- Furniture and decoration
- Railings, handrails and lightweight structures
- Ventilation and various mechanical systems
- Curtain systems, stands, display and retail equipment
- Industrial chassis and frame applications
- Solar energy and similar support systems
- Architectural and construction applications
- Custom-manufactured machine parts
- Defence industry
- Automotive industry
- Marine materials
Aluminium Tube Prices
Aluminium tube prices cannot be evaluated based on a single figure. Product prices vary depending on many factors, including alloy, temper, outer dimension, wall thickness, product length, order quantity, surface treatment, production method and custom-section requirements. In particular, for custom-sized aluminium tube production, die costs and production quantities may affect the unit price. A standard product and a product requiring a project-specific extrusion die do not have the same cost structure. Looking only at the price per kilogram when evaluating a quotation can also be misleading. The project’s total requirement, cutting waste, surface treatments, tolerances and delivery conditions should be considered together.
How to Select the Right Aluminium Tube for Your Project?
When selecting an aluminium tube for your project, you should first clarify the role the tube will perform and the conditions in which it will be used. The following information should then be defined:
Cross-section and dimensions:
Specify whether the section is round, square, rectangular or custom. For round tubes, the outer diameter, inner diameter and wall thickness should be defined together.
Alloy and temper:
Select the material according to the expected mechanical properties. An application-appropriate balance should be established between extrudability and strength.
Tolerance:
For applications where the tube must fit precisely with other parts, check whether standard tolerances are sufficient.
Surface treatment:
If the product will be used on a visible surface, anodising, painting or another surface solution may be required.
Production quantity:
The number of pieces and total kilograms are important when evaluating custom die investment and production planning.
Machining requirements:
If subsequent operations such as cutting, drilling, bending, CNC machining or welding are required, the product should be selected accordingly.
ÖZAK Aluminium in Aluminium Tube Production
ÖZAK Aluminium Extrusion, with its expertise in aluminium extrusion, carries out manufacturing processes for both standard and project-specific profile requirements. For custom sections evaluated based on technical drawings, die design, manufacturability, alloy selection, dimensional tolerances and surface treatments can be considered together. ÖZAK Aluminium Extrusion provides production and supply support based on technical requirements for projects that require custom sections, as well as standard aluminium profile solutions. By sharing your project dimensions, technical drawing or required product specifications, you can obtain information about the appropriate product and production method.
Frequently Asked Questions
How Is Aluminium Tube Weight Calculated and a Size Table Prepared?
The basic formula used to calculate the weight of an aluminium tube per metre is as follows:
Weight (kg/m) = π × [(D² − d²) / 4] × ρ
Where:
D = Outer diameter of the tube (mm)
d = Inner diameter of the tube (mm)
ρ = Aluminium density (approximately 2.70 g/cm³ or 2700 kg/m³)
π = 3.14
If the inner diameter is not known:
d = D − (2 × wall thickness)
For example, for a tube with an outer diameter of Ø30 mm and a wall thickness of 2 mm:
Inner diameter = 30 − (2 × 2) = 26 mm
These values can be inserted into the formula to calculate the weight of 1 metre of tube.
Do Aluminium Tubes Rust?
No, aluminium tubes do not rust. However, factors such as chemical environments, salt water, galvanic contact and surface conditions can affect corrosion behaviour.
Can Aluminium Tubes Be Manufactured in Custom Sizes
Yes, they can. When standard dimensions do not meet project requirements, custom sections can be produced using the aluminium extrusion method.
Which Is Stronger: Aluminium Tube or Steel Tube?
Steel tubes generally offer higher strength. However, aluminium tubes are lighter, corrosion-resistant and easier to machine, which makes them advantageous in projects where weight is important. The correct choice should be made according to the intended use and the load to be carried.