Custom Alloy Aluminum Threaded Studs M3 M4 M5 M6 M8 for Connector

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What is a Aluminum Threaded Stud?

An Aluminum Threaded Stud is a cylindrical fastener with threads on one or both ends, made from aluminum or aluminum alloy. It is used to join components in lightweight, corrosion-resistant, or thermally conductive applications. These aluminum threaded studs are common in industries where weight reduction, electrical conductivity, and resistance to oxidation are critical.

Specifications of Aluminum Threaded Studs

Material

• Aluminum Alloys (Common grades:

  • 6061-T6 – High strength, good corrosion resistance, weldable.

  • 7075-T6 – Aerospace-grade, very strong but less corrosion-resistant.

  • 2024-T3 – High strength-to-weight ratio, used in aircraft.

  • Pure Aluminum – Excellent corrosion resistance but lower strength.

Surface Treatment

• Anodizing (Clear or Colored) – Enhances corrosion and wear resistance.

• Chromate Conversion Coating (Alodine/Iridite) – Improves corrosion resistance and paint adhesion.

• Powder Coating – Provides additional protection and color options.

• Natural (Bare Aluminum) – Used when oxidation is acceptable.

Standard Specifications

• Thread Standards: Metric (M3, M4, M6, etc.), UNC, UNF

• Length: 10mm to 300mm (custom lengths available)

• Diameter: M2 to M20 (or larger for industrial use)

• Thread Pitch: Fine or coarse, depending on application

Applications of Aluminum Threaded Studs

• Aerospace & Aviation – Lightweight fastening in aircraft structures.

• Automotive – Used in engines, radiators, and electric vehicles (EVs).

• Electronics & Heat Sinks – Provides thermal conductivity for cooling systems.

• Marine & Offshore – Corrosion-resistant fasteners for saltwater environments.

• Renewable Energy – Solar panel mounting and wind turbine assemblies.

• Consumer Goods – Bicycles, cameras, and lightweight machinery.

Excellent Case: Electric Vehicle (EV) Battery Pack Assembly

Challenge

An EV manufacturer needed a lightweight, corrosion-resistant fastener to secure battery modules while ensuring good electrical grounding and thermal dissipation. Steel fasteners added unnecessary weight and risked galvanic corrosion when in contact with aluminum battery housings.

Solution

• Anodized 6061-T6 Aluminum Threaded Studs were chosen because they:

  • Reduce weight, improving vehicle efficiency.

  • Resist corrosion from battery electrolytes.

  • Provide excellent thermal conductivity to help manage heat.

  • Prevent galvanic corrosion when paired with aluminum components.

Result

• Weight reduction (~30% lighter than steel fasteners).

• Long-term durability (no rust or galvanic corrosion issues).

• Improved thermal management (better heat dissipation from battery cells).

• Lower maintenance costs (no need for frequent replacements).