Common sizes of inch aluminum angle stock include: - 1/2" x 1/2" x 1/16" - 3/4" x 3/4" x 1/8" - 1" x 1" x 1/8" - 1-1/2" x 1-1/2" x 1/8" - 2" x 2" x 1/8" - 2" x 2" x 1/4" - 3" x 3" x 1/4" - 4" x 4" x 1/4" - 6" x 6" x 1/2" These sizes refer to the length of each leg and the thickness of the angle.

To cut aluminum angle stock, follow these steps: 1. **Select the Right Tools**: Use a miter saw with a carbide-tipped blade designed for cutting non-ferrous metals. Alternatively, a hacksaw with a fine-toothed blade or a metal-cutting bandsaw can be used for smaller or thinner stock. 2. **Measure and Mark**: Measure the length you need using a tape measure. Mark the cut line on the aluminum angle with a permanent marker or a scribe for precision. 3. **Secure the Stock**: Clamp the aluminum angle securely to a workbench or saw table to prevent movement during cutting. Use a vise or C-clamps to hold it in place. 4. **Set Up the Saw**: If using a miter saw, adjust the angle and depth settings as needed. Ensure the blade is appropriate for aluminum and is sharp. 5. **Safety Precautions**: Wear safety goggles, gloves, and ear protection. Aluminum can produce sharp edges and loud noise when cut. 6. **Cutting Process**: Start the saw and let it reach full speed before making contact with the aluminum. Slowly and steadily guide the saw through the material, applying consistent pressure. If using a hacksaw, use long, even strokes. 7. **Deburring**: After cutting, use a file or deburring tool to smooth any sharp edges or burrs on the cut ends of the aluminum angle. 8. **Clean Up**: Remove any metal shavings or debris from the work area to maintain a safe and tidy workspace. By following these steps, you can achieve a clean and precise cut on aluminum angle stock.

Aluminum angle stock is a versatile material used in various applications due to its strength, lightweight nature, and resistance to corrosion. Here are some of its primary applications: 1. **Construction and Architecture**: Aluminum angle stock is commonly used in building frameworks, supports, and structural components. Its lightweight and durable properties make it ideal for window frames, door frames, and trim work. 2. **Furniture Manufacturing**: It is used in the production of furniture, providing structural support for tables, chairs, and shelving units. Its aesthetic appeal and ease of fabrication make it a popular choice for modern furniture designs. 3. **Automotive and Aerospace**: In the automotive and aerospace industries, aluminum angle stock is used for constructing frames, supports, and brackets. Its lightweight nature contributes to fuel efficiency and performance. 4. **Electrical and Electronics**: It serves as a component in electrical enclosures, heat sinks, and mounting brackets for electronic devices, offering both structural support and thermal management. 5. **Industrial Applications**: Aluminum angle stock is used in machinery and equipment manufacturing, providing support and structural integrity to various industrial machines and conveyor systems. 6. **DIY Projects and Home Improvement**: Due to its ease of cutting and shaping, it is popular among DIY enthusiasts for creating custom shelving, brackets, and other home improvement projects. 7. **Marine Applications**: Its corrosion resistance makes it suitable for marine environments, where it is used in boat building and dock construction. 8. **Signage and Display**: Aluminum angle stock is used in the construction of sign frames and display stands, offering durability and a professional appearance. 9. **HVAC Systems**: It is used in the construction of ductwork and support structures for heating, ventilation, and air conditioning systems. These applications highlight the material's adaptability across various industries, making it a valuable resource for both commercial and personal projects.

To join aluminum angle stock, you can use several methods depending on the application and required strength: 1. **Welding**: - **TIG Welding**: Ideal for aluminum, providing strong, clean joints. Requires a TIG welder and filler rod. - **MIG Welding**: Faster than TIG, suitable for thicker sections. Requires a MIG welder with aluminum wire. 2. **Mechanical Fastening**: - **Bolting**: Drill holes through the angles and use bolts and nuts. Use washers to distribute load and prevent damage. - **Riveting**: Use aluminum or stainless steel rivets for a permanent joint. Requires a rivet gun. 3. **Adhesive Bonding**: - Use epoxy or specialized aluminum adhesives for a clean, non-mechanical joint. Ensure surfaces are clean and roughened for better adhesion. 4. **Brazing/Soldering**: - Use aluminum brazing rods and a torch. Suitable for thin sections and requires precise temperature control. 5. **Brackets and Connectors**: - Use pre-fabricated aluminum brackets or connectors to join angles without altering the stock. 6. **Interlocking Joints**: - Design interlocking cuts or notches for a snug fit, then secure with adhesive or fasteners. Each method has its pros and cons, such as strength, ease of application, and cost. Choose based on the specific requirements of your project.

Aluminum angle stock offers several benefits in construction: 1. **Lightweight**: Aluminum is significantly lighter than steel, reducing the overall weight of structures and making it easier to handle and transport. 2. **Corrosion Resistance**: Aluminum naturally forms a protective oxide layer, making it highly resistant to corrosion and ideal for outdoor and marine applications. 3. **Strength-to-Weight Ratio**: Despite its lightness, aluminum provides excellent strength, making it suitable for structural applications where weight is a concern. 4. **Versatility**: Aluminum angle stock can be easily cut, drilled, and welded, allowing for versatile use in various construction projects, from framing to supports. 5. **Aesthetic Appeal**: Aluminum has a modern, sleek appearance and can be anodized or painted for enhanced visual appeal, making it a popular choice for architectural features. 6. **Recyclability**: Aluminum is 100% recyclable without loss of properties, making it an environmentally friendly option that supports sustainable construction practices. 7. **Thermal Conductivity**: Aluminum's high thermal conductivity makes it useful in applications requiring efficient heat dissipation, such as in window frames and HVAC systems. 8. **Non-Magnetic**: Aluminum is non-magnetic, which is beneficial in applications where magnetic interference needs to be minimized. 9. **Cost-Effective**: While the initial cost may be higher than some materials, aluminum's durability and low maintenance requirements can lead to cost savings over time. 10. **Fire Resistance**: Aluminum does not burn and can help improve fire safety in buildings. These benefits make aluminum angle stock a preferred choice in various construction applications, from residential to industrial projects.