Sheets of aluminum, like sheets of any other metal, are formed by applying an external force to the metal to modify its structure and allow it to be cut or shaped for specific purposes. While there are a wide variety of aluminum types on the market, many of those types are actually aluminum alloys, which include an additional element in the aluminum compound, such as copper, zinc or magnesium, to affect the strength of the metal. Aluminum sheets are used to form cans for consumer drinks, cars (to manufacture parts and for license plates) and as siding on homes.
Apply force to the aluminum until the metal begins to yield to the force, but not completely fail, which would result in the aluminum tearing or losing its integration. Apply force to the aluminum until it flattens and begins to stretch, spreading out across the surface area on which you are working. This process may be conducted on cold aluminum or aluminum that has been heat-treated.
Raise the temperature of the aluminum until it becomes soft and then work the softened metal onto a flat surface and begin to flatten. This process may be undertaken while the aluminum is being flattened, which means that the metal can be flattened, heated and flattened again.
Roll the aluminum by passing it between a machine's rolls until the resulting flat aluminum sheet reaches the goal for thickness, determined by the resulting sheet's application (from aluminum siding to license plates). The previously discussed processes can come before rolling, or an actual ingot of aluminum specifically designed to be rolled into a sheet can be used in a rolling mill. In one rolling process, the aluminum is heated, while another process rolls cold aluminum.
Cut the flattened aluminum into sheets or roll into coils based on the desired application. The final thickness of the aluminum sheet can range from .008 inch to just under 1/4 inch. If the sheet is thinner, it will be referred to as foil. If it is thicker than 1/4 inch, it is referred to as a plate.
