Welding is not recommended for aluminum rather brazing is used which is a process similar to soldering and thanks to new development in welding materials it has become very easy to do with a propane torch at temperature far below melting point of aluminum.
You can try scrap sheets of aircraft aluminum they have a "springy" feel like steel unlike pure aluminum and are easy to work, bend and form while retaining shape. Such is very difficult for pure aluminum unless it is thick enough otherwise it will deform due to vibrations. I have a relative in Karachi who buys scrap aircraft aluminum sheets to form different parts so this is coming from first hand experience plus they are brazeable too with the right kind of material. Aircraft aluminum is expensive to recycle therefore it has very low scrap value. It is only purchased by people who have a secondary use for the sheet. That is why many air crafts end up being crushed to heaps because there are no takers for their metals.
[h=3]2024-T3[/h]This is the most common of the the high-strength aluminum alloys. It is aircraft quality. 2024-T3 aluminum sheet is thought of as the aircraft alloy because of its strength. It has excellent fatigue resistance. Welding is generally not recommended. Typical uses for 2024-T3 Alclad aluminum sheet are aircraft skins, cowls, aircraft structures, and also for repair and restoration because of its shiny finish (2024-T3 Alclad).
Ultimate strength is 62000 PSI with a shearing strength of 40000 PSI.
[h=3]6061-T6[/h]This alloy has a very good corrosion resistance and finishing ability, welding goes good too. The strength level of 6061-T6 aluminum sheet is about that of mild steel. 6061-T6 aluminum sheet can be fabricated by most of the commonly used techniques. Typical uses are aircraft landing mats, truck bodies and frames, structural components and more.
Ultimate strength is 45000 PSI with a shearing strength of 30000 PSI.
[h=3]5052-H32[/h]This one has the highest strength in the NON-heatable alloys. It is not structural. 5052 aluminum sheet has higher fatigue strength than most alloys. 5052 aluminum sheet has excellent corrosion resistance, particularly in marine applications and has excellent workability. 5052 aluminum sheet is commonly used to make fuel tanks.
[h=3]3003-H14[/h]Most widely used of aluminum alloys, pure aluminum with manganese added for strength, approx 20% stronger than the 100 series. 3003-H14 aluminum sheet has great workability and may be deep drawn, spun, welded or brazed. 3003 aluminum sheet is NON-heat treatable. This aluminum sheet is widely used for cowls and baffle plating.
Ultimate strength is 21000 PSI with a shearing strength of 14000 PSI.
[h=3]7075[/h]Aircraft manufacturers use high-strength alloys (principally alloy 7075) to strengthen aluminum aircraft structures. Aluminum alloy 7075 has Copper (1.6%), Magnesium (2.5%) and zinc (5.6%) added for ultimate strength, but the copper content makes it very difficult to weld. On the other hand it anodizes really beautifully. 7075 has the best machinability and it will result in a very nice finish.
Ultimate strength is 33000 PSI (-0) and 82000 PSI (-T6) with a shearing strength of 22000 PSI (-0) and 49000 PSI (-T6).
