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Aluminium 3003: A Comprehensive Overview

Introduction

Aluminium 3003 is a versatile and widely used wrought aluminium alloy, known for its exceptional corrosion resistance, strength, and weldability. This alloy is commonly employed in various industries, including transportation, construction, and consumer products. Here is a comprehensive overview of Aluminium 3003, covering its properties, applications, and comparative advantages.

Chemical Composition and Properties

Aluminium 3003 is characterized by the following chemical composition:

| Element | Percentage (%) |
|—|—|
| Aluminium | 95.4 – 96.7 |
| Copper | 0.1 – 0.2 |
| Manganese | 1.0 – 1.5 |
| Iron | <0.7 |
| Silicon | <0.6 |

This alloy exhibits excellent corrosion resistance, making it suitable for applications exposed to harsh environments, such as marine and coastal areas. Aluminium 3003 also has high strength and a low density, resulting in a great strength-to-weight ratio. Additionally, it possesses good formability and weldability, making it easy to fabricate and join.

Applications

Aluminium 3003 finds applications in a wide range of industries, including:

• Transportation: Automotive trim, bumpers, wheels, and aircraft components
• Construction: Window frames, roofing, siding, and interior panels
• Consumer Products: Cookware, appliances, and furniture
• Packaging: Beverage cans, food containers, and pharmaceutical packaging

Comparative Advantages

When compared to other wrought aluminium alloys, Aluminium 3003 offers several advantages:

| Alloy | Corrosion Resistance | Strength | Weldability |
|—|—|—|—|
| Aluminium 3003 | Excellent | High | Good |
| Aluminium 5052 | Good | Moderate | Excellent |
| Aluminium 6063 | Moderate | High | Excellent |

Formability and Weldability

Aluminium 3003 exhibits excellent formability, which allows it to be easily shaped and molded into complex forms. This property makes it ideal for manufacturing products with intricate designs. Additionally, Aluminium 3003 possesses good weldability, enabling it to be joined using various welding techniques, such as Gas Metal Arc Welding (GMAW) and Tungsten Inert Gas Welding (TIG).

Corrosion Resistance

The presence of manganese in Aluminium 3003 enhances its corrosion resistance. This alloy forms a protective oxide layer on its surface, which resists corrosion and maintains its structural integrity even in severe environments.

Strength

Aluminium 3003 offers a high strength-to-weight ratio, making it a suitable choice for applications that require both strength and weight reduction. Its tensile strength ranges from 290 to 310 MPa, depending on the temper.

Conclusion

Aluminium 3003 is a versatile and widely used wrought aluminium alloy that offers a unique combination of corrosion resistance, strength, weldability, and formability. Its versatility and proven performance make it a cost-effective and reliable material for a wide range of applications across various industries.

Introduction:

Introduction

Aluminium 3003 is a versatile and durable alloy that is commonly used in a wide range of applications, including construction, automotive, and marine industries. Its composition and properties make it an ideal choice for applications where strength, corrosion resistance, and formability are essential.

Definition and Composition

Aluminium 3003 is a manganese-based aluminium alloy. It is primarily composed of aluminium (98.8-99.3%), with additions of manganese (1.2-1.6%), iron (0.5-1.0%), silicon (0.6-1.2%), and copper (0.05-0.2%). This specific blend of elements gives Aluminium 3003 its unique properties.

Properties and Characteristics

Aluminium 3003 possesses several notable properties and characteristics:

• High strength: Despite its relatively low alloy content, Aluminium 3003 offers good strength-to-weight ratio, making it suitable for structural applications.
• Corrosion resistance: The presence of manganese and silicon provides Aluminium 3003 with excellent corrosion resistance, especially in marine and coastal environments.
• Formability: Aluminium 3003 is highly formable, allowing it to be easily shaped into complex shapes and components.
• Weldability: Aluminium 3003 can be readily welded using various techniques, making it versatile for fabrication.
• Machinability: This alloy has good machinability, allowing it to be easily cut, drilled, and turned.

Applications

Due to its combination of properties, Aluminium 3003 is used in a diverse range of applications, including:

• Construction: Architectural panels, roofing, siding, window frames
• Automotive: Body panels, trim, heat exchangers
• Marine: Boat hulls, decks, structural components
• Food processing: Equipment, containers, utensils
• Chemical processing: Tanks, piping, vessels

Comparison with Other Aluminium Alloys

The following table compares Aluminium 3003 with other common aluminium alloys:

| Property | Aluminium 3003 | Aluminium 6061 | Aluminium 7075 |
|—|—|—|—|
| Strength | Medium | High | Very high |
| Corrosion resistance | Excellent | Good | Moderate |
| Formability | Excellent | Good | Poor |
| Weldability | Good | Good | Difficult |
| Machinability | Good | Excellent | Poor |

Conclusion

Aluminium 3003 is a versatile and durable aluminium alloy that combines good strength, corrosion resistance, formability, and weldability. This makes it an ideal choice for a wide range of applications where these properties are essential. Its cost-effectiveness and ease of fabrication further contribute to its widespread use across various industries.

Mechanical Properties:

Mechanical properties are essential characteristics that describe how materials respond to external forces and stresses. They play a crucial role in determining the suitability of materials for various applications. Key mechanical properties include:

Strength

Strength refers to the ability of a material to withstand external forces without breaking or yielding. It is typically measured in terms of ultimate tensile strength (UTS) and yield strength (YS). UTS represents the maximum stress a material can sustain before failure, while YS indicates the stress at which the material begins to deform permanently.

Hardness

Hardness measures the resistance of a material to surface penetration or scratching. It is commonly determined using the Rockwell, Brinell, or Vickers hardness tests. Higher hardness values indicate a reduced likelihood of surface damage or wear.

Ductility

Ductility is the ability of a material to undergo permanent deformation without breaking. It is measured by the percentage elongation at break, which represents the increase in length of a material sample before it ruptures. Ductile materials are often used in applications where bending or forming is required.

Formability

Formability refers to the ease with which a material can be shaped or deformed without cracking or tearing. It is influenced by factors such as ductility, strength, and yield strength. Highly formable materials are suitable for processes like bending, stamping, and drawing.

Machinability

Machinability measures the ease with which a material can be cut or machined using tools. It is affected by factors such as hardness, strength, and ductility. Materials with good machinability allow for efficient and cost-effective manufacturing operations.

Comparison of Mechanical Properties

The mechanical properties of materials vary significantly depending on their composition, microstructure, and processing. The following table compares the mechanical properties of three common metals:

| Material | Ultimate Tensile Strength (MPa) | Yield Strength (MPa) | Rockwell Hardness | Ductility (%) |
|—|—|—|—|—|
| Steel | 500-1200 | 300-800 | 70-120 | 10-25 |
| Aluminum | 70-700 | 20-500 | 30-100 | 25-60 |
| Copper | 200-500 | 70-300 | 40-90 | 30-60 |

As evident from the table, steel possesses the highest strength and hardness, making it suitable for applications where structural integrity is critical. Aluminum, on the other hand, offers good formability and machinability, making it ideal for use in aerospace and automotive industries. Copper combines moderate strength with excellent electrical and thermal conductivity.

Applications of Mechanical Properties

The mechanical properties of materials guide their selection for various applications. For instance:

• High-strength steel is used in bridges, buildings, and aircraft.
• Ductile materials like aluminum and copper are employed in cables, wires, and heat exchangers.
• Hard and wear-resistant materials, such as ceramics and composites, find applications in cutting tools and armor.
• Materials with good machinability are preferred for manufacturing components using CNC machining and other cutting processes.

By understanding and characterizing the mechanical properties of materials, engineers can optimize material selection and design to meet specific performance requirements.

Corrosion Resistance:

Corrosion, the degradation of materials by chemical or electrochemical reactions with their surroundings, is a significant challenge in various industries. Choosing materials with excellent corrosion resistance is crucial to ensure the longevity and reliability of products and structures. This article explores the different aspects of corrosion resistance, including atmospheric corrosion and resistance to various chemicals and environments.

Atmospheric Corrosion Resistance

Atmospheric corrosion, also known as rust, is a common form of corrosion caused by exposure to oxygen and moisture in the air. Different materials exhibit varying degrees of resistance to atmospheric corrosion, depending on their composition and surface characteristics.

| Material | Atmospheric Corrosion Resistance |
|—|—|
| Stainless Steel | Excellent |
| Aluminum | Good |
| Carbon Steel | Poor |
| Copper | Fair |
| Zinc | Good |

Factors Influencing Atmospheric Corrosion Resistance:

• Oxygen Content: Higher oxygen levels increase the rate of corrosion.
• Humidity: High humidity provides a conductive environment for corrosion.
• Pollutants: Airborne pollutants, such as sulfur dioxide and nitrogen oxides, can accelerate corrosion.
• Temperature: Elevated temperatures generally increase the rate of corrosion.

Resistance to Various Chemicals and Environments

Materials can also encounter various chemical media and environmental conditions that can cause corrosion. Different materials have specific resistances to different chemicals, and it is essential to select materials that are compatible with the intended application.

| Material | Chemical Resistance | Environments |
|—|—|—|
| Stainless Steel | Acids, Alkalis, Oxidizing Agents | Marine, Food Processing |
| Aluminum | Acids, Weak Alkalis | Automotive, Architectural |
| Carbon Steel | Acids, Alkalis | Industrial, Construction |
| Copper | Most Acids, Alkalis | Plumbing, Electrical |
| Plastics | Weak Acids, Solvents | Chemical Processing, Packaging |

Factors Influencing Chemical Resistance:

• Chemical Nature: The specific chemical composition of the environment determines the type of corrosion that can occur.
• Concentration: Higher chemical concentrations increase the rate of corrosion.
• Temperature: Elevated temperatures generally increase the rate of corrosion.

Material Selection for Corrosion Resistance

Selecting the right material for a specific application requires careful consideration of the following factors:

• Type of corrosion expected (atmospheric, chemical, etc.)
• Chemical composition of the environment
• Temperature and humidity levels
• Mechanical strength and other performance requirements

By understanding the different aspects of corrosion resistance and the resistance of various materials to different environments, engineers and designers can make informed choices to ensure the longevity and integrity of their products and structures.

Conclusion

Corrosion resistance is a crucial property for materials used in various applications. By selecting materials with appropriate atmospheric corrosion resistance and resistance to specific chemicals and environments, industries can minimize the risk of corrosion-related failures and ensure the durability and reliability of their equipment and infrastructure.

Applications:

Industrial robots have revolutionized various industries, automating complex tasks and enhancing productivity. Their versatility and adaptability make them invaluable assets in a wide range of applications.

Automotive Industry:

• Assembly: Robots can assemble vehicles with precision and speed, completing tasks such as welding, painting, and part placement.
• Inspection: Robots equipped with vision systems can inspect vehicles for defects, ensuring quality control.
• Logistics: Automated guided vehicles (AGVs) can move materials and parts around manufacturing facilities autonomously.

Construction Industry:

• Bricklaying: Robots can lay bricks with accuracy and speed, reducing labor costs and improving construction efficiency.
• Welding: Robots can perform complex welding tasks with precision, ensuring structural integrity.
• Painting: Robots can paint large structures and surfaces with uniform coverage and reduced waste.

Food Processing Industry:

• Packaging: Robots can pack products with speed and consistency, ensuring food safety and minimizing product damage.
• Sorting: Robots equipped with sensors can sort products based on size, shape, or color, improving quality control.
• Material handling: Robots can move heavy loads and ingredients throughout processing facilities efficiently.

Additional Common Applications:

• Manufacturing: Robots can perform repetitive and hazardous tasks in manufacturing environments, increasing productivity and reducing workplace accidents.
• Healthcare: Robots can assist in surgeries, dispense medications, and provide medical assistance in hospitals.
• Aerospace: Robots can assemble and inspect aircraft components with precision and accuracy.
• Logistics: Robots can automate warehousing and distribution processes, optimizing inventory management and reducing labor costs.

Comparative Analysis of Industrial Robot Parameters:

| Parameter | Description |
|—|—|
| Payload Capacity: The maximum weight a robot can lift. |
| Reach: The distance from the robot’s base to its end effector. |
| Accuracy: The precision with which the robot can move. |
| Speed: The rate at which the robot can perform movements. |
| Degrees of Freedom: The number of axes of movement the robot has. |
| End Effector: The tool or attachment at the end of the robot’s arm. |

The optimal combination of these parameters depends on the specific application. For example, automotive assembly robots require high accuracy and speed, while food processing robots need to be able to handle delicate products with precision.

Conclusion:

Industrial robots continue to play a vital role in enhancing productivity, quality, and safety across numerous industries. Their versatility and adaptability make them essential components of modern manufacturing and production processes, driving innovation and transforming the way we work.

Forming and Fabrication:

Metal forming and fabrication are essential processes in the manufacturing industry, used to transform raw metal materials into functional parts and components. These processes involve a wide range of techniques and technologies, each tailored to specific applications and material requirements.

Metal Forming Methods

Metal forming involves reshaping metal without altering its properties. Common forming methods include:

• Stamping: Using dies to punch, cut, bend, or shape metal sheets into desired shapes.
• Bending: Applying force to bend metal into curves or angles.
• Forging: Heating and hammering metal to shape it into desired geometries.
• Extrusion: Forcing metal through a die to create specific shapes, such as rods or tubes.
• Rolling: Passing metal between rollers to reduce its thickness or shape it into sheets or bars.

Welding and Joining Techniques

Welding and joining are processes used to permanently connect metal pieces together. The most common techniques include:

• Arc Welding: Using an electric arc to melt and fuse metal together.
• Gas Welding: Using a gas flame to melt and fuse metal.
• Brazing: Using a lower-melting-point metal (brazing alloy) to join two metal pieces.
• Soldering: Using an even lower-melting-point metal (solder) to join two metal pieces.
• Mechanical Joining: Using bolts, screws, rivets, or other mechanical fasteners to secure metal pieces.

Comparison of Forming and Fabrication Processes

| Feature | Forming | Welding / Joining |
|—|—|—|
| Purpose | Reshape metal | Permanently connect metal pieces |
| Material Properties | No change | May alter material properties |
| Precision | High | Dependent on process and equipment |
| Strength | Relies on material properties | Requires strong joints |
| Cost | Can be lower | Generally higher |
| Applications | Sheet metal parts, structural components | Piping, tanks, machinery |

Applications of Forming and Fabrication

Forming and fabrication processes are used in a myriad of industries, including automotive, aerospace, construction, and electronics. Some typical applications include:

• Automobile body panels and chassis
• Aircraft wings and fuselages
• Structural beams and columns
• Electrical enclosures and circuit boards
• Medical implants and instruments

Conclusion

Metal forming and fabrication are indispensable techniques in modern manufacturing. By reshaping and joining metals, these processes enable the creation of a vast array of products and components that meet the demands of various industries and applications. With advancements in technology and materials science, the possibilities for forming and fabrication continue to expand, leading to innovative and efficient solutions for a wide range of challenges.

Finishes:

In various industries, surface finishes play a crucial role in enhancing the durability, functionality, and appearance of metal surfaces. They provide protection against corrosion, wear, and other environmental factors, while also allowing for customization and aesthetic appeal. Among the most common surface finishes are anodizing, painting, and powder coating.

Types of Surface Finishes

Anodizing

• Process: Electrolytic process that converts the metal surface into a protective oxide coating.
• Benefits: Enhanced corrosion and wear resistance, improved electrical insulation, and increased surface hardness.
• Applications: Aerospace, automotive, electronics, construction

Painting

• Process: Application of a liquid or powder coating onto the metal surface.
• Benefits: Wide range of colors and finishes, cost-effective, relatively easy to repair.
• Applications: General metal fabrication, architectural coatings, machinery

Powder Coating

• Process: Dry application of electrostatically charged powder particles, which are then cured at high temperature.
• Benefits: Durable and corrosion-resistant, provides a smooth and even finish, strong adhesion.
• Applications: Appliances, furniture, automotive parts, industrial equipment

Comparison of Surface Finishes

| Feature | Anodizing | Painting | Powder Coating |
|—|—|—|—|
| Corrosion resistance | High | Moderate | High |
| Wear resistance | High | Moderate | High |
| Electrical insulation | Excellent | Poor | Good |
| Surface hardness | High | Low | High |
| Cost | Moderate | Low | Moderate |
| Flexibility | Low | High | Low |
| Appearance | Satin or matte | Glossy, satin, or matte | Glossy or textured |
| Color options | Limited | Wide | Wide |

Applications of Surface Finishes

Surface finishes have a wide range of applications in various industries, including:

• Aerospace: Enhanced corrosion and wear resistance for aircraft components.
• Automotive: Rust protection for car bodies, decorative finishes for wheels.
• Electronics: Electrical insulation and heat dissipation for electronic boards.
• Construction: Weatherproofing and aesthetics for building materials.
• Medical: Sterilization for surgical instruments, biocompatibility for implants.

Selection Criteria

When selecting a surface finish, several factors should be considered:

• Intended application: Determine the required durability, corrosion resistance, and other performance characteristics.
• Budget: Compare the costs of different finishes and consider their long-term value.
• Aesthetics: Consider the desired color, texture, and overall appearance.
• Substrate: Ensure compatibility between the surface finish and the base metal.

Conclusion

Surface finishes offer a versatile and effective means of protecting and enhancing metal surfaces. By understanding the different types of finishes, their benefits, and applications, manufacturers can make informed decisions to optimize the performance and appearance of their products.

Environmental Considerations:

In today’s environmentally conscious society, businesses and consumers are increasingly prioritizing products and practices that align with sustainable principles. Environmental considerations, such as recyclability, sustainability, and the environmental impact of production and disposal, have become crucial factors in decision-making.

Recyclability and Sustainability

Recyclability refers to the ability of a material to be transformed into a new product or material. Sustainable materials are those that can be obtained, used, and disposed of without depleting natural resources and significantly harming the environment.

Table 1: Comparison of Recyclability and Sustainability

| Material | Recyclability | Sustainability |
|—|—|—|
| Aluminum | Highly recyclable | Sustainable; abundant and easily processed |
| Paper | Moderately recyclable | Sustainable; renewable resource, but deforestation concerns |
| Plastic | Varies by type; some highly recyclable, others not | Unsustainable; derived from non-renewable fossil fuels, contributes to pollution |
| Glass | Highly recyclable | Sustainable; abundant and inert, no degradation over time |

Environmental Impact of Production and Disposal

The environmental impact of a product extends beyond its material composition. The production and disposal processes should also be considered:

Production: The extraction and processing of raw materials, manufacturing processes, and transportation contribute to greenhouse gas emissions, water consumption, and pollution. Products that use renewable energy sources, reduce waste, and employ efficient manufacturing practices have a lower environmental footprint.

Disposal: Improper disposal of products can contribute to landfills, litter, and toxic contamination. Products designed for biodegradability, composting, or reuse have a less detrimental impact on the environment.

Assessment and Comparison

Table 2: Environmental Impact of Production and Disposal

| Product | Environmental Impact |
|—|—|
| Solar panels | Low production impact, end-of-life recycling programs available |
| Disposable coffee cups | High production and disposal impact; non-biodegradable, contribute to landfills |
| Electric vehicles | Low production impact if powered by renewable energy; end-of-life battery recycling required |
| Conventional vehicles | High production impact, emissions during use; contribute to air pollution |

Conclusion

Environmental considerations are essential in product development, consumer behavior, and policy decisions. By embracing recyclability, sustainability, and minimizing environmental impact, we can contribute to a more sustainable and environmentally friendly future. Informed choices made by businesses and consumers can incentivize responsible practices, reduce pollution, and conserve precious resources.

Standards and Certifications:

Introduction

In today’s competitive global market, adhering to industry standards and obtaining relevant certifications has become essential for businesses seeking to differentiate themselves and maintain a high level of quality. Standards and certifications provide a framework for evaluating and measuring the performance and quality of products, services, and processes. By meeting or exceeding these established criteria, organizations can demonstrate their commitment to quality and competence.

Relevant Industry Standards

Depending on the specific industry, there are various standards that businesses must comply with. Some of the most common include:

• ISO 9001: Quality Management System: Defines the requirements for an effective quality management system that ensures consistent and high-quality products or services.
• ISO 14001: Environmental Management System: Outlines the requirements for implementing an environmental management system to mitigate environmental risks and improve sustainability.
• ISO 27001: Information Security Management System: Provides guidelines for establishing and maintaining an information security management system to protect sensitive data and assets.
• ANSI/ASQ Z1.4: Calibration Laboratories: Specifies requirements for the competence, impartiality, and technical abilities of calibration laboratories.
• ASME Boiler and Pressure Vessel Code: Contains rules for the design, construction, and inspection of boilers, pressure vessels, and related components.

Certifications

In addition to adhering to industry standards, obtaining certifications from accredited organizations provides further evidence of a business’s commitment to quality. Common certifications include:

• ISO 9001 Certification: Demonstrates compliance with the ISO 9001 quality management system standard.
• ISO 14001 Certification: Verifies the implementation of an environmental management system that meets the ISO 14001 standard.
• TL 9000 Certification: Specifically designed for the telecommunications industry, this certification ensures compliance with quality requirements for the development, supply, and maintenance of telecommunications products and services.
• LEAN Six Sigma Certification: Indicates proficiency in applying Lean and Six Sigma methodologies to improve process efficiency and reduce defects.
• CQM Certification (Certified Quality Manager): A professional certification that recognizes individuals with expertise in quality management principles and practices.

Benefits of Standards and Certifications

Meeting industry standards and obtaining certifications offers numerous benefits, including:

• Enhanced quality: Standards and certifications provide a structured approach to quality control and assurance, ensuring consistency and reliability in products or services.
• Improved customer satisfaction: Customers are more likely to trust and purchase from businesses that have demonstrated a commitment to quality through standards and certifications.
• Reduced risks: Compliance with standards and certifications helps mitigate risks associated with legal liability, product defects, and environmental hazards.
• Increased efficiency: By streamlining processes and reducing defects, standards and certifications can improve efficiency and productivity.
• Market recognition: Obtaining certifications can enhance a business’s reputation and visibility in the marketplace, signaling to potential customers that they are committed to excellence.
• Competitive advantage: In competitive industries, standards and certifications can provide a differentiating factor, giving businesses an edge over their rivals.

Quality Control and Assurance

Standards and certifications play a vital role in quality control and assurance within an organization. Quality control measures focus on identifying and eliminating defects during the production or service delivery process. Quality assurance, on the other hand, encompasses the broader system of processes and measures designed to ensure the ongoing quality of products or services.

Conclusion

In the modern business world, adhering to industry standards and obtaining relevant certifications is imperative for organizations that seek to achieve and maintain high levels of quality. Standards and certifications provide a framework for evaluating and measuring performance, mitigating risks, and enhancing customer satisfaction. By embracing standards and certifications, businesses can demonstrate their commitment to excellence, gain a competitive advantage, and ultimately achieve long-term success.

Comparison to Other Aluminium Alloys:

Similarities and Differences with Other 3000 Series Alloys

3000 series aluminum alloys are known for their high strength and excellent corrosion resistance. They are commonly used in marine applications, construction, and transportation. Among the 3000 series alloys, some of the most notable similarities and differences include:

| Alloy | Composition | Strength | Corrosion Resistance | Weldability |
|—|—|—|—|—|
| 3003 | Al-Mn | Medium | Good | Good |
| 3004 | Al-Mn | Medium | Good | Good |
| 3105 | Al-Mn | High | Very Good | Poor |
| 3005 | Al-Mn | Low | Good | Excellent |

• Composition: 3003 and 3004 alloys have a similar composition, primarily composed of aluminum and manganese. 3105 alloy, on the other hand, has a higher manganese content, resulting in increased strength.
• Strength: 3105 alloy has the highest strength among the listed alloys, followed by 3003 and 3004 alloys.
• Corrosion Resistance: All 3000 series alloys offer good to very good corrosion resistance, making them suitable for a wide range of applications.
• Weldability: 3005 alloy has excellent weldability, while 3105 alloy has poor weldability.

Advantages and Limitations in Specific Applications

Marine Applications:

• Advantages: 3003 and 3004 alloys are widely used in marine applications due to their good corrosion resistance and moderate strength.
• Limitations: 3105 alloy is not recommended for marine applications due to its poor weldability.

Construction:

• Advantages: 3005 alloy is commonly used in construction due to its low strength and excellent weldability.
• Limitations: 3003 and 3004 alloys may not be suitable for high-strength applications.

Transportation:

• Advantages: 3003 and 3004 alloys are used in transportation applications, such as automotive parts and aircraft components, where moderate strength and corrosion resistance are required.
• Limitations: 3105 alloy is not commonly used in transportation due to its poor weldability and limited formability.

Conclusion

The choice of aluminum alloy for a specific application depends on the required properties. For applications requiring high strength and corrosion resistance, 3105 alloy may be the optimal choice. However, for applications emphasizing weldability or low strength, 3003 or 3005 alloys may be more suitable.