The standard material for an Xpandrel is 6061 Aluminum.  

Each series has different specific material needs based on the design.  Materials can sometimes be readily substituted other times some design work may need to be done to accommodate the forced & deflection of the new material properties.

Harder materials such as 7075, 4041, & D2 are generally reserved for small diameters, long length to diameter ratios and the 2000 series models.

5000 Series always uses a 6061 body with various steel alloy internal components and 4140-HT caps.  End caps can be made form 6061 and hard coated or sleeved with 4140 HT to obtain a lighter finished product if required.

Material Designations in Part Numbers:

AA - All Aluminum 6061 - Standard

AH - All Aluminum 7075 - Not Standard*

AC - Aluminum Body 4140-HT End Caps (5000 series)

HT - 4140 HT - Standard for some designs*

D2 - D2 Tools Steel - Not Standard*

CM - Custom -  Call with special needs

* harder materials may affect the expansion .  Designs may be modified to accomdate that however, aluminum is the prefered body material

The Basics of Xpandrel Functionality Design Series Versatility End Conditions & Actuation Methods Materials Standard, Modified or Custom? How To Buy  Xpandrels

General Work Holding Process Flow Portability Inspection Timing & Balancing Composites and Windings Laminite Stacking

Thin Wall Machining Milling Grinding Stepped ID Holding

1000 Series  - expanding mandrel for small parts 2000 Series - expanding mandrel for short length parts 3000 Series - expanding mandrel for medium size parts 4000 Series - expanding mandrel for long length to diameter ratio parts 5000 Series - expanding mandrel for large parts