This isn't a question most sabersmiths like to answer since they either don't know the difference or don't want to share the secrets of their trade. But, what the heck, we're all friends here, so...
The aircaft grade aluminum alloys are:
7075
6061
6063
2024
5052
The term aircraft aluminium usually refers to a T6 alloy of either 7075 or 6061. We use 6061-T6 for most of our construction of the main bodies of the hilts (the same alloy used to make the famous
Pioneer Plaque) and 7075-T6 for some internal parts or thinner parts. 6061 offers superior corrosion resistance, so it is the alloy of choice for external surfaces, and 7075's superior strength is ideal for parts that are made thin, yet still need to be rugged.
T6 temper 6061 has an ultimate tensile strength of at least 42,000 psi and yield strength of at least 35,000 psi. T6 temper 7075 has an ultimate tensile strength of 78,000 psi and yield strength of at least 69,000 psi.
