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Aluminium is a material that has shaped the modern world, yet its journey from a rare, precious metal to an industrial powerhouse is nothing short of remarkable.
As a UK-based aluminium extrusion provider, we understand not only the practical benefits of aluminium but also the incredible history behind it. This blog explores aluminium’s past, from its discovery to its pivotal role in industry today.
The Discovery of Aluminium
Despite being the most abundant metal in the Earth’s crust (making up about 8%) aluminium remained undiscovered as a usable material for centuries. Unlike iron or copper, aluminium is never found in its pure form in nature due to its strong affinity for oxygen. It exists primarily in compounds like bauxite and alumina, which early metallurgists lacked the technology to refine.
The first recorded evidence of aluminium compounds being used dates back to ancient times. The Greeks and Romans utilised alum (potassium aluminium sulfate) for medicinal and dyeing purposes. However, they had no idea it contained a metal that would later revolutionise industries.
The breakthrough came in 1808 when British chemist Sir Humphry Davy first hypothesised the existence of aluminium, naming it ‘alumium’ before settling on ‘aluminium’—a term that aligns with the Latin naming conventions for metals like sodium and potassium.
Aluminium: A Precious Metal
For much of the 19th century, aluminium was more valuable than gold or silver due to the difficulty of extracting it. In 1825, Danish physicist Hans Christian Ørsted successfully produced an impure aluminium sample, and by 1845, German chemist Friedrich Wöhler refined the process further. Still, aluminium remained rare.
In 1855, the first small ingots of aluminium were displayed at the Exposition Universelle in Paris, where Napoleon III reportedly commissioned aluminium cutlery for his most distinguished guests, while the rest had to make do with gold or silver utensils. At that time, aluminium cost around £450 per kilogram—equivalent to tens of thousands of pounds today.
The Hall-Héroult Process: Aluminium for the Masses
Everything changed in 1886 when two scientists working independently - Charles Martin Hall in the United States and Paul Héroult in France - developed an electrolytic process to extract aluminium from alumina using molten cryolite. This method, now known as the Hall-Héroult process, drastically reduced production costs and remains the foundation of modern aluminium production.
This discovery coincided with Karl Bayer’s 1888 invention of the Bayer Process, which made extracting alumina from bauxite more efficient. Together, these two methods paved the way for large-scale aluminium production, slashing its price from around £400 per kg in the 1850s to just a few pence per kg by the early 20th century.
Aluminium in the 20th Century: From Aviation to Everyday Use
The early 20th century saw aluminium emerge as an industrial game-changer. Its strength-to-weight ratio made it ideal for aviation, with the Wright brothers using aluminium components in their first powered aircraft in 1903. By World War I, aluminium was vital for military aircraft production, a role it would expand upon during World War II, with both the UK and the US ramping up production to unprecedented levels.
By the 1950s, aluminium had firmly established itself in the consumer market. The first aluminium beverage can was produced in 1958, and the rise of aluminium extrusion techniques enabled the development of lightweight, corrosion-resistant structures across industries from construction to automotive manufacturing.
Aluminium Today: A Metal of the Future
Fast forward to today, and aluminium is one of the most widely used metals worldwide, with global production exceeding 70 million tonnes annually. The UK alone produces and recycles hundreds of thousands of tonnes each year, with a focus on sustainability: 75% of all aluminium ever produced is still in use thanks to its recyclability.
At our aluminium extrusion facility, we continue this legacy by providing high-quality aluminium solutions for industries ranging from architecture to engineering. With ongoing advancements in alloy technology, 3D printing, and carbon-free smelting, aluminium is set to remain a cornerstone of innovation for decades to come.
Conclusion
From a rare and precious metal to an essential part of modern life, aluminium’s journey is a testament to human ingenuity. Its unique properties; lightweight, strong, corrosion-resistant, and infinitely recyclable, make it indispensable. As the industry evolves, aluminium will continue to shape the world around us, just as it has for centuries.
If you’re looking for high-quality aluminium extrusions for your next project, get in touch to find out how we can help.