What's in an aluminum bat, anyway?

When aluminum bats were first introduced, the lower strength 6061, 6063, and 7005 alloys were used. As the designs and the applications became more sophisticated, better alloys were required. Continued development of alloys is taking place. Aluminum bats were first made in the early 1970’s. The NCAA legalized aluminum bats in 1974.

The list below was compiled between 1996 and 2003.  Since then alloys have remained pretty much the same, with some minor adjustments to the amounts of zinc, magnesium, scandium, nickel and other elements.  Most every year bat and aluminum companies make some new variation and give it a new name.  But since there is no major change to the alloy, the process of extruding the alloy has become more refined.  Sometimes the old alloy and the new process generates a new name for the alloy, but the basic elements are the same. 

The biggest difference year to year is the manipulation of wall thicknesses to produce more durability and trampoline effect.  Research and development has focused more on this aspect of the design producing some of the best bats ever made.  So when someone says that the new bats are the same bat with a new paint job, that isn't exactly accurate.

Alcoa's Cu31: Prior to 1996 aluminum, the top-of-the-line softball bats offered by the bat companies were made out of an alloy designated Cu31. This extremely popular Al-Zn-Mg-Cu alloy is more commonly known as 7050. The trademarked designation Cu31 means that not only is the alloy 7050 but that it was supplied by ALCOA.

Alcoa's C405: C405 is the trademarked designation of aluminum alloy 7055 when supplied by ALCOA to the bat industry. Worth was the first to introduce C405 in softball bats in 1996 and since then, essentially all major producers of bats use C405 in most, if not all, of their top-of-the-line bats.

C405 Ultra (Plus) is the '98 to present version of C405, which has undergone even further optimization of the heat treatment process resulting in an even stronger version of the alloy. C405 Ultra was introduced in the 1998 line of Easton bats. But the composition of C405 has remained the same throughout the years. It is the manner in which the alloy has been heat treated that has changed. But the outcome is what counts -- stronger bats.

C555 was introduced by Alcoa for the year 2000. C555 is a unique blend of Scandium and other metals that is slow aged to produce an aluminum that is reported to be 8-10% stronger than C405. At print time of this catalog, no more information could be found regarding exactly what is in it, but it does seem as though Alcoa has manufactured an aluminum similar to SC500 in that it has trace amounts of scandium and that this makes for an even thinner walled bat with added durability. It is also the first Alcoa aluminum to be manufactured specifically for aluminum bats. Bats made with this alloy have performed very well so far.

Sc777 is Easton's designation for the alloy used for the aluminum shell in the Easton Connexion, Z-Core, and Triple 7. This alloy was developed jointly by Kaiser Aluminum and Ashurst Technology for exclusive use by Easton. The composition for this alloy does not fall exactly in the range for any of the common 7xxx alloys but is most similar to 7055. What is so special about this alloy is the presence of a dilute Sc addition. Scandium is a very rare, expensive, and lightweight metal. When added to Aluminum in dilute quantities it is responsible for increased strength from Al3Sc precipitation, enhanced weldability, and significant resistance to recrystallization.  SC777 is a more advanced version of the old SC500 alloy.  The Z-Core Series of bats also have strands of titanium in the carbon fiber core for more durability and a bigger sweet spot.

Sc888 is an improved version of Sc777 with an "Advanced Metal Matrix™ which provides 4ksi additional strength with 10% additional toughness."

Sc900 is a continued improvement of the successful Sc777 that has proven to be stronger and more flexible than ever before.

3DX is a trademark for fiber metal composites in bats from Worth.  Fiber Flex Technology is a new 50% carbon, 50% fiber glass shell that allows for greater flexibility in the shell (50% fiber glass increases flex) while maintaining the same durability standard (50% carbon maintains stiffness).

GX4 is the latest version of Worth's patented 3DX technology.  3DX was Worth's highest selling brand of all time.  GX4 has 50% less carbon to make the bat hotter out of the wrapper with no break-in period.  This also increases the flex properties.  The patent pending GX4 shell is constructed of materials that are 4 times stronger than aluminum.

DRS  The first composite dynamic shell bat. It has an enlarged sweet spot with a better feel. This exclusive patent pending DRS (Dynamic Response System) technology blends multiple components which optimize performance, power, feel and durability.

MG46 is a magnesium enhanced, exclusive new alloy from Worth. Magnesium enhances the hardness characteristics of alloys while maintaining lightweight properties. Magnesium (Mg) is 46% lighter than Scandium (Sc).

WS23 is a brand new alloy exclusive to Worth softball bats.  We have not heard much about this new alloy.  Here's what Worth has to say: Never before has the EST seen an alloy as strong as the exclusive Worth WS23 alloy. EST is currently the #1 selling softball technology in the world! It's new for 2002!  They also claim it is 9% stronger than C555.  Our best guess is that it is similar to C555 and SC777.

Scandium XS - New for exclusively from Louisville Slugger and Alcoa.  Scandium XS, developed by Alcoa and enhanced by Louisville Slugger, features double the amount of Scandium as offered by other aluminum alloy suppliers making it the most advanced Scandium based alloy on the market.  Scandium XS added to aluminum tightens the alloy grain structure, which is key to an alloy’s tensile strength and durability.  A proprietary alloy heat treatment, developed by Louisville Slugger  R&D Engineers, maximizes the bat’s overall design, performance and durability.  This alloy basically replaces C555 for Louisville Slugger products.  From what we can tell, they have taken the C555 alloy and enhanced it by pouring a mixture of extra Scandium and other elements over the outer bat wall.  This fills in any microscopic gaps or crevices on the surface of the bat to make the bat more durable.

GEN1X Louisville Slugger, the world’s leading bat manufacturer, and Alcoa, the number one supplier of aluminum bat tubing, have teamed up to offer GEN1X —The strongest and toughest alloy ever developed for aluminum bats. In aluminum bat construction, the alloy’s “yield strength” is key to bat design, performance and durability. GEN1X, the strongest alloy on the market, is one of the first aluminum bat alloy to measure over 100 ksi (THE MEASUREMENT OF AN ALLOY’S STRENGTH). The result is the most technologically advanced line of aluminum bats to ever be developed. Years in the development process, Alcoa Research and Development Engineers formulated a breakthrough combination of Aluminum, Zinc, Copper, Zirconium, Magnesium and traces of Titanium to obtain this incredible strength. GEN1X’s cutting edge toughness and strength allows Louisville Slugger to design a line of bats with the ultimate combination of balance, wall thickness, performance and durability. In an unprecedented move - GEN1X, the newest and most technologically advanced aluminum bat alloy ever developed by Alcoa, is offered exclusively by Louisville Slugger.

GEN1X with Scandium  In aluminum bat construction, the alloy's strength is key to bat design, performance and durability. GEN1X with Scandium combines the ultra strong GEN1X and Scandium, the best alloy-strengthening additive available for aluminum bat development. The result is an alloy with unprecedented levels of strength and toughness.

Dynasty's alloy is an improved version of the successful GEN1X alloy.  The process has been refined and the result is a stronger and more durable alloy with improved performance.

What does this mean? Thinner walled aluminum bats have a much bigger sweet spot and provide the batter with two very noticeable advantages. First, the bat can be made lighter, especially in youth and fast pitch bats.
Second, the thinner walls give the bat a "trampoline effect".   This means that when the bat strikes the ball, the aluminum actually springs in and then instantly springs back out, to trampoline the ball off the bat like a tennis racket. The big draw back is durability. Whenever you bend metal it causes metal fatigue. This could result in dented or cracked bats. The less expensive bats, usually made of 7046 or 7050 aluminum, will last longer because they have much thicker walls, are much heavier, and do not trampoline. Which bat is right for you? That depends on your budget, but the trampoline effect of the thinner walls and lighter alloys do provide an exceptional advantage.

Bat Durability - a contradiction when you think of the money a good bat costs.  As a consumer you should know that durability and performance are not synonymous.  Please keep in mind you get a 1 year (or more) warranty with your bat.  There is a reason for this: high tech bats fail.  If your bat dents, cracks or goes dead, even after only a few at-bats, do not think there is a problem.  This is very normal.  You must realize that you paid that much for your bat for performance (pop and distance), not longevity.  Should your bat fail, don't panic.  Click here and use the warranty.  Also keep in mind that The Batter's Box cannot take care of the warranty for you.  All of the bat manufacturers have taken this out of all the retailers' hands; it's not just us.  And please save the receipt we send you.  You must have it to use the bat warranty.

Composite materials:  This is new territory for everyone.  As we research them more we will post new information.