Aluminum is indeed harder to work with, so much that whole processes have to be changed just to accommodate for the complexities, at least on the passenger vehicle end of production it is.
Hello,
One crash on aluminum crash bars and they would be crushed by a 500+ lb
Adventure Bike right into your engine or farings. Aluminum isn't strong enough, it's too expensive and most of the aluminum alloys don't weld or bend worth a ****.
Now high strength aerospace titanium is super strong, half the weight of steel and would cost about $5000.00 a set. They'd make great crash bars for that door knob Trump....LOL.
No...we're pretty well limited to Mild Steel, Alloy Steel or Stainless Steel.
EZ