Aluminium has many positive characteristics that make it easy to work with. When using self-tapping screws on aluminium, choose a self-tapping screw with a drill-like point and sharp cutting blade threads that extend down the whole length of the screw. These self-tapping screws are designed to keep thin metal from denting.
To use self-tapping screws, place the screw directly on the aluminium sheet. The screw's sharp point will make its own hole. Stabilise the screw so it doesn't tilt as it is put in. Let the screw turn until it goes through. Take care not to over-tighten the screw as this can damage the metal or break the screw.
The advantage of self-tapping screws for aluminium is that they don't need pre-drilling and are easily removed without damaging the metal. They can also be reused in the same material.
Aluminium in certain applications can vibrate which causes other fastener types to work loose. For example, aluminium is used to build boats. Boat engines cause the boat frame to vibrate which can result in other fasteners such as nails or regular screws falling out. Trilobular stainless steel self-tapping screws are ideal in situations where vibration is present as their thread design reduces friction during thread forming whilst providing resistance to vibrational loosening.