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Welcome to the Bunnings Workshop community @Jenny19. It's brilliant to have you join us, and many thanks for your question about removing paint.
If you want to avoid strong chemicals, then sanding or scraping are really the only practical options for removing old paint from aluminium window frames. Aluminium itself is quite soft, so the key is to take your time and use the least aggressive method that will still do the job.
Start by testing a paint scraper in a small area. Often older paint will lift or flake away reasonably well once you get an edge started. If the paint is well-bonded, you can move to sanding. Using medium-grit sandpaper to begin with, around 120 to 180 grit, will help break through the paint. Once most of it is removed, switch to a finer grit, around 240 to 320, to smooth the surface back out.
For detailed sections and corners, sanding sponges or folded sandpaper work better than a flat sanding block. A small wire brush can also help in tight areas, but it should be used very lightly, as it can easily scratch the aluminium. If you have access to a random orbital sander, it can speed things up on flat sections, but again, it needs to be used gently and kept moving.
Once the paint is removed, make sure the frames are thoroughly cleaned to remove all dust before doing anything further, such as repainting. The process is slow and a bit labour-intensive, but it is the safest approach if you want to avoid chemical strippers and still end up with a clean, well-prepared aluminium surface.
I'd also like to ask why it is that you need to remove the paint. Total removal might not be necessary if you are planning on re-painting the frames. Check out this helpful Best Advice article: What is the best way to paint aluminium windows?
Please let me know if you have any questions.
Mitchell
