6061 aluminium alloy

6061 aluminium alloy (Unified Numbering System (UNS) designation A96061) is a precipitation-hardened aluminium alloy, containing magnesium and silicon as its major alloying elements. Originally called "Alloy 61S", it was developed in 1935.[2] It has good mechanical properties, exhibits good weldability, and is very commonly extruded (second in popularity only to 6063).[3] It is one of the most common alloys of aluminium for general-purpose use.

A6061
Material typeAlloy
Alloy properties
UNS identifierA96061
Physical properties
Density (ρ)2.70 g/cm3[1]
Mechanical properties
Young's modulus (E)68 GPa (9,900 ksi)
Tensile strength (σt)124–290 MPa (18.0–42.1 ksi)
Elongation (ε) at break12–25%
Poisson's ratio (ν)0.33
Thermal properties
Melting temperature (Tm)585 °C (1,085 °F)
Thermal conductivity (k)151–202 W/(m·K)
Linear thermal expansion coefficient (α)2.32×10−5 K−1
Specific heat capacity (c)897 J/(kg·K)
Electrical properties
Volume resistivity (ρ)32.5–39.2 nOhm·m

It is commonly available in pre-tempered grades such as 6061-O (annealed), tempered grades such as 6061-T6 (solutionized and artificially aged) and 6061-T651 (solutionized, stress-relieved stretched and artificially aged).

Chemical composition

6061 Aluminium alloy composition by mass:[4]

6061 Aluminium alloy
Constituent
element		 Minimum
(% by weight)		 Maximum
(% by weight)
Al95.85%98.56%
Mg0.80%1.20%
Si0.40%0.80%
Fe00.70%
Cu0.15%0.40%
Cr0.04%0.35%
Zn00.25%
Ti00.15%
Mn00.15%
(others)00.15% total
(0.05% each)

Properties

The mechanical properties of 6061 depend greatly on the temper, or heat treatment, of the material.[5] Young's Modulus is 69 GPa (10,000 ksi) regardless of temper.[6]

6061-O

Annealed 6061 (6061-O temper) has maximum ultimate tensile strength no more than 150 MPa (22 ksi),[7][8] and maximum yield strength no more than 83 MPa (12 ksi)[7] or 110 MPa (16 ksi).[8] The material has elongation (stretch before ultimate failure) of 10–18%. To obtain the annealed condition, the alloy is typically heat soaked at 415 °C for 2-3 hours.[9]

6061-T4

T4 temper 6061 has an ultimate tensile strength of at least 180 MPa (26 ksi)[8] or 210 MPa (30 ksi)[7] and yield strength of at least 110 MPa (16 ksi). It has elongation of 10-16%.

6061-T6
6061-T6 aluminium standard heat treating process

T6 temper 6061 has been treated to provide the maximum precipitation hardening (and therefore maximum yield strength) for a 6061 aluminium alloy. It has an ultimate tensile strength of at least 290 MPa (42 ksi) and yield strength of at least 240 MPa (35 ksi). More typical values are 310 MPa (45 ksi) and 270 MPa (39 ksi), respectively.[10] This can exceed the yield strength of certain types of stainless steel.[11] In thicknesses of 6.35 mm (0.250 in) or less, it has elongation of 8% or more; in thicker sections, it has elongation of 10%. T651 temper has similar mechanical properties. The typical value for thermal conductivity for 6061-T6 at 25 °C (77 °F) is around 152 W/m K. The fatigue limit under cyclic load is 97 MPa (14 ksi) for 500,000,000 completely reversed cycles using a standard RR Moore test machine and specimen.[12] Note that aluminium does not exhibit a well defined "knee" on its S-N curve, so there is some debate as to how many cycles equates to "infinite life". Also note the actual value of fatigue limit for an application can be dramatically affected by the conventional de-rating factors of loading, gradient, and surface finish.

Microstructure

Different aluminium heat treatments control the size and dispersion of Mg
2Si precipitates in the material. Grain boundary sizes also change, but do not have as important of an impact on strength as the precipitates. Grain sizes can change orders of magnitude based upon stress and can have grains as small as a few hundred nanometres, but are typically a few micrometres to hundreds of micrometres in diameter. Iron, manganese, and chromium secondary phases (Fe
2Si
2Al
9, (Fe, Mn, Cr)
3SiAl
12) often form as inclusions in the material.[13]

Grain boundaries in extruded plate 6061 aluminium alloy

Grain sizes in aluminium alloys are heavily dependent upon the processing techniques and heat treatment. Different cross-sections of material which has been stressed can cause order of magnitude differences in grain size.[14] Some specially processed aluminium alloys have grain diameters which are hundreds of nanometres,[15] but most range from a few micrometres to hundreds of micrometres.[16]

Uses

6061 is commonly used for the following:

  • construction of aircraft structures, such as wings and fuselages, more commonly in homebuilt aircraft than commercial or military aircraft.[17] 2024 alloy is somewhat stronger, but 6061 is more easily worked and remains resistant to corrosion even when the surface is abraded. This is not the case for 2024, which is usually used with a thin Alclad coating for corrosion resistance.[18]
  • yacht construction, including small utility boats.[19]
  • automotive parts, such as the chassis of the Audi A8 and the Plymouth Prowler.[20]
  • flashlights
  • aluminium cans for the packaging of food and beverages.
  • Scuba tanks and other high pressure gas storage cylinders (post 1995)

6061-T6 is used for:

Welding

6061 is highly weldable, for example using tungsten inert gas welding (TIG) or metal inert gas welding (MIG). Typically, after welding, the properties near the weld are those of 6061-T4, a loss of strength of around 40%. The material can be re-heat-treated to restore near -T6 temper for the whole piece. After welding, the material can naturally age and restore some of its strength as well. Most strength is recovered in the first few days to a few weeks. Nevertheless, the Aluminum Design Manual (Aluminum Association) recommends the design strength of the material adjacent to the weld to be taken as 165 MPa/24000 PSI without proper heat treatment after the welding. Typical filler material is 4043 or 5356.

Extrusions

6061 is an alloy used in the production of extrusions—long constant–cross-section structural shapes produced by pushing metal through a shaped die.

Forgings

6061 is an alloy that is suitable for hot forging. The billet is heated through an induction furnace and forged using a closed die process. This particular alloy is suitable for open die forgings. Automotive parts, ATV parts, and industrial parts are just some of the uses as a forging. Aluminium 6061 can be forged into flat or round bars, rings, blocks, discs and blanks, hollows, and spindles. 6061 can be forged into special and custom shapes.[25]

Castings

6061 is not an alloy that is traditionally cast due to its low silicon content affecting the fluidity in casting. It can be suitably cast using a specialized centrifugal casting method. Centrifugally cast 6061 is ideal for larger rings and sleeve applications that exceed the limitations of most wrought offerings.[26]

Equivalent materials

6061 Aluminium Equivalent Table[27]

US European Union ISO Japan China
Standard Grade (UNS) SAE AMS Standard Grade Standard Numerical (Chemical Symbols) Standard Grade Standard Grade Standard Grade
AA;

ASTM B209;

ASTM B211;

ASTM B221;

ASTM B210;

ASTM B308/B308M;

ASTM B241/B241M

 6061 (UNS A96061) SAE AMS 4025;

SAE AMS 4026;

SAE AMS 4027;

SAE AMS 4117

 6061 EN 573-3 EN AW-6061

(EN AW-AlMg1SiCu)

 ISO 209 AW-6061 JIS H4000;

JIS H4040

 6061 GB/T 3880.2

GB/T 3190

 6061

Standards

Different forms and tempers of 6061 aluminium alloy are discussed in the following standards:[28]

  • ASTM B209: Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
  • ASTM B210: Standard Specification for Aluminum and Aluminum-Alloy Drawn Seamless Tubes
  • ASTM B211: Standard Specification for Aluminum and Aluminum-Alloy Bar, Rod, and Wire
  • ASTM B221: Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
  • ASTM B308/308M: Standard Specification for Aluminum-Alloy 6061-T6 Standard Structural Profiles
  • ASTM B483: Standard Specification for Aluminum and Aluminum-Alloy Drawn Tube and Pipe for General Purpose Applications
  • ASTM B547: Standard Specification for Aluminum and Aluminum-Alloy Formed and Arc-Welded Round Tube
  • ISO 6361: Wrought Aluminium and Aluminium Alloy Sheets, Strips and Plates

References
  1. ASM Handbook Volume 2: Properties and Selection: Nonferrous Alloys and Special-Purpose Materials (10 ed.). Materials Park, Ohio. 1990. ISBN 978-0-87170-377-4. OCLC 21034891.{{cite book}}: CS1 maint: location missing publisher (link)
  2. Robert E. Sanders Jr. (2001). "Technology Innovation in Aluminum Products". JOM. 53 (2): 21–25. Bibcode:2001JOM....53b..21S. doi:10.1007/s11837-001-0115-7. S2CID 111170376.
  3. "Aluminum Alloys". Materials Management Inc. 23 December 2015. Archived from the original on 31 July 2016. Retrieved 2016-07-25.
  4. Specification for Aluminum and Aluminum-Alloy Sheet and Plate (metric) (Report). B07 Committee. doi:10.1520/b0209m-14.
  5. Alcoa 6061 data sheet Archived 2006-10-20 at the Wayback Machine (pdf), accessed October 13, 2006
  6. Aluminum Standards and Data 2006 Metric SI, by the Aluminum Association Inc.
  7. ASTM B209
  8. ASTM B221
  9. ASM Handbook Committee (1991). "Heat Treating of Aluminum Alloys". Volume 4: Heat Treating (PDF). ASM. p. 871. doi:10.1361/asmhba0001205 (inactive 2023-08-01). hdl:11115/192.{{cite book}}: CS1 maint: DOI inactive as of August 2023 (link)
  10. Material Properties Data: 6061-T6 Aluminum
  11. "ASM Material Data Sheet". Archived from the original on 2018-10-01. Retrieved 2020-12-23.
  12. "ASM Material Data Sheet". Archived from the original on 2018-10-22. Retrieved 2010-03-21.
  13. Hatch, John (1984). "Microstructure of Alloys". Aluminum: Properties and Physical Metallurgy. ASM International. pp. 54–104. ISBN 9780871701763.
  14. Nakai, Manabu; Itoh, Goroh (2014). "The Effect of Microstructure on Mechanical Properties of Forged 6061 Aluminum Alloy". Materials Transactions. 55 (1): 114–119. doi:10.2320/matertrans.ma201324. ISSN 1345-9678.
  15. Lee, S. H; Saito, Y; Sakai, T; Utsunomiya, H (2002-02-28). "Microstructures and mechanical properties of 6061 aluminum alloy processed by accumulative roll-bonding". Materials Science and Engineering: A. 325 (1): 228–235. doi:10.1016/S0921-5093(01)01416-2. ISSN 0921-5093.
  16. Easton, M.A.; StJohn, D.H. (2008). "Improved prediction of the grain size of aluminum alloys that includes the effect of cooling rate". Materials Science and Engineering: A. 486 (1–2): 8–13. doi:10.1016/j.msea.2007.11.009.
  17. Aluminum Information at aircraftspruce.com, accessed October 13, 2006
  18. 6061 vs 2024 Archived 2013-01-25 at archive.today. Homebuiltairplanes.com. Retrieved on 2012-04-04.
  19. Boatbuilding with Aluminum, Stephen F. Pollard, 1993, ISBN 0-07-050426-1
  20. Sorokanich, Bob (16 December 2015). "The Plymouth Prowler Was Secretly Chrysler's Most Important Engineering Experiment". Road & Track. Archived from the original on 28 January 2022. Retrieved 2 November 2022.
  21. Koch, Susanne (9 June 2021). "What aluminium alloys are best for bicycle frames?". Shapes – The Aluminium Design Knowledge Hub. Archived from the original on 26 October 2021. Retrieved 27 September 2022.
  22. EVOLUTION 9mm, 1/2-28 TPI Archived 2011-08-01 at the Wayback Machine. Advanced Armament. Retrieved on 2012-04-04.
  23. Amphibian S .22LR : Suppressor : AWC Systems Technology Archived 2011-10-01 at the Wayback Machine. Awcsystech.com. Retrieved on 2012-04-04.
  24. Bothell, Jed (30 September 2015). "Next Generation Vacuum Systems: Aluminum". Atlas Technologies. Archived from the original on 17 January 2022. Retrieved 27 September 2022.
  25. "6061 Aluminum Alloy Forging | Anderson Shumaker". www.andersonshumaker.com. Archived from the original on 2016-01-17. Retrieved 2015-10-08.
  26. "Aluminum Alloys | Johnson Centrifugal". johnsoncentrifugal.com. 27 August 2019. Retrieved 2019-10-14.
  27. Cole, Andrew (2020-05-24). "AL 6061-T6 Aluminium Alloy Properties, Tensile & Yield Strength, Thermal Conductivity, Modulus of Elasticity, Equivalent Material". The World Material. Retrieved 2020-08-03.
  28. 6061 (3.3214, H20, A96061) Aluminum. Retrieved on 2014-11-14.

Further reading
  • "Properties of Wrought Aluminum and Aluminum Alloys: 6061 Alclad 6061", Properties and Selection: Nonferrous Alloys and Special-Purpose Materials, Vol 2, ASM Handbook, ASM International, 1990, p. 102-103.

Aluminium alloy table
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