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Aluminum 6061-T6

Aluminum 6061-T6 is one of the most widely used structural aluminum alloys, known for its excellent mechanical properties, superior corrosion resistance, and outstanding machinability. The T6 temper involves solution heat treatment followed by artificial aging, delivering a balanced combination of strength, weldability, and finishability that makes it ideal for precision CNC machining and structural applications across aerospace, automotive, and industrial sectors.

Mechanical Properties

Density: 2.70 g/cm³

Tensile Strength: 310 MPa

Yield Strength: 275 MPa

Elongation at Break: 12%

Shear Strength: 207 MPa

Fatigue Strength: 96.5 MPa

Hardness (Brinell): 95 HB

Modulus of Elasticity: 68.9 GPa

Thermal Conductivity: 167 W/m·K

Melting Point: 582–652°C

Coefficient of Thermal Expansion: 23.6 ×10⁻⁶ /°C

Electrical Conductivity: 43% IACS

Advantages

  • Excellent machinability — consistent chip formation and low tool wear across a wide range of cutting conditions
  • High strength-to-weight ratio — enables lightweight structural components without sacrificing durability
  • Superior corrosion resistance — naturally forms a protective oxide layer, further enhanced by anodizing
  • Good weldability — compatible with MIG, TIG, and friction stir welding methods

Machining & Manufacturing

ParameterSpecificationNotes
Cutting SpeedRoughing: 800–1,500 SFM (245–460 m/min)Finishing: 1,200–2,000 SFM (365–610 m/min)-
Feed Rate0.005–0.020 ipt (0.13–0.51 mm/rev)Adjust based on depth of cut and tool diameter
ToolingCarbide end mills for production; High-speed steel (HSS) for prototypes and low-volume work-
CoolantWater-based semi-synthetic or full synthetic cutting fluidFlood cooling for longer tool life; mist coolant for light finishing
Chip ControlShort powdery chips in annealed areas, long stringy chips in heat-treated zonesUse chip breakers and sufficient coolant for smooth chip evacuation
Difficulty LevelEasyExcellent machinability among structural aluminum alloys, suitable for beginner aluminum CNC machining

Common Applications

Aerospace: Structural brackets, wing components, and fuel system housings requiring a balance of strength and weight
Automotive: Engine mounts, chassis crossmembers, suspension components, and drive shafts
Marine: Deck hardware, railings, and hull fittings where corrosion resistance is critical
Electronics: Heat sinks, PCB enclosures, and structural frames for thermal management
Industrial: Conveyor frames, machinery housings, tooling fixtures, and pneumatic cylinders

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