You’re at the right place if you’re like our valued customers concerned about the quality and specification of materials. What is the difference between Aluminum 6061 vs 6063, and which will work best for your project? Not just you—people in the industry often ask this question.
Aluminum 6061 and Aluminium 6063 have their advantages, but each has unique characteristics. Aluminum 6061 is more robust but has less formability. 6063, on the other hand, offers better corrosion resistance and it’s easier to shape. Your project requirements will determine the choice.
We are excited to dig deeper into these two types of aluminum. We designed this comparison to give you all the necessary information for making a well-informed decision on your next project.
Explore the Evolution of Aluminum Alloys: 6063 VS 6061 Aluminum
A Brief History of Aluminium
Aluminum is ubiquitous today but is only used sometimes. It was more valuable than any other metal until the late 19th Century due to its difficulty extracting bauxite. The Hall-Heroult Process, invented in 1886, revolutionized aluminum production by making it more affordable. People have always praised aluminum for its lightweight, corrosion-resistant, and durable qualities. These characteristics make aluminum popular in various industries, from consumer goods to aerospace.
The Development and Application of Aluminum 6061 vs 6063 Alloys
Aluminum is a relatively soft metal and does not have the strength required for most industrial applications. 6061 and 6063 are ideal for industrial applications.
Aluminum 661 was developed during the 1930s and quickly gained popularity for its outstanding mechanical properties. Initially used for aircraft structures during World War II, aluminum eventually found applications in automotive parts, building construction, and even components for spacecraft.
Introduced in the 1940s, Aluminum-6063 is renowned for its superior finish and formability, frequently finding use in electronic heat sinks and architectural profiles. Its corrosion resistance made it a popular material for outdoor fixtures and even pipelines.
Milestones of aluminum 6063 vs 6061 usage
We’ll talk about the pivotal moments in the history of aluminum alloys.
Military and Aerospace: During World War II, Aluminum 6061 became popular, making aircraft lighter and more durable. The high tensile strength made it an indispensable material for military applications. Aluminum continues to play a role in modern aerospace applications.
Automotive Industry:
The trend towards lighter and more fuel-efficient vehicles has led to a rise in the use of Aluminum 6061. Aluminum 6061 was chosen for its high strength and low weight characteristics, making it an excellent choice for automotive components.
Construction & Architecture:
In the 1950s and 60s, skyscraper building boomed. Chosen for their strength and aesthetic appeal, the alloys 6061 and 6063 serve to construct window frames, curtain walls, and structural beams.
Consumer Electronics
Aluminum 6063 was the material of choice for heat sinks on computers and electronic devices as technology boomed in the 20th century.
Unlocking the Basics: Basic Properties and Characteristics of Aluminum Alloys
Aluminum: The Chemistry Behind It
Aluminum, about 8% of Earth’s crust, is the third-most abundant element. It is a member of Group 13 and has an atomic number of 13. Chemically represented as “Al,” aluminum has an atomic weight of approximately 26.98 atomic mass units (AMU).
Aluminum forms a protective layer of oxide when it reacts with oxygen. This is why aluminum resists corrosion so well. Passivation is a method that allows the metal to form a non-reactive, hard surface layer. This prevents further corrosion.
Its Characteristics Make it Useful.
What makes aluminum popular in the automotive, aerospace, and construction industries? Aluminum has many characteristics that make it valuable.
Lightweight:
Aluminum’s low density is one of its most notable features. Aluminum is lightweight and robust. It is ideal for applications requiring a weight reduction, like airplanes or automobiles.
Corrosion-Resistant:
Aluminum is a good choice for outdoor and harsh environments because of the protective oxide layer formed on it.
Excellent Conductivity:
Aluminum is an excellent conductor of heat and electricity, making it a popular material for cooling systems and wires.
Formability:
Due to its high malleability, aluminum can take many shapes and sizes, making it ideal for intricate designs and structures.
Recyclability:
Aluminum is recyclable at 100% without losing any of its natural properties. This makes it an environmentally friendly choice for today’s world.
General Properties of Aluminum Alloys
Aluminum is alloyed to improve specific properties. Alloys like 6061 and 6063 are ideal for particular applications.
Strength:
Aluminum is a robust structural material with its tensile strength enhanced by adding magnesium and silicon.
Formability:
Certain alloys like 6063 offer superior formability. They can be shaped into complex geometries while maintaining their original properties.
Thermal conductivity:
Designers can specifically engineer aluminum alloys to improve thermal conductivity, which is crucial for heat exchangers and electronic heat sink applications.
Corrosion Resistant:
Enhancing pure aluminum’s excellent corrosion resistance makes alloys better suited for marine and acidic environments.
I am decoding the 6xxx series: What sets these aluminum alloys apart?
Series Classification
Series group alloys of aluminum according to their main alloying elements. A four-digit code identifies each series. Here’s a quick rundown:
- 1xxx: Pure aluminum
- 2xxx: Copper
- 3xxx: Manganese
- 4xxx: Silicon
- 5xxx: Magnesium
- 6xxx: Magnesium and silicon
- 7xxx：Zinc
- 8xxx： Other Elements
The 6xxx Series is unique because it contains silicon and magnesium as the primary alloying elements. These alloys are highly desirable for their unique properties in various industrial applications.
Common Alloying Element
The 6xxx series’ defining feature is the addition of silicon and magnesium. Let’s look at some more details:
Magnesium:
Magnesium increases strength and hardness. Heat treatment can further strengthen the material.
Silicon (Si):
Silicon improves an alloy’s corrosion resistance and formability. It also helps lower the alloy’s melting point, which is beneficial when casting.
Different alloys of the 6xxx series, such as our 6061 and 6063 aluminum, are characterized by other alloying elements.
The 6xxx Series: Unique Features
What makes the 6xxx Series stand out from the others? What are their most notable attributes?
Strength-to-Weight Ratio:
A high strength-to-weight ratio characterizes the 6xxx Series. This makes them perfect for applications in automotive and aerospace, where weight reduction is essential without compromising on strength.
Excellent Formability：
The silicon content in these alloys makes them easy to form ideal for creating intricate shapes and parts.
Good corrosion resistance:
Aluminum’s natural corrosion resistance is enhanced by the 6xxx Series, making it ideal for outdoor applications or environments where corrosion may be problematic.
Heat Treatable：
The 6xxx series of aluminum alloys is heat-treatable. This allows for an additional strengthening process through processes such as aging.
Weldability:
The 6xxx Series is characterized by excellent welding properties, making it suitable for various joining methods.
| GRADE | ALLOY | FEATURES |
|---|---|---|
| 1000 series | 99% pure aluminium | Electrically conductive |
| 2000 series | Copper | Increased strength |
| 3000 series | Manganese | Food safe |
| 4000 series | Silicon | Lower melting point |
| 5000 series | Magnesium | Higher corrosion resistance |
| 6000 series | Magnesium and silicon | Respond well to heat treatment |
| 7000 series | Zinc | High strength |
What’s Inside? What’s Inside?
Aluminum 6061 Elements
Aluminum 6061 alloy is famous for its corrosion resistance, strength, and workability. What exactly is it made of? Here are some of the main components:
Aluminum (Al):
The 6061 steel consists of at least 95.8% aluminum.
Magnesium:
Magnesium, present in the 0.8-1.2% range, enhances the material’s mechanical properties.
Silicon (Si):
The alloy is more malleable when silicon is present in the composition.
Copper (Cu):
Add a small amount of copper (0.15-0.4%) to the mix for strength.
Other Elements
There are also trace amounts of chromium and zinc. However, these usually are at most 0.35%.
Aluminum 6063 Elements
Aluminum 6063, on the other hand, is known for its superior formability. It also has a smooth finish. This alloy is made up of:
Aluminum (Al):
This alloy is also made up of aluminum, usually around 97.5%.
Magnesium:
6063 has a little less magnesium than 6061. It is usually around 0.45-0.19%.
Silicon :
Its excellent formability is due to the silicon content, which is higher at 0.2-0.6%.
Other Elements
6061 vs 6063 aluminum can also contain trace metals like copper, iron, and zinc. However, these elements are usually less than 0.35 percent.
Comparison of both compositions
Let’s compare the aluminum 6061 vs 6063 side by side now that we have a better understanding of their key elements:
Aluminum Content:
Both alloys contain a lot of aluminum, but 6063 has a little more.
Magnesium to Silicon Ratios
6061 contains more magnesium for increased strength, whereas 6063 contains more silicon for improved formability.
Copper:
The 6061 steel contains a significant amount of copper. This is absent from 6063. The increased tensile strength of 6061 can be a problem for applications that require a high-quality surface finish.
Trace Elements:
The alloys both contain traces of other elements. However, these do not affect their primary properties.
Strength Matters: Comparing the mechanical properties of 6061 and 6063 Aluminum
Yield Strength
The yield strength measures how much stress the material can handle before it begins to deform. The yield strength of 6061 is typically between 40,000 and 50,000 psi. This makes it ideal for structural applications that require power.
The yield strength 6063 is lower and can range from 31,000 psi to 40,000. It is, therefore, ideal for projects more concerned with formability and aesthetics than high-strength performance.
Tensile strength
The tensile strength describes the alloy’s resistance to breaking. The tensile strength of 6061 ranges from 45,000 to 58,000 psi. This is a high value and suitable for applications that will subject the material to high tensile forces.
The 6063 is less potent, with tensile strength ranging from 27,000 to 41,000. It is less suitable for applications that require high stress, but it’s excellent for those that need a good surface finish.
Hardness Levels
The hardness of an alloy is a good indicator of its resistance to wear and deformation. Brinell hardness of aluminum 6061 ranges from 90 to 95. This makes it an excellent choice for parts exposed to high wear or stress.
6063 is typically softer than 6061, with a Brinell Hardness of 73-79. It is ideal for window frames, where hardness is not a significant concern.
Fatigue Strength
The fatigue strength of a material is a measure of its ability to withstand repeated loadings and unloadings over time. While 6061 has a higher fatigue strength of around 14,000-15,000 psi than 6063, the two are not far apart, with values typically around 10,000-12,000 psi. Both materials are suitable for cyclic load applications. However, 6061 is more durable than 6063 under repeated stress.
How hot or cold? What is the difference between 6061 and 6063 aluminum?
Melting Points
The melting point is the temperature at which an alloy changes from solid to liquid. Aluminum 6061’s melting point ranges between 577 and 652degC (570 to 1205degF). The range of melting points is due to the specific alloy composition and heat treatment.
Aluminum 6063 also has a melting temperature ranging between 568 and 643degC. The difference may be subtle, but it can significantly impact high-temperature applications.
Coefficient of Thermal Expansion
The coefficient of thermal contraction (CTE), or thermal expansion, describes how a material expands and contracts when temperature changes. Aluminum 6061 has a CTE of 13.1 x 10–6/degC. It is a very stable material, which makes it an excellent choice for applications requiring dimensional stability at varying temperatures.
Aluminum 6063 has a CTE of around 21.0 x 10–6/degC. This makes 6063 slightly less stable than 6061 but still reasonably stable.
Thermal Conductivity
The thermal conductivity of a material is a measure of its ability to conduct heat. Aluminum 6061 is a heat-exchange material in radiators and air conditioners due to its thermal conductivity.
What’s the Surface? What’s on the Surface?
Natural Finish 6061
Aluminum 6061 is a natural silvery color with a rough texture. The magnesium and silicon in this alloy give it a “brushed,” “scratched,” or “scratched” appearance. The natural finish on 6061 is still functional but may be better for more aesthetic applications.
Natural Finish 6063
Aluminum 6063, on the other hand, has a smoother surface right out of the factory. It is more attractive in its natural state and has a shinier surface. People choose 6063 for architectural applications because it offers strength and an appealing appearance.
Surface Treatment Options Both for the Ones and the Other
Both 6061 and 63 are highly responsive to surface treatments that can enhance their appearance and protect qualities.
Anodizing both alloys will improve their corrosion resistance. This process allows color customization.
This option adds color and texture to the fabric while providing extra protection from wear and tear.
Both 6061 and 6063 are suitable for projects that require a high-reflective surface.
Painting:
Painting is an option, but powder or anodizing is more durable.
How well do they bend and join? Compare the formability and weldability of aluminum 6061 vs 6063
For 6061
Aluminum 6061 has good formability and is suitable for many forming techniques. These include:
- Bending：You can successfully bend 6061, although you may need to heat it at higher temperatures for tighter curves.
- Spinning：This alloy is used for metal spinning, creating conical or rounded shapes.
- Stamping: 6061 aluminum is easy to stamp. It’s less soft, however.
For 6063
Due to its excellent formability, aluminum 6063 is famous for projects requiring intricate shapes. Here are some of the most common methods.
- Extrusion: 6063 aluminum alloy is one of the best aluminum alloys to extrude, allowing for complex cross-sectional shapes.
- Deep DrawingThis alloy is ideal for deep drawing processes.
- Rolled: You can also shape 6063 into rounded or curved forms.
Comparative Weldability Analysis
Here’s how weldability measures up for our top contenders:
- 6061：This alloy is readily welded using the most common welding techniques, such as TIG or MIG. It is important to remember that 6061 may lose some of its mechanical properties around the weld area if it is not heat-treated correctly.
- 6063：This alloy can also be welded and often has a better look in the area of the weld than 6061. It is easier to work with if aesthetics and joint strength are essential.
How does Aluminum 6061 vs 6063 resist corrosion?
General Corrosion Resistant
The protective oxide layer on the surface of both Aluminum 6061 & 6063 is mainly responsible for their excellent corrosion resistance. The protective oxide layer is a barrier against corrosive substances, whether you use these alloys in marine applications, automotive components, or industrial uses.
Galvanic corrosion in 6061
When two metals come into contact with an electrolyte, such as seawater, galvanic corrosion can occur. Aluminum 6061 is less susceptible to rot than metals such as steel or copper. Galvanic corrosion is accelerated if 6061 comes into contact with nobler metals such as gold or silver. It’s best to choose fasteners made from a compatible metal or use an isolating material between dissimilar metals.
Galvanic corrosion in 6063
Aluminum 6063, like 6061 aluminum, is resistant to galvanic corrosive corrosion. Its slightly different composition could make it more vulnerable than 6061 under extreme conditions. It’s important to know what metals will come into contact with it to avoid galvanic corrosion. This alloy benefits from similar preventive measures, such as isolating the alloy or using compatible fasteners.
Where do they shine? Aluminum 6061 and 6063: Exploring their Application Areas
6061: Common uses
Aerospace
Aluminum 6061 is used frequently in aerospace due to its incredible strength-to-weight ratio and corrosion resistance. You can use 6061 for various applications, from aircraft components to satellite frames. It is versatile and meets the high standards of the aerospace industry.
Structural Engineering
Aluminum 6061 is an excellent choice for structural engineering because of its strength, formability, and weldability. Bridges, scaffolding, and high-speed boat frames are all common uses. These applications take advantage of the alloy’s corrosion resistance and mechanical properties.
Common uses of 6063
Architectural Applications
People commonly use Aluminum 6063 in construction, particularly for architectural applications. The high corrosion resistance of this material and its excellent surface finish make it perfect for window frames, doors, and other architectural components.
Custom Extrusions
Its excellent formability makes 6063 the ideal alloy for custom-made aluminium profile. It is great for intricate, complex, structurally sound, and aesthetically pleasing shapes.
Calculating the cost: Is Aluminum in 6061 vs 6063 more economical?
Cost Average of 6061
Aluminum 6061 is usually more expensive than the other aluminum alloys. Why? The superior mechanical properties of the alloy and its versatility. This high-strength alloy is versatile and suitable for various applications, from structural engineering to aerospace. This often justifies the higher price.
6063 Average Cost
Aluminum 6063, on the other hand, is less expensive than 6061. It’s mainly because aluminum 6063 is easier to extrude. This makes it more available and cheaper to produce. It is ideal for architectural applications and aesthetics because it has a high level of formability and surface finishing.
Value for money
Although 6061 is more expensive, its versatility and mechanical strength can make it a better choice for high-performance applications. The cost may be justified in industries like aerospace, where material performance is crucial.
Greener Choices: What is the environmental impact of aluminum 6061 vs 6063?
Recyclability 6061
Aluminum 6061 has a high recycling rate, an essential advantage in terms of its environmental impact. Recycling this alloy requires only 5% of the energy needed to produce it. This makes 6061 an ideal application choice considering the product’s lifecycle or recyclability after use.
Recyclability 6063
Like its 6061 counterpart, Aluminum 6063, it is highly recyclable. The aluminum 6063 can also be melted and reformed without losing quality. This easy recycling makes 6063 an ideal choice for many applications.
Sustainability Issues
Due to their high levels of recyclability, both 6061 and 6063 offer excellent sustainability profiles. It is essential to consider the whole life cycle of a product. The more substantial 6061 may use less material to achieve the same result, thus reducing its impact on the environment. In contrast, 6063’s lower melting point and easier extrusion could lead to lower energy consumption in production.
What’s Trending? What’s Trending?
Demand from Industry for 6061
Aluminum 6061 is in high demand, especially for sectors that require high-strength materials, like the aerospace and automotive industries. The alloy’s outstanding mechanical properties, corrosion resistance, and weldability drive this growth. The demand for 6061 will continue to grow as more and more applications require robust materials.
Demand from Industry for 6063
Architectural and design industries are increasingly requesting aluminum 6063. The demand for materials that combine aesthetics and formability is also increasing as urbanization and construction projects increase. The market for 6063 is growing, particularly in applications such as window and door frames.
Predictive Analysis of Future Demand
It’s difficult to predict the market trends 100% accurately, but specific indicators can help you determine the demand trajectory for 6061 or 6063. We can expect a rise in demand for 6061 as the electric vehicle and renewable energy sectors continue to grow. We can also expect growth for 6063, as the focus continues to be on modern architectural designs and sustainable construction.
How do you decide? How do I choose between Aluminum 6061 and 6063?
Important Considerations
It’s essential to consider several factors when choosing between the two alloys. If you need a higher tensile and durability, 6061 is the best option. If you are more concerned with surface finish and formability, 6063 is a good choice.
You should also consider your application requirements. Are you in the aerospace or automotive sector? You might prefer 6061. Are you working on a project that is architectural or aesthetic? Most recommendations usually favor the 6063 option.
Practical Tips
- Please select the suitable alloy for the application: Determine the main requirements of your project and choose the alloy that meets them.
- Budget Constraints：While 6061 may be more expensive in general, it can provide more excellent value over the long term for applications subject to high stress. For projects that require excellent formability, 6063 could be a better choice.
- Environmental Concerns：Both alloys can be recycled, but you should consider their environmental impact over the entire life cycle, including energy requirements for production and recycling.
- Consult Experts: Conversing with a material scientist or industry expert can provide valuable insight tailored to your needs.
Expert Opinions
Experts agree that the choice of alloy heavily depends upon the project’s requirements. Experts often choose 6061 for applications that require high strength and versatility. For projects that require aesthetics and formability, 6063 is the preferred choice.
Case Studies: What are the real-world performance of Aluminum 6061 vs 6063?
Case Study No. 1: 6061 Automotive Manufacturing
A client in the automotive industry chose Aluminum 6061 to produce vehicle frames and chassis. Here, the high tensile and corrosion resistance of this alloy were critical. The vehicles showed excellent performance over two years with minimal wear, thus validating the 6061 alloys.
This case confirms 6061’s reputation as a durable, high-strength material suitable for heavy-duty uses where mechanical properties are paramount.
Case Study 2: Building Construction 6063
The construction team chose Aluminum 6063 to form the frames of large-scale windows and doors due to its superior surface finish and formability. People praised the structures for their aesthetics and weather resistance. The client was especially pleased with the material’s visual appeal and workability.
This case illustrates the suitability of 6063 in architectural applications, where aesthetics and formability play a crucial role.
Comparative Case Study: Aluminum 6061 vs 6063 in a Similar Application
In this case, we are considering a project for outdoor furniture, where we have tested 6061 and 6063 on various garden furniture pieces. The 6061 material was more expensive but offered a more robust structure. 6063, on the other hand, was easier to shape into intricate designs with a more polished appearance. Stress tests on 6063 furniture revealed signs of wear earlier than expected.
The conclusion of the article is:
Once again, hello to our valued clients and industry experts! It’s time to summarize our technical exploration, case studies, and market trends. Understanding the subtle differences between 6061 Aluminum and 6063 ensures your project’s success.
Core Differences
Aluminum 6061’s superior mechanical properties are what make it so popular. It has a higher tensile resistance, good corrosion resistance, and is easy to weld. This is the alloy of choice for heavy-duty uses. Aluminum 6063 is a formable alloy with a beautiful finish. It’s perfect for architectural and design applications.
The areas where each alloy excels
- Aluminum 6061：This alloy is perfect for sectors like aerospace, automotive, and structural engineering, where compromising on strength and durability is not an option.
- Aluminum 6063: For projects that demand intricate designs and finishes with a pleasing aesthetic — think window frames or extrusions made to order–6063 is the best choice.
Final Recommendations
How should you decide? If you need high strength, durability, and corrosion resistance for your project, then 6061 is the right choice. If aesthetics, formability, and surface finish are more important, 6063 will be the best choice.
The final decision is not just about choosing the suitable material. It’s also about matching that material to the needs and goals specific to your project.
Considerations of application, aesthetics, and material properties are all part of the process to choose between Aluminium 6061 VS 6063. This guide will help you make an informed choice.
More Resources:
Aluminum Alloys/Grades – Source: DECO
Mechanical properties of Aluminum 6061 – Source: Aluminum Association
Hey, I'm Kevin Lee
For the past 10 years, I’ve been immersed in various forms of sheet metal fabrication, sharing cool insights here from my experiences across diverse workshops.
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Kevin Lee
I have over ten years of professional experience in sheet metal fabrication, specializing in laser cutting, bending, welding, and surface treatment techniques. As the Technical Director at Shengen, I am committed to solving complex manufacturing challenges and driving innovation and quality in each project.
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