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6063 Extruded Aluminum Bar

6063 extruded aluminum bar is a versatile and widely used material in the aluminum alloy industry, renowned for its combination of strength, corrosion resistance, and excellent workability. This alloy belongs to the 6000 series, which primarily contains magnesium and silicon as its alloying elements, providing it with a balance of mechanical properties and welding characteristics.

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1. Material Composition & Manufacturing Process

6063 aluminum alloy (AlMgSi0.5) is a medium-strength alloy with excellent extrudability, surface finish, and corrosion resistance. This popular architectural alloy combines good mechanical properties with superior formability and anodizing response:

Primary Alloying Elements:

Magnesium (Mg): 0.45-0.90% (precipitation hardening)

Silicon (Si): 0.20-0.60% (forms Mg₂Si strengthening precipitates)

Base Material:

Aluminum (Al): ≥98.0% (balance)

Controlled Impurities:

Iron (Fe): ≤0.35% max

Copper (Cu): ≤0.10% max

Manganese (Mn): ≤0.10% max

Chromium (Cr): ≤0.10% max

Zinc (Zn): ≤0.10% max

Titanium (Ti): ≤0.10% max

Other elements: ≤0.05% each, ≤0.15% total

Premium Extrusion Manufacturing Process:

Billet Preparation:

High-purity primary aluminum (99.7% minimum)

Precise alloying element additions

Degassing treatment (hydrogen < 0.2 ml/100g)

Direct-chill (DC) semi-continuous casting

Homogenization at 560-580°C for 4-8 hours

Billet Preheating:

Computer-controlled heating to 450-480°C

Temperature uniformity: ±5°C

Oxide layer removal (scalping)

Extrusion:

Breakthrough pressure: 35-45 MPa

Running pressure: 20-35 MPa

Ram speed: 5-15 mm/sec (profile-dependent)

Exit temperature control: 510-540°C

Die temperature: 480-500°C

Cooling:

Air cooling or water quenching (temper-dependent)

Controlled cooling rate for optimal properties

Maximum distortion control

Stretching:

0.5-2.0% permanent deformation

Straightening and stress relief

Artificial Aging (T5/T6):

T5: 175-185°C for 2-4 hours

T6: Solution heat treatment (520-530°C) + Artificial aging (175-185°C for 6-8 hours)

Finishing Operations:

Cut-to-length precision: ±1mm

Surface finish enhancement

Final straightness check and correction

All manufacturing maintains digital process monitoring for complete traceability.

2. Mechanical Properties of 6063 Extruded Bar

Property	T5 (min)	T5 (typical)	T6 (min)	T6 (typical)	Test Method
Ultimate Tensile Strength	150 MPa	160-185 MPa	205 MPa	215-230 MPa	ASTM E8
Yield Strength (0.2%)	110 MPa	120-145 MPa	170 MPa	180-200 MPa	ASTM E8
Elongation (2 inch)	8%	10-14%	8%	10-12%	ASTM E8
Hardness (Brinell)	60 HB	65-75 HB	75 HB	80-90 HB	ASTM E10
Fatigue Strength (5×10⁸)	70 MPa	75-85 MPa	95 MPa	100-110 MPa	ASTM E466
Shear Strength	90 MPa	95-110 MPa	120 MPa	125-140 MPa	ASTM B769
Modulus of Elasticity	69.5 GPa	69.5 GPa	69.5 GPa	69.5 GPa	ASTM E111

Property Distribution:

Longitudinal to transverse property ratio: 1.00:0.95

Wall thickness effect: <5% variation for up to 10mm thickness

Corner to flat section property variation: <10%

Surface to core hardness variation: <5 HB

3. Surface Finish & Appearance

Surface Quality Classifications:

Architectural Grade (AA10):

Ra ≤ 0.4μm surface roughness

No visible defects at 1m viewing distance

Suitable for decorative anodizing

Consistent color after anodizing

Commercial Grade (AA20):

Ra ≤ 0.8μm surface roughness

Minor defects acceptable at >2m viewing distance

Good anodizing response

Industrial Grade (AA30):

Ra ≤ 1.6μm surface roughness

Functional applications where appearance is secondary

Surface Treatment Compatibility:

Anodizing Response: Excellent

Type II (sulfuric acid): 5-25μm thickness

Type III (hard coat): 25-75μm thickness

Color consistency rating: Excellent

Architectural Class I: 18μm minimum coating

Architectural Class II: 10μm minimum coating

Mechanical Finishing:

Brushing/Polishing: Excellent response

Bead blasting: Uniform matte finish

Bright dipping: High reflectivity achievable

Painting/Coating:

Powder coating adhesion: Excellent

Wet paint compatibility: Good with proper pretreatment

Chromate conversion coating: Class 1A achievable

4. Dimensional Specifications & Tolerances

Parameter	Standard Range	Precision Tolerance	Commercial Tolerance	Test Method
Diameter (Round)	5-300 mm	±0.15mm up to 30mm	±0.25mm up to 30mm	Micrometer
		±0.3% above 30mm	±0.5% above 30mm
Width (Rectangle)	10-200 mm	±0.15mm up to 50mm	±0.25mm up to 50mm	Caliper
		±0.3% above 50mm	±0.5% above 50mm
Length	1000-6500 mm	±2mm	±5mm	Tape measure
Straightness	N/A	0.3mm/m	0.5mm/m	Straightedge
Twist (Rectangular)	N/A	1° max per meter	3° max per meter	Protractor
Corner Radius	N/A	±0.2mm	±0.5mm	Radius gauge

Standard Available Forms:

Round Bar: Diameters 5-300mm

Hexagonal Bar: Across flats 8-75mm

Square Bar: Side dimensions 5-150mm

Rectangular Bar: Width up to 200mm, thickness from 3mm

Custom profiles available with appropriate tooling

5. Temper Designations & Heat Treatment Options

Temper Code	Process Description	Optimal Applications	Key Characteristics
T1	Cooled from extrusion and naturally aged	Non-critical applications	Moderate strength, excellent formability
T4	Solution heat treated and naturally aged	Forming applications	Good formability, moderate strength
T5	Cooled from extrusion and artificially aged	General purpose	Good strength, excellent extrudability
T6	Solution heat treated and artificially aged	Structural applications	Maximum strength and hardness
T52	Cooled from extrusion, stress relieved, artificially aged	Length-critical applications	Improved straightness, good strength
T83	Solution heat treated, cold worked, artificially aged	High-stress applications	Enhanced strength with good toughness

Temper Selection Guidance:

T5: Most economical for standard applications

T6: When maximum strength is required

T4: When post-extrusion forming is needed

T52: For applications requiring strict dimensional stability

6. Machining & Fabrication Characteristics

Operation	Tool Material	Recommended Parameters	Comments
Turning	HSS, Carbide	Vc=200-500 m/min, f=0.1-0.4 mm/rev	Excellent surface finish
Drilling	HSS, Carbide	Vc=80-150 m/min, f=0.15-0.3 mm/rev	Low cutting forces
Milling	HSS, Carbide	Vc=200-600 m/min, fz=0.1-0.25 mm	Excellent chip evacuation
Tapping	HSS, TiN coated	Vc=10-30 m/min	Excellent thread quality
Sawing	Carbide tipped	Vc=800-1500 m/min, medium pitch	Clean cuts with minimal burr
Threading	HSS, Carbide	Vc=150-300 m/min, fine feed	Excellent thread finish

Fabrication Guidance:

Machinability Rating: 90% (1100 aluminum = 100%)

Surface Finish: Excellent (Ra 0.5-1.6μm easily achievable)

Chip Formation: Short chips with proper tooling

Coolant: Water-soluble emulsion or minimal lubrication

Tool Wear: Minimal with proper parameters

Formability: Excellent in T1/T4 conditions

Bendability: Minimum radius = 1× thickness (T1/T4), 2× thickness (T6)

Weldability: Good with TIG/MIG methods

Thread Rolling: Excellent results in T4 condition

7. Corrosion Resistance & Protection Systems

Environment Type	Resistance Rating	Protection Method	Expected Performance
Rural/Urban Atmosphere	Excellent	Mill finish or anodizing	15-20+ years
Industrial Atmosphere	Very Good	Anodizing Class I	10-15 years
Marine Environment	Good	Anodizing + sealing	5-10 years with maintenance
High Humidity	Excellent	Standard anodizing	10-15 years
Chemical Exposure	Moderate	Hard anodizing + sealing	Application specific
UV Exposure	Excellent	Clear anodizing	No degradation

Surface Protection Options:

Anodizing:

Clear (natural): Excellent clarity and transparency

Color anodizing: Consistent color development

Hard anodizing: Superior wear resistance

Sealing options: Hot water, nickel acetate, PTFE

Conversion Coatings:

Chromate per MIL-DTL-5541

Non-chromium alternatives

Mechanical Finishing:

Brushed finish: Uniform directional pattern

Polished finish: Mirror-like appearance achievable

Sandblasted: Consistent matte texture

Organic Coatings:

Powder coating: Excellent adhesion and durability

Liquid paint: Good with proper pretreatment

Clear protective coatings: UV and abrasion protection

8. Physical Properties for Engineering Design

Property	Value	Design Consideration
Density	2.70 g/cm³	Weight calculation for components
Melting Range	615-655°C	Thermal processing limitations
Thermal Conductivity	200-220 W/m·K	Heat sink applications
Electrical Conductivity	50-55% IACS	Electrical applications
Specific Heat	900 J/kg·K	Thermal mass calculations
Thermal Expansion (CTE)	23.4 ×10⁻⁶/K	Thermal expansion allowances
Young's Modulus	69.5 GPa	Structural calculations
Poisson's Ratio	0.33	Structural analysis parameter
Reflectivity	80-85% (polished)	Optical/lighting applications

Design Considerations:

Operating Temperature Range: -80°C to +175°C

Property Retention: Excellent below 100°C

Electrical Conductivity: Higher than many aluminum alloys

Magnetic Properties: Non-magnetic

Recyclability: 100% recyclable, high scrap value

Environmental Impact: Low carbon footprint compared to steel

9. Quality Assurance & Testing

Standard Testing Procedures:

Chemical Composition:

Optical emission spectroscopy

Verification of all major elements and impurities

Mechanical Testing:

Tensile testing (longitudinal)

Hardness testing (Webster/Brinell)

Dimensional Inspection:

Diameter/dimensions at multiple locations

Straightness verification

Surface finish measurement

Visual Inspection:

Surface defects assessment

Die line evaluation

Surface appearance uniformity

Specialized Testing (When Required):

Anodizing response test

Grain structure evaluation

Conductivity testing

Standard Certifications:

Mill Test Report per EN 10204 2.1/3.1

Chemical analysis certification

Mechanical properties certification

Dimensional inspection report

Heat treatment certification (for T6 temper)

10. Applications & Design Considerations

Primary Applications:

Architectural components:

Window and door frames

Curtain wall systems

Railings and balustrades

Decorative trim and moldings

Transportation:

Automotive trim and components

RV and trailer components

Bicycle frames and components

Electrical:

Heat sinks and thermal management

Electrical enclosures and housings

LED lighting fixtures and profiles

Consumer goods:

Furniture components

Appliance trim and parts

Shower enclosures and bathroom accessories

Industrial components:

Pneumatic cylinder tubes

Machine guards and frames

Conveyors and material handling

Design Advantages:

Excellent surface finish for aesthetic applications

Superior extrudability for complex profiles

Good strength-to-weight ratio

Excellent corrosion resistance

Outstanding anodizing response

Ease of fabrication and joining

Cost-effective compared to higher-strength alloys

Consistent properties and quality

Readily available in diverse shapes and sizes

Sustainable material with high recycled content potential

Design Limitations:

Lower strength compared to 6061/6082 alloys

Not recommended for highly stressed structural applications

Limited weldability compared to 6061

Reduced mechanical properties in weld heat-affected zones

Temperature limitations above 175°C

Economic Considerations:

Excellent balance of cost and performance

Lower processing costs than higher-strength alloys

Reduced machining costs due to excellent machinability

Long service life with minimal maintenance

High scrap value at end of life cycle

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