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6061 Large Diameter Aluminum Alloy Tube

6061 aluminum alloy is known for its excellent corrosion resistance, especially in marine and industrial environments. It also has good mechanical properties, including high tensile strength and yield strength, as well as good ductility and formability. In addition, 6061 aluminum can be easily welded and processed, making it the preferred choice for various applications.

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1. Material Composition & Manufacturing Process

6061 aluminum alloy (ASTM B241, AMS 4025) large diameter tubes feature a balanced magnesium-silicon composition optimized for structural integrity and fabrication flexibility:

Alloy Chemistry:

Magnesium (Mg): 0.8-1.2% (solution strengthening)

Silicon (Si): 0.4-0.8% (precipitation hardening)

Copper (Cu): 0.15-0.40% (enhanced machinability)

Chromium (Cr): 0.04-0.35% (grain refinement)

Base Material:

Aluminum (Al): ≥97.5% (balance)

Controlled Impurities:

Iron (Fe): ≤0.7% max

Manganese (Mn): ≤0.15% max

Zinc (Zn): ≤0.25% max

Titanium (Ti): ≤0.15% max

Advanced Manufacturing Process:

Hot Extrusion: 480-520°C at extrusion ratios of 10:1 to 30:1

Cold Drawing: 10-20% reduction for dimensional accuracy

Stretch Straightening: 1.5-3% elongation for stress relief

Heat Treatment: T4/T6 temper options

Surface Finishing: Anodizing or chemical conversion coatings

Certified to AMS-QQ-A-200/9 and EN 755-7 standards with full material traceability systems.

2. Mechanical Properties for Structural Applications

Property	T4 Temper	T6 Temper	Test Standard
Ultimate Tensile Strength	180-215 MPa	260-310 MPa	ASTM E8
Yield Strength (Rp0.2)	110-130 MPa	240-280 MPa	ASTM E8
Elongation (%)	16-22%	10-15%	ASTM E8
Shear Strength	125-145 MPa	170-200 MPa	ASTM B769
Bearing Strength	365-415 MPa	480-550 MPa	ASTM E238
Fatigue Strength (10⁷)	75-95 MPa	90-115 MPa	ASTM E466
Hardness (Brinell)	65-75 HB	95-105 HB	ASTM E10
Impact Toughness	20-25 J	16-20 J	ASTM E23

Maintains 85% of mechanical properties at temperatures from -50°C to 150°C.

3. Heat Treatment & Microstructure Control

Temper Processing Options:

T4 Solution Treatment:

Heating: 530°C ±5°C for 1-2 hours

Quenching: Water spray (cooling rate >200°C/min)

Natural aging: 96+ hours at ambient

T6 Full Hardening:

Solution treatment: Same as T4

Artificial aging: 160-180°C for 8-12 hours

Microstructural Characteristics:

Primary Phases: β-Mg₂Si precipitates

Grain Structure: ASTM 5-7 (30-60μm)

Precipitate Size:

T4 condition: 2-10nm GP zones

T6 condition: 50-200nm β" needles

Dislocation Density: 5-7×10⁹/cm²

Recrystallization Fraction: 70-90%

4. Dimensional Specifications for Large Tubing

Parameter	Standard Range	Precision Tolerance	Special Capabilities
Outer Diameter	150-1000 mm	±0.15% OD	Up to 1800 mm
Wall Thickness	5-40 mm	±10% WT	2.5-60 mm available
Length	3-20 m	+15mm/-0mm	Up to 25m sections
Ovality	≤0.6%	≤0.2% (critical)	-
Straightness	1.2 mm/m	0.4 mm/m	-
Perpendicularity	≤1.0°	≤0.5°	-
Wall Runout	≤0.8% TIR	≤0.3% TIR	-

Forming Capabilities:

Rotary Swaging for end forming

Mandrel Bending (R/D ratios down to 3:1)

Flange Roll Forming

Localized Annealing for complex shapes

Expansion/Reduction Operations

5. Corrosion Resistance & Environmental Durability

Environment	Performance Rating	Corrosion Rate	Protection Methods
Marine Atmosphere	Excellent	<0.001 mm/year	Alodine 1200S conversion
Industrial Atmosphere	Good	0.002-0.005 mm/year	Chromic acid anodizing
Fresh Water	Excellent	Negligible pitting	Powder coating
Chemical Exposure	Fair-Good	Varies by chemical	PTFE coating
Stress Corrosion	Excellent	SCC threshold >75MPa	T73 overaged temper option

Surface Treatment Options:

Anodizing (Type II): 5-25μm thickness

Powder Coating: 60-120μm thickness

PVDF Coating: Weather-resistant finish

Electrophoretic Deposition: Uniform coverage

Chemical Film Coating: Chromate-free options

6. Machining & Fabrication Performance

Operation	Tool Material	Recommended Parameters	Surface Quality
Turning	Carbide inserts	200-350 m/min, 0.1-0.3mm/rev	Ra 0.8-2.0 μm
Drilling	HSS drills	30-70 m/min, 0.05-0.15mm/rev	±0.05 mm hole size
Milling	PCD cutters	500-800 m/min	Ra 0.4-1.5 μm
Reaming	Carbide tipped	20-50 m/min	IT7 tolerance
Tapping	Coated HSS taps	10-15 m/min	6H thread quality

Fabrication Advantages:

Weldability: Excellent (ER4043 filler)

Formability: High (min bend radius = 2.5T)

Brazeability: Good with proper flux

Shear and Punch: Low tool wear

Polishing Response: Mirror finish achievable

7. Welding & Joining Technologies

Preferred Welding Methods:

Gas Metal Arc Welding (GMAW):

Wire: ER4043/ER5356

Parameters: 19-23V, 150-220A

Friction Stir Welding (FSW):

Tool Speed: 400-800 RPM

Travel Speed: 120-250 mm/min

Tungsten Inert Gas (TIG):

Purity: 99.996% Argon

Electrode: 2% thoriated

Specialized Joining Systems:

Mechanical Fastening:

Hi-Tigue® collars

Rivnut® threaded inserts

Adhesive Bonding:

Epoxy structural adhesives (20-30MPa)

Methacrylate systems (15-25MPa)

Brazing Processes:

Vacuum brazing: 590-620°C

Flame brazing with aluminum-silicon fillers

8. Physical Properties for Design Applications

Property	Value	Design Significance
Density	2.70 g/cm³	Weight reduction advantage
Young's Modulus	68.9 GPa	Stiffness optimization
Poisson's Ratio	0.33	Stress distribution control
CTE (20-100°C)	23.6 μm/m·°C	Thermal expansion matching
Thermal Conductivity	167 W/m·K	Heat dissipation capability
Electrical Conductivity	40% IACS	Electromagnetic properties
Melting Range	582-652°C	Processing parameters
Magnetic Permeability	1.00002	EM transparency

9. Quality Control & Certification

Comprehensive Testing:

Ultrasonic Testing: ASTM E588 standard

Hydrostatic Testing: 1.5x design pressure

Dye Penetrant Inspection: ASTM E1417

Tensile Testing: Each 500kg batch

Chemical Analysis: Optical emission spectrometry

Certification Standards:

ISO 9001:2015 Certified

AS9100 Aerospace Quality

PED 2014/68/EU Compliance

NACE MR0175/ISO 15156

AWS D1.2 Structural Welding Code

NADCAP Accredited Processing

10. Industry Applications & Handling

Primary Application Sectors:

Construction structural framing

Material handling systems

Marine components and railings

Agricultural equipment frames

Renewable energy structures

Industrial machinery guarding

Transportation equipment

Architectural elements

Handling & Storage Protocols:

End caps for protection

Horizontal storage on V-blocks

Wood spacers for stacking

Protective film covering

Climate-controlled storage for T6 temper

VCI paper wrapping for long-term storage

Packaging Specifications:

Plastic sheeting + desiccant packs

Custom-fitted wooden crates

UV-resistant shrink wrapping

Non-metallic banding systems

Corner protectors for safe transport

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