If you’re choosing between 6061, 6063, 6082 (and cousins like 6005A, 6060, 6463, 6101, 6026), this guide gives you the fast, practical answers buyers and engineers look for—and ends with a clear bridge to custom aluminum die-casting when a wrought grade shows up on a drawing.
What is 6000 series aluminum?
The 6000 series (6xxx) are Al-Mg-Si alloys where magnesium and silicon form Mg₂Si as the primary strengthening phase. Common grades include 6063, 6061, 6082, 6005A, 6060, 6463, 6101, 6026. They are available mainly as wrought products (extrusions, plate, sheet, bar) and are heat-treatable to tempers like T5/T6/T6511.
Why it’s different:
- Heat treatable: Precipitation hardening of Mg₂Si gives a wide strength range (e.g., 6063-T5 → 6082-T6).
- Highly extrudable: Flows well into thin-wall, complex profiles; ideal for architectural and structural shapes.
- Balanced performance: Useful mix of strength + weldability + corrosion resistance + finishability (excellent anodize/powder response, especially 6063/6463).
- Versatile alternatives: Grades within the family cover cosmetic (6463), structural (6061/6082), conductivity (6101), and machining (6026) needs.
Quick contrast:
- 5000 (Al-Mg): non-heat-treatable but great marine corrosion resistance.
- 7000 (Al-Zn-Mg-Cu): highest strengths but poorer weldability/corrosion tolerance.
- Cast alloys (e.g., A380/ADC12, AlSi10Mg): optimized for die-casting; 6xxx are generally not used as casting alloys.
Which 6000 series alloys are most used and why?
6063 — best for extrusions and finishing
- Why choose it: Excellent extrudability, tight tolerances, smooth surfaces; takes anodize very well.
- Typical uses: Window/door frames, architectural trim, heat-sinks, LED housings, furniture, display systems.
- Strength: Lower than 6061/6082 but reliable for light structural work (e.g., T5/T6).
6061 — general-purpose structural
- Why choose it: “Workhorse” balance of strength, machinability, weldability and availability.
- Typical uses: Fixtures, machine frames, plates, brackets, bike parts, automotive, general fabrication.
- Notes: Often specified in plate and bar as well as extrusion.
6082 — for higher strength
- Why choose it: Among the strongest common 6xxx in T6; good fatigue resistance.
- Typical uses: Heavy structures, cranes, bridges, truck frames, offshore/industrial platforms, machined components.
- Caution: More notch-sensitive; bending in T6 may require generous radii or a softer temper.
6005 / 6005A — when you need more than 6063
- Why choose it: Higher strength than 6063 with good extrudability; a nice middle ground below 6061/6082.
- Typical uses: Ladders, platforms, railings, vehicle structures, industrial profiles.
6060 & 6463 — for cosmetic/bright anodize
- Why choose them: Very smooth extrudability; 6463 is optimized for bright-dip/clear anodize.
- Typical uses: Decorative trim, appliance and automotive brightwork, display profiles.
6101 — for electrical conductivity
- Why choose it: Keeps conductivity high while still extrudable.
- Typical uses: Bus bars, electrical conductors, power distribution hardware.
6026 — lead-free machinability
- Why choose it: Designed to machine fast yet RoHS-friendly (lead-free).
- Typical uses: High-speed machining of fittings and connectors that must be compliant.
6000 Series Aluminum and Die Casting
Quick take: 6xxx (Al–Mg–Si) is primarily extrusion/sheet (6061/6063/6082). There are no mainstream 6xx.x die-casting alloys. When converting extruded/machined 6xxx designs to casting, use A380/ADC12 or AlSi10Mg (T6) and redesign for castability.
- You cannot copy 6061-T6 properties 1:1 in HPDC; use AlSi10Mg-T6 plus structural features (ribs, bosses, fillets) to reach functional targets.
- Cosmetic anodize is tricky on die castings—most programs use powder/e-coat for appearance and protection.
- Casting can reduce part count, machining time, and assembly.
Wrought → Cast Substitutes
| Wrought intent | Castable substitute | Why / when |
|---|---|---|
| 6063 decorative extrusion | A380 + powder | Complex geometry, stable cosmetics |
| 6061 CNC block | AlSi10Mg (T6) | Strength + machinability; lower overall machining |
| Heat-sink profile (multi-fin) | A380 / ADC12 | Excellent thin-fin fill; post-coat for durability |
Have a 6061/6063 design to consolidate into one casting? We’ll deliver DFM (gates/vents/draft), a castable geometry, and a costed plan.
How do tempers like T5, T6 and T6511 change strength?
- T5: Cooled from extrusion + artificially aged. Good strength, nice surface (common for 6063).
- T6: Solution heat treated + artificially aged. Highest common strength for 6xxx (e.g., 6061-T6, 6082-T6).
- T651/T6511: Stress-relieved (stretching) variants for flatness/stability in plate (-T651) or extrusion (-T6511).
What typical mechanical properties should buyers expect?
(Indicative “typical” values; always confirm with your mill/extruder MTRs.)
| Alloy & Temper | Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) |
|---|---|---|---|
| 6063-T5 | 145–190 | 110–160 | 8–12 |
| 6063-T6 | 205–240 | 170–215 | 8–12 |
| 6061-T6 | ~290 | ~240 | 8–12 |
| 6082-T6 | 300–340 | 250–290 | 8–12 |
| 6005A-T6 | 260–320 | 230–280 | 8–12 |
Rough guide only; temper, shape and section thickness change results.
Can 6000 series be welded and which filler should I use?
- Weldability: Generally good across 6xxx, but T6 strength drops in the HAZ. Post-weld re-aging may recover some strength depending on geometry.
- Filler selection:
- ER4043 (Al-Si): Smooth puddle, good crack resistance, better anodize color match; slightly lower as-welded strength.
- ER5356 (Al-Mg): Higher as-welded strength in many joints; may give a different anodized shade.
- Practical tips: Clean thoroughly, use proper joint design, expect reduced HAZ strength in load paths, and consider designing for T5 where welding is heavy.
What finishes work best on 6000 series?
- Anodizing: Excellent on 6063/6060; 6463 for bright-dip cosmetic parts.
- Powder coating: Widely used on architectural and industrial profiles.
- E-coat/paint: For color durability on exterior assemblies.
- Machined parts: 6061/6082 take clear or hard anodize for wear and corrosion resistance.
How do 6000 series compare to 5000 and 7000?
- 5000 (Al-Mg): Naturally non-heat-treatable, great corrosion resistance, often better for marine; lower yield than 6xxx T6 but no HAZ over-aging.
- 6000 (Al-Mg-Si): Balanced: heat-treatable, extrudable, weldable, good finishing; the “default” for structural extrusions.
- 7000 (Al-Zn-Mg-Cu): Highest strengths (e.g., 7075) but poorer weldability/corrosion tolerance; used where ultra-high strength is mandatory.
Can 6000 series be die-cast? What are die-casting equivalents?
Short answer: 6xxx grades are mainly wrought/extrusion alloys; they’re not used for high-volume die-casting because their casting fluidity and solidification behavior aren’t optimized for thin-wall, high-complexity molds.
Functional die-casting substitutes we recommend:
- A380 / ADC12: General-purpose, excellent castability, good strength-to-cost, widely available.
- A360: Better fluidity and pressure-tightness; good for thin sections.
- AlSi10Mg (EN AC-AlSi10Mg): Heat-treatable die-casting alloy that achieves higher strengths after T6—often chosen when a print calls for “6061-like” performance in a cast geometry.
When to keep a wrought grade:
- If the part must be extruded/plate + heavy machining (flatness, fibers, or directional properties).
- If extremely tight dimensional stability after welding is required (often 6061-T651 plate).
Which 6000 alloy should choose for your project?
Architectural & heat-sinks: 6063 or 6060
- Great for thin fins, smooth surfaces, high anodize quality.
Heavy structures: 6082 or 6005A
- Higher strength for frames, platforms, vehicle substructures.
General structural & machining: 6061
- Reliable, versatile, excellent availability in plate, bar and extrusion.
Bright trim: 6463
- Optimized for bright-dip and premium cosmetic anodize.
Conductive bus bars: 6101
- Keeps conductivity high while still extrudable.
High-speed machining (lead-free): 6026
- RoHS-friendly substitute where free-cutting behavior matters.
FAQs
Is 6063 strong enough for frames?
For light structural frames and architectural systems, yes (often in T5/T6). For heavy load-bearing structures, step up to 6005A/6061/6082.
Why does T6 lose strength after welding and can I re-age it?
The HAZ over-tempers the precipitates. A post-weld artificial age can recover some strength depending on geometry and alloy, but design conservatively.
Which filler gives a better anodize color match?
ER4043 (Al-Si) generally matches clear anodize better than ER5356.
What bend radius should I use for 6082-T6?
Use generous radii; many shops bend in a softer temper (e.g., T4), then re-age to T6 after forming.
My drawing says 6061 but I want a casting—what should I do?
Share the print. We’ll confirm requirements and propose die-casting equivalents such as AlSi10Mg, A360, or A380/ADC12 to meet strength, finish, and cost.
Need custom aluminum die-cast parts, not extrusions?
Send your drawing and annual volume. We’ll:
- review any callouts like 6061/6063/6082 and propose die-casting equivalents (A380/ADC12, A360, AlSi10Mg) that meet your strength, surface, and cost targets,
- optimize gating/parting, draft, walls, ribs, bosses for casting success,
- specify post-machining and surface finishing (clear/hard anodize, powder, e-coat) to match your cosmetic and corrosion needs.
We operate 800–2000-ton die-casting presses and deliver complete, machined, finished components—built to print.
Quick spec recap
- 6063: best extrudability & anodize; architectural, fins, heat-sinks.
- 6061: general structural + machining; fixtures, brackets, plate.
- 6082: higher strength; heavy frames, platforms, vehicles.
- 6005A: between 6063 and 6061 for stronger extrusions.
- 6463: bright-dip cosmetic trim.
- 6101: electrical conductivity (bus bars).
- 6026: lead-free free-machining.
If you’re deciding between a wrought 6xxx and a cast solution, we can evaluate cost, tooling, lead time, and performance and recommend the best path—extrusion + machining or die-casting.
