Aluminum is one of the most commonly used metals in the world today, and 6061 aluminum is one of the most popular aluminum alloys. 6061 is a precipitation-hardening alloy, meaning it has been age hardened to increase its yield strength. Originally developed in 1935, it is now available in pre-tempered grades such as 0, T6 and T651
6061 aluminum is probably the most commonly available, heat treatable alloy. It is a medium to high-strength alloy that offers good weldability, although there will be a significant loss of strength at the weld site.
Both gas and arc welding methods can be used, although gas tungsten arc welding is generally preferred for thin sections – less than 0.032″ – while gas metal arc welding is the method of choice for heavier sections. Alloy 4043 filler wire gives the best results, although you will notice a decrease in T6 properties.
Applications
It is most commonly used in heavy-duty structures requiring good corrosion resistance. Applications include:
* Components for ship building and trucks
* Furniture
* Pylons and towers
* Bridges
* Aerospace applications such as wings, fuselages and helicopter rotor skins
* Railroad cars
* Tank fittings
* In pipelines
* Wire products
* Aluminum cans for drinks and food
* General structural and high-pressure applications
* Recreational sports equipment, such as SCUBA tanks, fly fishing reels and bicycle frames
Composition
6061 aluminum is alloyed with a number of different metals, including manganese (up to 0.15%), iron (up to 0.70%), magnesium (up to 1.20%), silicon (up to 0.80%), copper (up to 0.40%), zinc (up to 0.25%), titanium (up to 0.15%) and chromium (up to 0.35%).
Forming
The alloy is easily cold worked and formed in its annealed state. Annealing should be done at 775 F for two to three hours, followed by controlled cooling at 50 F until a temperature of 500 F is reached. Thereafter, it should be air-cooled. It is easy to bend, stamp, spin and deep draw using standard methods.
Hot and Cold Working
Hot working can be carried out within a temperature range of 700 F to 500 F. Cold working is easily done when the alloy is in the 0 temper condition, but less so in the T6 and T4 tempers.
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