What is the difference between 6061 T5 and 6063 T5?
6061-T6 is suitable for high-strength and demanding applications, while 6063-T5 is more suitable for aesthetic, architectural, and lower-strength applications. Both alloys have similarities in welding, machinability, and extrudability, making them versatile across various industries.
6061 T5 has higher strength and wider applications; while 6063 T5 is more suitable for applications requiring excellent surface finish and better extrudability, but with slightly lower strength.
| Property | 6061-T6 | 6063-T5 |
| Strength and Durability | Higher strength, with greater tensile, shear, and fatigue strength, suitable for high-strength structural applications. | Lower strength, suitable for general load-bearing applications. |
| Thermal and Electrical Performance | Relatively low thermal and electrical conductivity. | Excellent thermal and electrical conductivity, suitable for applications requiring heat dissipation and electrical performance. |
| Formability | Poorer formability, suitable for simple shapes and structures. | Generally better ductility, easy to form, suitable for complex profiles and architectural applications. |
| Strength-to-Weight Ratio | Better strength-to-weight ratio under axial and bending conditions, ideal for high-stress applications (such as aerospace). | Lower strength, suitable for general load-bearing applications. |
Similarities between 6061-T6 and 6063-T5
| Property | 6061-T6 and 6063-T5 |
| Composition | Both are aluminum alloys containing primary elements such as aluminum (Al), magnesium (Mg), and silicon (Si). |
| Weldability | Both alloys are highly weldable and can be easily welded using methods such as TIG, MIG, and stick welding. |
| Machinability | Both exhibit excellent machinability, meaning they can be easily cut, drilled, milled, and turned using standard machining techniques. |
| Anodizing | Both alloys are well-suited for anodizing, enhancing corrosion resistance and wear resistance. |
| Extrudability | Both alloys are highly extrudable, suitable for producing a wide range of products. |
| Heat Treatment | Both are heat treatable to enhance their strength and hardness. |
Differences between 6061-T6 and 6063-T5
| Property | 6061-T6 | 6063-T5 |
| Strength and Durability | High strength and durability, making it ideal for demanding applications such as in aerospace, automotive, and structural industries. | Good strength for many applications but generally used in less demanding scenarios, commonly found in architectural and decorative applications. |
| Aesthetic Properties | Primarily chosen for its strength and durability rather than its appearance. | Favored for its excellent aesthetic properties, smooth surface finish ideal for applications where appearance matters. |
| Corrosion Resistance | Offers excellent corrosion resistance but is slightly less resistant than 6063-T5. | Slightly more resistant to corrosion, making it a better option for marine or highly corrosive environments. |
| Cost | Generally more expensive, suitable for applications where cost is not a primary concern. | Generally less expensive, making it a popular choice when cost is a significant factor. |
6061 T5 Aluminum vs. 6063 T5 Aluminum Mechanical Properties
6061 T5:It has better overall strength and can be heat-treated to achieve even higher strength.
6063 T5:6063 T5 is typically weaker but has better extrudability and is more suitable for applications where aesthetic finish is important.
| Property | 6061-T6 Aluminum | 6063-T5 Aluminum |
| Brinell Hardness | 93 | 60 |
| Elastic (Young's, Tensile) Modulus (x 10⁶ psi) | 10 | 9.9 |
| Elongation at Break (%) | 10 | 11 |
| Fatigue Strength (x 10³ psi) | 14 | 10 |
| Poisson's Ratio | 0.33 | 0.33 |
| Shear Modulus (x 10⁶ psi) | 3.8 | 3.7 |
| Shear Strength (x 10³ psi) | 30 | 17 |
| Tensile Strength: Ultimate (UTS) (x 10³ psi) | 45 | 26 |
| Tensile Strength: Yield (Proof) (x 10³ psi) | 39 | 20 |
6061-T6 and 6063-T5 Formability and Workability
6061 T5: Slightly less formable than 6063 but can be heat treated to improve its strength. It is often used in applications requiring higher strength.
6063 T5: Easier to extrude and form than 6061, making it more ideal for architectural and decorative applications, such as window frames, door frames, and railings.
6061-T6 and 6063-T5 Corrosion Resistance
Both alloys offer good corrosion resistance, but 6063 T5 has a slightly better resistance to atmospheric corrosion due to its lower magnesium content.
6061 T5 Aluminum vs. 6063 T5 Aluminum Thermal Properties
| Property | 6061-T6 Aluminum | 6063-T5 Aluminum |
| Latent Heat of Fusion (J/g) | 400 | 400 |
| Maximum Temperature: Mechanical (°F) | 330 | 320 |
| Melting Completion (Liquidus) (°F) | 1190 | 1210 |
| Melting Onset (Solidus) (°F) | 1080 | 1140 |
| Specific Heat Capacity (BTU/lb-°F) | 0.21 | 0.22 |
| Thermal Conductivity (BTU/h-ft-°F) | 97 | 120 |
| Thermal Expansion (µm/m-K) | 24 | 23 |
6061 T5 Aluminum vs. 6063 T5 Aluminum Electrical Properties
| Property | 6061-T6 Aluminum | 6063-T5 Aluminum |
| Electrical Conductivity: Equal Volume (% IACS) | 43 | 55 |
| Electrical Conductivity: Equal Weight (Specific) (% IACS) | 140 | 180 |
Other Unclassified Properties
| Property | 6061-T6 Aluminum | 6063-T5 Aluminum |
| Base Metal Price (% relative) | 9.5 | 9.5 |
| Calomel Potential (mV) | -740 | -740 |
| Density (lb/ft³) | 170 | 170 |
| Embodied Carbon (kg CO₂/kg material) | 8.3 | 8.3 |
| Embodied Energy (x 10³ BTU/lb) | 66 | 66 |
| Embodied Water (gal/lb) | 140 | 140 |
Common Calculations
| Property | 6061-T6 Aluminum | 6063-T5 Aluminum |
| Resilience: Ultimate (Unit Rupture Work) (MJ/m³) | 30 | 17 |
| Resilience: Unit (Modulus of Resilience) (kJ/m³) | 520 | 140 |
| Stiffness to Weight: Axial (points) | 14 | 14 |
| Stiffness to Weight: Bending (points) | 50 | 50 |
| Strength to Weight: Axial (points) | 31 | 18 |
| Strength to Weight: Bending (points) | 37 | 26 |
| Thermal Diffusivity (mm²/s) | 68 | 86 |
| Thermal Shock Resistance (points) | 14 | 8.0 |
6061 T5 Aluminum vs. 6063 T5 Aluminum Alloy Composition
6061 T5: Compared to 6063, it has higher magnesium and silicon content, resulting in higher strength and better mechanical properties.
Magnesium (Mg): 0.8 to 1.2%
Silicon (Si): 0.4–0.8%
6063 T5: Primarily composed of magnesium and silicon, but at lower concentrations, resulting in lower strength than 6061.
Magnesium (Mg): 0.45–0.9%
Silicon (Si): 0.2–0.6%
| Alloy Composition Element | 6061-T6 Aluminum | 6063-T5 Aluminum |
| Aluminum (Al) (%) | 95.9 to 98.6 | 97.5 to 99.4 |
| Chromium (Cr) (%) | 0.040 to 0.35 | 0 to 0.1 |
| Copper (Cu) (%) | 0.15 to 0.4 | 0 to 0.1 |
| Iron (Fe) (%) | 0 to 0.7 | 0 to 0.35 |
| Magnesium (Mg) (%) | 0.8 to 1.2 | 0.45 to 0.9 |
| Manganese (Mn) (%) | 0 to 0.15 | 0 to 0.1 |
| Silicon (Si) (%) | 0.4 to 0.8 | 0.2 to 0.6 |
| Titanium (Ti) (%) | 0 to 0.15 | 0 to 0.1 |
| Zinc (Zn) (%) | 0 to 0.25 | 0 to 0.1 |
| Residuals (%) | 0 | 0 to 0.15 |
6061-T6 and 6063-T5 Applications
6061 T5 is often used in structural applications where strength is a priority, such as in aerospace, marine, and automotive industries. It is also commonly used for structural components like beams, frames, and supports.
6063 T5 is primarily used in architectural and ornamental applications, such as window frames, door frames, and furniture due to its better surface finish and ease of extrusion.
