6061 Aluminum Vs 6063 In Extrusion Applications

Aluminum is one of the most versatile and widely used materials in modern manufacturing. Its light weight, corrosion resistance, and excellent formability make it ideal for countless applications across aerospace, automotive, construction, and consumer goods. Among the many aluminum grades available, 6061 aluminum and 6063 aluminum are two of the most common choices in extrusion applications.

While both belong to the 6xxx series of aluminum alloys (Al-Mg-Si family), they differ in mechanical properties, corrosion resistance, surface finish, and suitability for different extrusion projects. This article provides a comprehensive comparison of 6061 aluminum vs 6063 in extrusion applications, helping engineers, designers, and procurement specialists make informed material selections.

Understanding Aluminum Extrusion

Extrusion is a process where aluminum billets are heated and forced through a die to create long shapes with consistent cross-sections, such as tubes, channels, or profiles. This process enhances mechanical properties and allows for complex geometries with tight tolerances.

Both 6061 and 6063 alloys are widely used in extrusion because of their excellent machinability, corrosion resistance, and compatibility with surface finishing processes like anodizing and powder coating.

Composition of 6061 vs 6063 Aluminum

6061 Aluminum (UNS A96061)

  • Silicon: 0.4–0.8%

  • Magnesium: 0.8–1.2%

  • Chromium: 0.04–0.35%

  • Copper: 0.15–0.40%

  • Balance: Aluminum

6063 Aluminum (UNS A96063)

  • Silicon: 0.2–0.6%

  • Magnesium: 0.45–0.9%

  • Iron: ≤0.35%

  • Copper: ≤0.10%

  • Balance: Aluminum

Key Difference: 6061 contains more copper and chromium, improving strength but slightly reducing corrosion resistance compared to 6063.

Mechanical Properties

Property 6061 Aluminum 6063 Aluminum
Tensile Strength (MPa) ~290 (T6 temper) ~190 (T6 temper)
Yield Strength (MPa) ~240 ~160
Elongation (%) 8–12 12–17
Hardness (Brinell) ~95 ~73

Analysis:

  • 6061: Stronger, better for structural applications requiring load-bearing capacity.

  • 6063: More ductile and easier to extrude into complex shapes, with a smoother surface finish.

Corrosion Resistance

  • 6061 Aluminum: Offers good corrosion resistance but may be slightly affected by the copper content in certain environments.

  • 6063 Aluminum: Exhibits superior corrosion resistance in marine and architectural settings, making it ideal for exposed surfaces.

Surface Finish and Anodizing

  • 6061 Aluminum: Can be anodized but may not achieve as smooth or decorative a finish as 6063.

  • 6063 Aluminum: Often referred to as the “architectural alloy,” 6063 provides excellent anodizing results with bright and uniform finishes.

Extrusion Performance

  • 6061: More difficult to extrude due to higher strength; best for simpler shapes requiring mechanical strength.

  • 6063: Easier to extrude into intricate profiles with excellent dimensional accuracy, widely preferred for decorative and architectural profiles.

Common Applications

6061 Aluminum Applications

  • Aerospace components

  • Automotive frames and wheels

  • Marine fittings and structures

  • Heavy-duty pipelines

  • Structural beams and supports

6063 Aluminum Applications

  • Window frames and door frames

  • Curtain walls and architectural trim

  • Handrails and balustrades

  • Decorative extrusions

  • Electrical conduits

Cost Considerations

While both alloys are cost-effective compared to high-strength aerospace alloys, 6063 is typically more economical for extrusion projects due to its easier processing and lower production costs. 6061 may be slightly more expensive because of its higher mechanical performance and additional alloying elements.

Case Study: Structural vs. Architectural Extrusions

  • Structural Needs (6061): In an industrial project requiring high-strength aluminum beams, 6061 is chosen for its superior tensile strength and load-bearing capacity.

  • Architectural Needs (6063): In a building project emphasizing appearance and corrosion resistance, 6063 is used for curtain walls, achieving both durability and aesthetics.

Choosing Between 6061 and 6063

  • Choose 6061 Aluminum if:

    • High strength and load-bearing are required.

    • Applications involve aerospace, automotive, or heavy industrial use.

    • Machinability and welding strength are priorities.

  • Choose 6063 Aluminum if:

    • Aesthetics and surface finish are important.

    • The application involves decorative or architectural features.

    • Excellent corrosion resistance in marine or outdoor conditions is required.

Future of Extrusion Alloys

As industries move toward lightweight and sustainable materials, the demand for 6061 and 6063 alloys in extrusion applications will continue to grow. Emerging trends include:

  • Hybrid Structures: Combining 6061 strength with 6063 surface finishes in integrated assemblies.

  • Green Manufacturing: Increasing use of recycled aluminum billets for extrusion.

  • Precision Extrusion: Advanced die design and automation for tighter tolerances.

Suppliers like sasaaluminum are meeting these demands by providing reliable, high-quality extrusion-grade alloys tailored for industrial and architectural projects. By sourcing materials from trusted providers such as sasaaluminum, manufacturers can ensure long-term durability, sustainability, and performance.

Frequently Asked Questions

1. Which is stronger, 6061 or 6063?
6061 is stronger and better for structural applications, while 6063 is softer and easier to shape.

2. Can both alloys be anodized?
Yes, but 6063 provides a superior anodized finish compared to 6061.

3. Is 6061 more expensive than 6063?
Generally, yes, due to higher alloying content and strength properties.

4. Which alloy is best for outdoor use?
6063 is preferred for outdoor and architectural use due to its excellent corrosion resistance.

Conclusion

When comparing 6061 aluminum vs 6063 in extrusion applications, both alloys offer unique advantages. 6061 aluminum stands out for its strength and structural performance, making it suitable for aerospace, automotive, and heavy-duty applications. 6063 aluminum, on the other hand, excels in surface finish, corrosion resistance, and extrudability, making it the alloy of choice for architectural and decorative applications.

The decision ultimately depends on the balance between mechanical strength and aesthetic requirements. With the right alloy selection, extrusion projects can achieve both durability and design flexibility.

Post time: Aug-22-2025