Aluminum extrusion has become a cornerstone in modern manufacturing—shaping everything from architectural frames and automotive parts to electronics and transportation systems. But when it comes to choosing the right alloy, engineers and designers often face a crucial question: Should you use 6060, 6061, or 6063 aluminum?
Each of these alloys belongs to the 6xxx series (Al-Mg-Si system), meaning they are heat-treatable and provide a balance of strength, corrosion resistance, and formability. However, subtle differences in composition and mechanical properties can significantly influence extrusion quality, finish, and performance.
In this article, we’ll break down the key differences between 6060, 6061, and 6063 aluminum alloys, explain how to choose the right one for your project, and show how sasaaluminum, a trusted global supplier, ensures consistent quality and precision across all extruded aluminum products.
Overview of 6xxx Series Aluminum Alloys
The 6xxx series alloys (including 6060, 6061, and 6063) are widely used in extrusion due to their excellent balance of strength, corrosion resistance, and extrudability. They contain magnesium (Mg) and silicon (Si), which combine to form magnesium silicide (Mg₂Si), the key strengthening phase during heat treatment.
These alloys are popular because they:
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Are heat-treatable for higher strength.
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Offer good surface finish suitable for anodizing or powder coating.
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Have excellent corrosion resistance in atmospheric and marine environments.
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Are lightweight yet strong enough for structural applications.
Despite these shared advantages, 6060, 6061, and 6063 have different strengths, extrusion speeds, and finishing properties that make each suitable for specific uses.
Chemical Composition Comparison
| Element | 6060 (%) | 6061 (%) | 6063 (%) |
|---|---|---|---|
| Silicon (Si) | 0.30–0.60 | 0.40–0.80 | 0.20–0.60 |
| Magnesium (Mg) | 0.35–0.60 | 0.80–1.20 | 0.45–0.90 |
| Iron (Fe) | ≤ 0.30 | ≤ 0.70 | ≤ 0.35 |
| Copper (Cu) | ≤ 0.10 | 0.15–0.40 | ≤ 0.10 |
| Chromium (Cr) | ≤ 0.05 | 0.04–0.35 | ≤ 0.10 |
| Zinc (Zn) | ≤ 0.15 | ≤ 0.25 | ≤ 0.10 |
| Titanium (Ti) | ≤ 0.10 | ≤ 0.15 | ≤ 0.10 |
| Aluminum (Al) | Balance | Balance | Balance |
Summary:
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6061 has the highest alloying content, making it the strongest.
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6063 balances strength and surface finish.
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6060 is designed for excellent extrudability and fine surface appearance.
Mechanical Properties Comparison
| Property | 6060-T6 | 6061-T6 | 6063-T6 |
|---|---|---|---|
| Tensile Strength (MPa) | 180–215 | 290–320 | 205–240 |
| Yield Strength (MPa) | 120–150 | 240–275 | 150–190 |
| Elongation (%) | 8–12 | 8–10 | 8–12 |
| Brinell Hardness (HB) | 60–70 | 95–100 | 70–80 |
| Density (g/cm³) | 2.70 | 2.70 | 2.70 |
Key Observations:
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6061 offers the highest strength for load-bearing and structural parts.
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6063 provides a smoother finish and better extrudability.
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6060 delivers excellent dimensional accuracy and is ideal for thin, complex profiles.
Extrudability and Surface Finish
Extrudability determines how easily an alloy can be shaped through the die.
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6060 Aluminum: Exceptional extrudability and surface smoothness; ideal for precision or decorative extrusions.
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6063 Aluminum: Excellent extrudability with very good surface finish—often used for anodized products.
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6061 Aluminum: Lower extrudability due to higher magnesium and silicon content, but provides superior strength.
In short:
If surface quality and high extrusion speed are critical, 6060 or 6063 are the better choices. For applications demanding strength, 6061 is ideal.
Corrosion Resistance
All three alloys have excellent corrosion resistance, but with slight variations:
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6060 and 6063: Perform extremely well in architectural and marine environments; ideal for anodizing.
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6061: Resists corrosion effectively but may require surface treatment for appearance-critical applications.
Anodizing both 6060 and 6063 results in a brighter and more uniform finish, making them perfect for architectural components, while 6061 may appear duller due to its alloy composition.
Weldability and Machinability
| Property | 6060 | 6061 | 6063 |
|---|---|---|---|
| Weldability | Excellent | Very Good | Excellent |
| Machinability | Very Good | Excellent | Good |
| Formability | Excellent | Moderate | Excellent |
Summary:
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6061 machines best but is harder to form.
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6063 and 6060 are easier to bend and shape, suitable for extrusion profiles requiring curvature or complex geometry.
Thermal and Electrical Conductivity
| Property | 6060 | 6061 | 6063 |
|---|---|---|---|
| Thermal Conductivity (W/m·K) | 200–210 | 170–180 | 200–210 |
| Electrical Conductivity (% IACS) | 45–50 | 40–45 | 45–50 |
Result:
6060 and 6063 both offer superior heat transfer compared to 6061, making them ideal for radiators, heat sinks, and air-conditioning components.
Applications
6060 Aluminum Applications
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Precision extrusions with tight tolerances
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Architectural trims, door and window frames
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Furniture and interior decorative profiles
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Heat exchangers and lighting systems
6061 Aluminum Applications
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Structural and load-bearing parts (bridges, truck frames)
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Marine and aerospace components
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High-stress mechanical assemblies
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Industrial machinery
6063 Aluminum Applications
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Curtain walls, railings, window frames
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Sign frames and display systems
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Solar panel frames and heat sinks
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Transport and infrastructure extrusions
How to Choose Between 6060, 6061, and 6063
| Requirement | Best Choice | Reason |
|---|---|---|
| Highest Strength | 6061 | For structural and load-bearing designs |
| Best Surface Finish | 6060 or 6063 | For decorative or anodized applications |
| Tight Tolerances / Thin Sections | 6060 | Excellent extrudability for complex shapes |
| Best Corrosion Resistance | 6063 | Excellent performance in marine or outdoor environments |
| Machining Performance | 6061 | Good chip formation and tool life |
| Formability / Bending | 6060 | Excellent for post-extrusion bending |
| Cost Efficiency | 6063 | Widely available and cost-effective |
Practical Guideline:
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Choose 6060 → For aesthetic and precision extrusions.
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Choose 6061 → For strength and mechanical reliability.
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Choose 6063 → For architectural, anodized, or general-purpose extrusions.
Standards and Specifications
All three alloys comply with international standards such as:
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ASTM B221 – Aluminum and Aluminum-Alloy Extruded Bars, Rods, and Shapes
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EN 755-2 / EN 573-3 – Mechanical and chemical composition requirements
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ISO 6362-3 – Mechanical properties for extruded bars and profiles
Manufacturers like sasaaluminum follow these standards to ensure every extrusion meets global quality benchmarks for dimensional precision, mechanical performance, and surface finish.
Quality Control by sasaaluminum
sasaaluminum guarantees consistent alloy performance through advanced production technologies and rigorous testing procedures.
Key Quality Control Measures Include:
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Vacuum Melting and Homogenization: Ensures uniform alloy distribution.
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Extrusion Monitoring: Automated systems for temperature and speed control.
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Aging and Tempering: Precise heat treatment for consistent mechanical strength.
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Mechanical Testing: Tensile, yield, elongation, and hardness verification.
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Surface Inspection: Ensures flawless anodizing and smooth finishes.
Each extrusion is delivered with a Mill Test Certificate (MTC) confirming its chemical composition, mechanical properties, and temper condition.
By maintaining tight process control, sasaaluminum ensures customers receive aluminum extrusions that meet both functional and aesthetic expectations.
Environmental and Economic Benefits
Using the right aluminum alloy not only enhances product performance but also contributes to sustainability.
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100% Recyclable: All 6xxx series alloys can be recycled without losing properties.
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Lightweight Design: Reduces transportation energy consumption.
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Long Service Life: Excellent corrosion resistance lowers maintenance and replacement costs.
sasaaluminum is committed to sustainable manufacturing, optimizing production to reduce energy use and carbon emissions while maintaining world-class quality.
Future Outlook
As industries transition toward lightweight, energy-efficient, and recyclable materials, demand for aluminum extrusions is rapidly increasing. From electric vehicles to smart buildings, alloys like 6060, 6061, and 6063 will remain essential.
Continuous innovation in extrusion technology and alloy optimization will further enhance performance, allowing manufacturers to achieve finer tolerances, higher strength, and improved surface finishes.
sasaaluminum continues to invest in advanced production facilities and R&D to meet the evolving needs of modern engineering and architecture.
Conclusion
Choosing between 6060, 6061, and 6063 aluminum alloys depends on balancing your project’s requirements for strength, formability, corrosion resistance, and surface appearance.
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6060 offers superb extrudability and finish for complex, decorative shapes.
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6061 delivers maximum strength and durability for structural and mechanical uses.
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6063 provides excellent anodizing quality and corrosion resistance for architectural applications.
With professional guidance and high-quality production from sasaaluminum, you can select the perfect alloy that meets your performance, design, and cost objectives—ensuring reliability, aesthetics, and efficiency in every project.
Post time: Nov-07-2025