When it comes to aluminum materials for construction, machinery, or architectural applications, 6060 Aluminum Bars are among the most popular choices. Known for their excellent surface finish, good extrudability, corrosion resistance, and moderate strength, they are widely used in frameworks, railings, windows, and heat exchangers.
However, for manufacturers, designers, and engineers, understanding the standard sizes and tolerances of 6060 aluminum bars is essential. Correct dimensions ensure that parts fit precisely during assembly, meet mechanical requirements, and comply with international standards.
In this article, we will explore the typical sizes, tolerances, and dimensional standards for 6060 aluminum bars, and how sasaaluminum, a trusted aluminum manufacturer, ensures consistent quality across all production batches.
Overview of 6060 Aluminum Alloy
6060 Aluminum Alloy is part of the 6xxx series, containing magnesium (Mg) and silicon (Si) as its main alloying elements. It is similar to 6063 but with slightly lower strength and higher extrudability, making it ideal for intricate shapes and decorative profiles.
Chemical Composition (%):
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Silicon (Si): 0.3–0.6
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Magnesium (Mg): 0.35–0.6
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Iron (Fe): ≤0.3
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Copper (Cu): ≤0.1
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Manganese (Mn): ≤0.1
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Zinc (Zn): ≤0.15
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Titanium (Ti): ≤0.1
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Aluminum (Al): Balance
This balanced composition gives 6060 aluminum its characteristic lightweight, corrosion-resistant, and anodizing-friendly properties.
Mechanical Properties
| Property | 6060-T6 | 6060-T5 |
|---|---|---|
| Tensile Strength (MPa) | 180–215 | 160–195 |
| Yield Strength (MPa) | 120–150 | 110–140 |
| Elongation (%) | 8–12 | 8–10 |
| Density (g/cm³) | 2.70 | 2.70 |
| Thermal Conductivity (W/m·K) | 200–210 | 200–210 |
These properties make 6060 Aluminum Bars suitable for structural and decorative applications that require precision and aesthetic appeal.
Standard Shapes and Sizes of 6060 Aluminum Bars
6060 Aluminum Bars are typically produced in several shapes depending on the end-use application. The most common types include:
1. Round Bars
Widely used in machining, fasteners, and structural assemblies.
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Standard Diameters: 6 mm to 300 mm
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Common Lengths: 3000 mm, 4000 mm, 6000 mm
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Surface Finish: Mill finish, anodized, or polished
2. Square Bars
Used in decorative parts, frameworks, and architectural components.
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Standard Sizes: 10 × 10 mm to 200 × 200 mm
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Length: Typically 4000 mm to 6000 mm
3. Flat Bars
Ideal for construction, busbars, and precision tooling.
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Width Range: 10 mm to 500 mm
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Thickness Range: 3 mm to 80 mm
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Standard Lengths: 3000 mm to 6000 mm
4. Hexagonal Bars
Common in mechanical parts, bolts, and nuts.
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Standard Sizes (Across Flats): 8 mm to 80 mm
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Length: 3000 mm to 6000 mm
These size ranges are based on EN 755-3 and ASTM B221 standards, which are widely recognized in the global aluminum industry.
Dimensional Tolerances for 6060 Aluminum Bars
Dimensional accuracy is critical for ensuring parts fit correctly during machining and assembly. The following tolerance values apply to 6060 aluminum extruded bars according to EN 755-9 and ASTM B221 standards.
1. Round Bars
| Nominal Diameter (mm) | Tolerance (mm) |
|---|---|
| Up to 10 | ±0.10 |
| Over 10 to 30 | ±0.15 |
| Over 30 to 50 | ±0.20 |
| Over 50 to 80 | ±0.25 |
| Over 80 to 120 | ±0.30 |
| Over 120 | ±0.50 |
2. Square Bars
| Side Dimension (mm) | Tolerance (mm) |
|---|---|
| Up to 25 | ±0.15 |
| 25–50 | ±0.20 |
| 50–100 | ±0.30 |
| Above 100 | ±0.50 |
3. Flat Bars
| Thickness (mm) | Tolerance (mm) |
|---|---|
| Up to 6 | ±0.10 |
| 6–25 | ±0.20 |
| 25–50 | ±0.30 |
| Above 50 | ±0.40 |
4. Hexagonal Bars
| Across Flats (mm) | Tolerance (mm) |
|---|---|
| Up to 10 | ±0.10 |
| 10–30 | ±0.15 |
| 30–60 | ±0.25 |
| Above 60 | ±0.40 |
Surface Finish and Straightness
Surface Finish:
6060 aluminum bars typically have a smooth mill finish, but they can also be supplied bright polished or anodized for enhanced corrosion resistance and visual appeal.
Straightness Tolerance:
For extruded bars longer than 3 meters, the maximum deviation allowed is 1 mm per 1000 mm of length. This ensures easy handling and alignment during fabrication or assembly.
Standards Governing 6060 Aluminum Bars
Manufacturers like sasaaluminum follow global standards to ensure consistency and interchangeability:
| Standard | Description |
|---|---|
| EN 755-3 | European standard for mechanical properties of extruded bars and profiles |
| EN 755-9 | Dimensional tolerances for extruded bars |
| ASTM B221 | U.S. standard for aluminum and aluminum-alloy extruded bars, rods, and shapes |
| ISO 6362-3 | International standard covering mechanical properties |
| GB/T 3191 | Chinese standard for extruded aluminum bars |
By complying with these standards, sasaaluminum ensures that every batch of 6060 aluminum bars meets international expectations for accuracy, strength, and surface quality.
Applications of 6060 Aluminum Bars
Due to their excellent extrudability and surface finish, 6060 bars are used across diverse industries:
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Architectural Structures: Door frames, curtain walls, window profiles
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Transportation: Automotive trim, railway components, and trailers
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Machinery: Fasteners, connectors, and machine bases
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Electrical Systems: Busbars and conductive rails
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Marine Equipment: Lightweight corrosion-resistant fittings
Each of these applications benefits from the alloy’s perfect balance of machinability, strength, and corrosion resistance.
Why Dimensional Precision Matters
Precision in size and tolerance affects:
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Assembly Fit: Ensures parts fit perfectly without rework.
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Machining Efficiency: Minimizes material waste and tool wear.
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Structural Safety: Prevents mechanical failures from dimensional inconsistencies.
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Surface Finishing: Allows even anodizing or coating across uniform surfaces.
With the right tolerance control, manufacturers can guarantee smoother production processes and longer-lasting products.
Quality Assurance by sasaaluminum
sasaaluminum uses advanced extrusion technology and rigorous inspection systems to ensure that all 6060 aluminum bars meet exact dimensional and mechanical specifications.
Quality Control Measures Include:
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Laser Measurement Systems for precise dimensional inspection
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Ultrasonic Testing for detecting internal flaws
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Surface Roughness Inspection using profilometers
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Mechanical Testing (tensile, yield, elongation)
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Anodizing Quality Check for surface uniformity
Each bar is supplied with a Mill Test Certificate (MTC) confirming compliance with EN or ASTM standards. This guarantees customers receive products ready for critical engineering use.
Advantages of Choosing sasaaluminum
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Wide Range of Sizes and Profiles – From small precision bars to large extrusions, customized to your needs.
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Tight Dimensional Tolerances – Ensures consistent performance in every application.
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High Surface Quality – Suitable for anodizing, polishing, or painting.
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Global Standard Compliance – ASTM, EN, ISO, and GB certifications available.
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Fast Delivery and Customization – Quick lead times with flexible order quantities.
By combining advanced manufacturing with strict quality control, sasaaluminum delivers 6060 aluminum bars that exceed industry expectations.
Future Outlook
As lightweight materials become essential for sustainable design and energy efficiency, the use of 6060 aluminum bars will continue to grow. Emerging trends such as electric vehicles, smart architecture, and modular construction rely on precision aluminum components.
With its proven expertise, sasaaluminum remains committed to providing high-quality aluminum materials that support innovation, efficiency, and environmental responsibility.
Conclusion
Understanding the standard sizes and tolerances for 6060 aluminum bars is vital for ensuring precision, performance, and cost-effectiveness in production. From round and flat bars to custom profiles, 6060 aluminum provides exceptional strength, corrosion resistance, and surface finish for diverse applications.
Manufactured under international standards and verified through stringent testing, 6060 Aluminum Bars from sasaaluminum represent reliability, precision, and long-term value — making them the preferred choice for industries that demand quality and consistency.
Post time: Nov-07-2025