6101 aluminum alloy (UNS A96101) is a heat-treatable forging Al-Mg-Si alloy with moderate strength and high conductivity, primarily used for electrical busbars and conductor applications. Its density is approximately 2.70 g/cm³ (0.097 lb/in³), with a melting range of 1150 – 1210 °F (620 – 655 °C), striking a balance between lightweight properties and thermal stability.
This alloy can be extruded into rods, bars, profiles, pipes, and custom shapes, with various temper states (F, T6, T61, T63, T64, T65) to adjust strength, formability, and conductivity. Key properties include good machinability, weldability, corrosion resistance, and formability, making 6101 widely used in power transmission, power plant hardware, and other power infrastructure components.
6101 Aluminum Chemical Composition
- Silicon (Si): 0.30 – 0.70 %
- Magnesium (Mg): 0.35 – 0.80 %
- Iron (Fe): ≤ 0.50 %
- Copper (Cu): ≤ 0.10 %
- Zinc (Zn): ≤ 0.10 %
- Chromium (Cr): ≤ 0.03 %
- Manganese (Mn): ≤ 0.03 %
- Boron (B): ≤ 0.06 %
- Titanium (Ti): ≤ 0.06 %
- Other residuals: ≤ 0.10 %
- Aluminum (Al): Balance .
The Mg‑Si combination enables precipitation hardening, while boron is added as a grain refiner to optimize electrical conductivity.
6101 Aluminum Physical Properties
- Density: 0.097 lb/in³ (2.70 g/cm³) .
- Melting Range: 1150 – 1210 °F (620 – 655 °C) .
6101 Aluminum Thermal Conductivity
- T6: ≈ 1510 BTU·in/(ft²·hr·°F) (218 W/m·K)
- T61: ≈ 1540 BTU·in/(ft²·hr·°F) (222 W/m·K)
- T63: ≈ 1510 BTU·in/(ft²·hr·°F)
- T64: ≈ 1570 BTU·in/(ft²·hr·°F) (226 W/m·K)
- T65: ≈ 1510 BTU·in/(ft²·hr·°F) .
- Coefficient of Linear Thermal Expansion (68 – 212 °F): 13.0 × 10⁻⁶ in/in·°F (23.4 × 10⁻⁶ m/m·°C) .
- Specific Heat: ≈ 0.22 BTU/lb·°F (920 J/kg·K)
6101 Aluminum Mechanical Properties
| Temper | UTS (ksi / MPa) | Yield (ksi / MPa) | Modulus (ksi / GPa) | Hardness (HRB) | Elongation |
| T6 | 29 (200) | 25 (170) | 9,900 (68) | — | — |
| T61 | 20 (140) | 15 (100) | 9,900 (68) | 71 | 10 % |
| T63 | 27 (185) | 22 (150) | 9,900 (68) | — | — |
| T64 | 15 (100) | 8 (55) | 9,900 (68) | — | — |
| T65 | 25 – 32 (170–220) | 20 – 27 (140–185) | 9,900 (68) | 71 | N/A |
6101 Aluminum Electrical Properties
Electrical conductivity (% IACS):
- T6: 55%
- T61: 57%
- T63: 56%
- T64: 59.5%
- T65: 56.5%
These electrical conductivities give it better performance than 6063 alloys and higher strength than 1350 alloys, making 6101 alloy the best choice for busbar applications.
6101 Aluminum Corrosion Resistance
Like other Al-Mg-Si alloys, 6101 has excellent corrosion resistance, performing well in atmospheric and mild aqueous environments. Its anodizing performance is satisfactory, and compared to pure aluminum, it has better bending and machinability.
6101 exhibits good resistance to atmospheric and marine environments; it is commonly anodized or coated to enhance its protective properties.
6101 Aluminum Heat Treatment and Temper
- F: As fabricated, no specific performance limitations.
- T6: Solution heat-treated and artificially aged to achieve maximum strength.
- T61: Overaged to improve conductivity, but sacrifices strength.
- T63: Medium temper, balancing strength and conductivity.
- T64: Highest conductivity and maximum formability.
- T65: Medium strength and conductivity, with controlled mechanical limits.
Special tempers (e.g., T61P, T64P) can further optimize yield to achieve stable bending performance.
6101 Aluminum Applications
- Power busbar conductors: Bars, beams, tubes, and custom busbar profiles in power plants and transmission systems.
- Electrical projects: Chassis, enclosures, and connectors requiring conductivity and moderate structural integrity.
- General extrusion materials: Bars, rods, and profiles for electronic products, automotive interiors, and non-structural building components.
- Structures: Lightweight frames, with a preference for supports that prioritize conductivity.
6101 Aluminum Processing and Manufacturing
6101 is easy to extrude, offering better machinability than 1xxx series alloys, and supports tightly toleranced complex shapes. It can be processed both hot and cold; bending radii vary by temper and thickness (e.g., T6: 0.125-0.375 inches is 2 times the thickness) without cracking. This alloy is suitable for welding, brazing, and anodizing operations, providing design flexibility for electrical and structural markets.
- Extrusion performance: Excellent, suitable for complex profiles (e.g., busbars).
- Machining performance: Moderate; better than pure aluminum, but requires lubrication.
- Welding: Compatible with TIG/MIG welding; post-weld heat treatment is recommended to restore strength in the heat-affected zone (HAZ).
- Tempers: Common tempers include T4 (natural aging), T5 (artificial aging after extrusion), and T6 (solution heat-treated + aging for peak strength).
6101 Aluminum vs. Similar Alloys
- Compared to 6061: Lower strength (6061-T6 tensile strength: approx. 310 MPa), but higher conductivity (6061: approx. 43% IACS).
- Compared to 1350 (EC aluminum): Better mechanical properties, but slightly lower conductivity (1350: approx. 61% IACS).
6101 Aluminum Standards and Specifications
- ASTM: B317 (extruded rod), B236 (electrical conductor).
- EN: EN 573-3 (European standard).
6101 Aluminum Limitations
- Not suitable for high-stress structural applications.
- Conductivity is lower than pure aluminum, but the strength is balanced, making it suitable for electrical applications.
6101 aluminum is optimized for electrical and thermal applications that require moderate strength, excellent extrusion properties, and good conductivity. Its Mg-Si composition and good heat treatment performance make it a versatile choice for power infrastructure and lightweight components.