6061 aluminum bars are solid extruded or drawn profiles made from 6061 aluminum alloy (AlMg1SiCu), one of the most widely used structural aluminum alloys worldwide. Supplied in round, square, hexagonal, and flat profiles, 6061 bars combine medium-to-high tensile strength (290 MPa in T6 temper), excellent machinability (rated Class B), good corrosion resistance, and superior weldability. The alloy is heat-treatable, with T6 and T651 being the most common tempers for bar stock. 6061-T651 bars are stress-relieved by stretching to minimize warpage during CNC machining, making them the industry standard for precision machined components.
HXM Aluminum supplies 6061 aluminum bars in round, square, hexagonal, and flat profiles. Round bar diameters range from 3mm to 400mm, with standard lengths up to 6000mm. Available tempers include T6, T651, T4, and O. All bars are certified to ASTM B221 standards.
Our bar processing services include cut-to-length, CNC turning, milling, and surface treatment. Contact us with your bar specifications for a competitive quotation.
Quick Specifications
| Specification | Details |
|---|---|
| Alloy | 6061 (AlMg1SiCu) |
| Temper | T6, T651, T4, O |
| Standard | ASTM B221, EN 755-2 |
| Profile | Round, square, hexagonal, flat |
| Diameter (Round) | 3mm – 400mm |
| Side (Square/Hex) | 5mm – 200mm |
| Length | Up to 6000mm (cut to size) |
| Surface | Mill finish, drawn, anodized |
| Processing | Cut-to-length, CNC turning, milling |
HXM Aluminum manufactures 6061 aluminum bars in four standard profiles. Custom sizes and special profiles are available upon request.
| Profile | Size Range | Tolerance | Typical Use |
|---|---|---|---|
| Round Bar | Dia: 3mm – 400mm | +/-0.05mm – +/-0.5mm | Shafts, machining |
| Square Bar | Side: 5mm – 200mm | +/-0.1mm – +/-0.5mm | Structural, fabrication |
| Hex Bar | AF: 5mm – 100mm | +/-0.1mm – +/-0.3mm | Fasteners, fittings |
| Flat Bar | 3x10mm – 50x300mm | +/-0.1mm – +/-0.5mm | Brackets, supports |
Extruded vs Drawn: Extruded bars are produced by pushing heated billet through a die, suitable for larger sizes and general applications. Drawn bars undergo additional cold drawing for improved dimensional accuracy and surface finish, preferred for precision machining applications.
Bar Processing Services
HXM Aluminum provides comprehensive in-house processing services for 6061 aluminum bars, from raw extrusion to finished precision components:
Cut-to-Length: Precision sawing to custom lengths, ±0.5mm tolerance. Mitre cutting available up to 60° angles.
CNC Turning: Lathe turning to reduced diameters, stepped shafts, threaded ends, custom profiles.
CNC Milling: Milling flats, slots, keyways, cross-holes, and custom geometries from bar stock.
Surface Treatment: Anodizing (Type II/III), powder coating, polishing, brushed finish, chromate conversion.
Export Packaging: Bundle wrapping, end caps, wooden crates, Fumigation certification, full shipping documentation.
Need custom processing? Our metal processing services include CNC machining, surface treatment, and quality testing. Visit our quality testing services page for inspection capabilities.
Chemical Composition
For extruded and drawn 6061 aluminum bars, the chemical composition per ASTM B221 and EN 573-3 determines the extrusion surface quality, machinability, and dimensional stability of solid profiles. The composition is optimized for extrudability while maintaining the high strength and excellent machining characteristics that make 6061 bars the preferred alloy for CNC machined components.
| Element | Min (%) | Max (%) |
|---|---|---|
| Silicon (Si) | 0.40 | 0.80 |
| Iron (Fe) | – | 0.70 |
| Copper (Cu) | 0.15 | 0.40 |
| Manganese (Mn) | – | 0.15 |
| Magnesium (Mg) | 0.80 | 1.20 |
| Chromium (Cr) | 0.04 | 0.35 |
| Zinc (Zn) | – | 0.25 |
| Titanium (Ti) | – | 0.15 |
| Others (each) | – | 0.05 |
| Aluminum (Al) | – | Remainder |
Composition notes for bars: The magnesium-silicon balance controls the extrusion speed and surface finish: higher silicon within the range improves extrudability and surface brightness, while magnesium drives the T6 age-hardening response. Chromium prevents grain growth during solution heat treatment, which is critical for bars that will be precision-machined. Iron content is controlled to minimize hard intermetallic particles that can damage cutting tools during CNC machining of bar stock.
Mechanical Properties
The mechanical properties of 6061 aluminum bars, tested per ASTM B221 and ASTM B557, are determined by the temper condition and the extrusion or drawing process. Drawn bars exhibit higher dimensional accuracy and slightly higher surface hardness due to work hardening from the cold drawing operation.
| Property | T6 Temper | T651 Temper | O Temper |
|---|---|---|---|
| Ultimate Tensile Strength (MPa) | 290 | 290 | 150 |
| Yield Strength (MPa) | 240 | 240 | 83 |
| Elongation in 50mm (%) | 10 | 12 | 18 |
| Hardness (Brinell) | 95 | 95 | 30 |
| Elastic Modulus (GPa) | 68.9 | 68.9 | 68.9 |
| Fatigue Strength (MPa) | 96 | 96 | 62 |
Bar-specific mechanical considerations:
- Machinability rating: 6061-T6 bars are rated Class B (good machinability), achieving surface finishes of Ra 0.8 microns or better on CNC lathes at cutting speeds of 150-300 m/min with carbide tooling.
- Straightness tolerance: T651 bars are stress-relieved by stretching (1-3% permanent set), achieving straightness of 1mm per 300mm length. This is critical for precision machining applications.
- Size effect: Bars above 200mm diameter may exhibit slightly lower tensile strength (270-280 MPa in T6) due to slower quench rates in the core during solution heat treatment.
Temper Selection Guide — Which Temper Should You Choose?
Choosing the right temper is critical for your application. Use this guide to select the optimal temper based on your manufacturing process and performance requirements.
| Temper | Tensile (MPa) | Best For | Key Characteristic |
|---|---|---|---|
| T6 | 290 | General structural, machined components, welded assemblies | Solution heat-treated + artificially aged. Most common and economical temper. Good strength, may warp slightly during heavy machining. |
| T651 | 290 | Precision CNC machining, tight tolerances, aerospace components | T6 + stress-relieved by stretching (1-3% permanent set). Dimensionally stable during machining — prevents warpage. Industry standard for CNC. |
| T4 | 210 | Moderate strength + post-forming aging, bent components | Solution heat-treated only (naturally aged). Softer, can be aged to T6 after forming. Good for bending before aging. |
| O (Annealed) | 150 | Forging, severe forming, bending, deep drawing | Softest condition. Maximum formability. Can be heat-treated to T6 after forming operations. |
Quick recommendation: For CNC machined parts → T651. For structural/welded parts → T6. For bending/forming → O or T4 (then age to T6).
For more details, read our 6061-T6 vs T651 Temper Guide in our technical blog.
Product Features
High Strength-to-Weight Ratio: 290 MPa tensile strength at only 2.70 g/cm3 density — one-third the weight of steel at comparable strength levels.
Excellent Machinability: Rated Class B — ideal for CNC turning, milling, drilling, and tapping. Superior chip breaking compared to 5000-series alloys.
Superior Weldability: Excellent response to GTAW (TIG), GMAW (MIG), and friction stir welding. Weld strength reaches 70% of base metal in T6 condition.
Good Corrosion Resistance: Forms protective oxide layer naturally. Performs well in atmospheric, marine, and mild chemical environments.
Heat Treatable: Precipitation hardening via solution heat treatment + artificial aging (T6) achieves full strength. T651 adds stress relief for dimensional stability.
Anodizing Compatible: Excellent response to Type II (sulfuric) and Type III (hardcoat) anodizing for enhanced corrosion and wear resistance.
Multiple Profiles Available: Round, square, hexagonal, and flat bars — all available in T6, T651, T4, and O temper conditions.
Applications
6061 aluminum bars are used across diverse industries for machined and structural components:
Machined components: CNC machined parts, shafts, bushings, fittings, and custom components requiring precision and strength.
Structural supports: Support bars, brackets, and structural elements in architectural and industrial applications.
Fasteners and hardware: Hex bars for bolt and nut manufacturing, threaded fasteners, and hardware fittings.
Aerospace components: Aircraft fittings, structural pins, and aerospace machined parts requiring high strength-to-weight ratio.
Automotive: Custom automotive components, drive shafts, and structural parts.
Marine hardware: Marine fittings, rail stanchions, and deck hardware benefiting from corrosion resistance.
Recommended temper by application: T6 for general structural and machined components; T651 for precision machining requiring dimensional stability; T4 for moderate strength with post-machining aging; O temper for forging and severe forming operations.
Why Choose HXM Aluminum
15+ Years Manufacturing Experience: Established aluminum bar production facility with mature extrusion and drawing capabilities.
60+ Countries Exported: Global supply network serving South America, Europe, Southeast Asia, Middle East, and Australia.
50,000+ Tons Annual Output: Large-scale production capacity ensuring competitive pricing and reliable delivery schedules.
Full Certifications: ISO 9001 quality management, ASTM B221/B211 product standards, EN 10204 3.1 MTC for every shipment.
Custom Solutions: Custom diameters, lengths, profiles, tempers, and surface treatments. CNC pre-machining available.
24-Hour Quote Response: Fast quotation turnaround with detailed pricing including material, processing, and freight.
Quality Testing Services: In-house spectrometer, mechanical testing, ultrasonic inspection, and dimensional verification.
Frequently Asked Questions
What is the difference between 6061-T6 and 6061-T651 aluminum bar?
6061-T6 is solution heat-treated and artificially aged. 6061-T651 undergoes the same treatment plus a stretching operation (1-3% permanent set) to relieve internal residual stresses. T651 is strongly recommended for precision machined components because it maintains dimensional stability during machining, preventing warpage and distortion. Both tempers have the same nominal mechanical properties (290 MPa tensile strength).
What is the difference between extruded and drawn 6061 aluminum bar?
Extruded bars are produced by pushing heated billet through a die, resulting in good but not precision tolerances (+/-0.1-0.5mm). Drawn bars undergo additional cold drawing after extrusion, improving dimensional accuracy (+/-0.02-0.05mm), surface finish, and straightness. Drawn bars are preferred for precision machining, while extruded bars are more economical for general applications.
Can 6061 aluminum bars be machined on standard CNC equipment?
Yes, 6061 aluminum is one of the most machinable aluminum alloys, rated Class B. It can be machined on standard CNC lathes and milling machines using carbide or high-speed steel tools. Recommended cutting speeds are 150-300 m/min for carbide tools. 6061 produces clean, broken chips and achieves excellent surface finish, making it ideal for automated CNC machining.
What profiles are available for 6061 aluminum bars?
HXM Aluminum supplies 6061 bars in four profiles: round (diameter 3-400mm), square (side 5-200mm), hexagonal (across flats 5-100mm), and flat (thickness 3-50mm x width 10-300mm). Each profile is available in T6, T651, T4, and O temper conditions. Custom profiles can be produced for volume orders.
Can 6061 aluminum bars be forged?
Yes, 6061 aluminum in O temper has good forgeability. Forging is typically performed at 400-480 degrees C. After forging, the parts can be solution heat-treated and aged to T6 temper to achieve full strength (290 MPa). 6061 is commonly forged into automotive components, aerospace fittings, and custom structural parts.
Why choose T651 temper bars for CNC machining?
T651 bars are stress-relieved by stretching (1-3% permanent set) after solution heat treatment, which removes internal residual stresses. Without this step, T6 bars can warp or distort during machining as stresses are released by material removal. T651 bars maintain straightness within 1mm per 300mm length during machining, making them the industry standard for precision CNC components.
How are 6061 aluminum bars packaged for export?
Bars are bundled in straight lengths with nylon or steel straps. Bundle weight is typically 500-2000kg. Bars are separated by protective material to prevent surface scratching, and ends are capped or wrapped. Bundles are loaded onto pallets or into wooden crates for sea freight, with full markings including alloy, temper, size, and heat number.
How do I request a quotation for 6061 aluminum bars?
Provide: alloy/temper, profile (round/square/hex/flat), dimensions, length, quantity, surface requirement, and delivery destination. HXM Aluminum will provide a quotation including unit price per kg, total weight, and lead time within 24 hours.
6061 vs 7075 aluminum bar — which should I choose?
Choose 6061 for general structural, machined, and welded applications — it offers 290 MPa tensile strength, excellent weldability, and good corrosion resistance at a moderate cost. Choose 7075 only when maximum strength is required (572 MPa tensile) and weldability/corrosion resistance are not critical. 7075 costs 2-3x more than 6061 and is primarily used in aerospace and high-stress applications. See our 7075 aluminum bars for specifications.
Can you supply custom 6061 aluminum bar sizes?
Yes. We produce custom diameters (3-400mm round, 5-200mm square/hex), custom lengths (up to 6000mm), and custom profiles including stepped shafts, threaded ends, and pre-machined blanks. Minimum order quantity for custom sizes is 500kg. Lead time is 15-25 working days for custom extrusion, 7-12 days for cut-to-length from stock.
Request Your 6061 Aluminum Bar Quote Now
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