6060 Aluminum Alloy: A Comprehensive Guide to Properties, Manufacturability, and Applications

 

 

 

For aluminum parts manufacturing through CNC machining and industrial extrusion, 6060 aluminum alloy stands out as the good choice when aesthetics, complex geometry, and superior surface finish are non-negotiable. As a heat-treatable 6xxx series (Al-Mg-Si) alloy, it becomes a highly valued material in both aesthetic engineering and architectural extrusion because of its excellent formality, good corrosion resistance, moderate strength, and surface treatments suitability.

 

This guide provides an in-depth look at 6060 aluminum properties and uses, its advantages over 6061, manufacturability, helping you determine whether it is a suitable material for your manufacturing or design needs.

 

 

 

 

What is 6060 Aluminum Alloy?

 

Aluminum 6060 is a medium-strength alloy known for its exceptional corrosion resistance and "extrudability." It is specifically designed to be pushed through dies to create intricate cross-sections that would be impossible with harder alloys.

 

 

 

 

Key Highlights:

 

• Main Elements: Magnesium (0.35-0.6%) and Silicon (0.3-0.6%);This helps enhance strength during heat treatment
  
• Extrudability: Capable of forming ultra-thin walls and complex hollow profiles.
  
• Surface Quality: Offers one of the best responses to decorative anodizing in the entire aluminum family.
  
• Comparison: Often compared to 6063, it offers slightly lower strength but superior complexity in extrusion and a finer surface finish.

 

 

 

Chemical Composition of 6060 Aluminum

 

 

The performance of aluminum alloy 6060 is dictated by its chemical balance, which is mainly affected by it Magnesium and Silicon content. By tightly controlling Magnesium and Silicon, the alloy forms Mg2Si precipitates during heat treatment; This helps enhance the alloy’s strength and achieve moderate strength while maintaining good extrusion performance. Below table shows 6060 aluminum alloy’s chemical composition:

 

 

Table 1: 6060 Aluminum Chemical Composition (Weight %)

 

 

 

     

 

 

Mechanical and Physical Properties of 6060 Aluminum

 

 

Mechanical Properties and Temper Conditions of 6060 Aluminum

 

The mechanical properties of 6060 aluminum alloy vary under different tempering conditions. Below table is based on EN 755-2 standards for profiles with wall thickness ≤ 15mm.

 

 

Table 2: 6060 Aluminum Mechanical Properties By Temper

 

 

 

               

6060 T4 Aluminum(Naturally Aged)

 

It is solution heat treated followed by natural aging at room temperature. In this state, the 6060 aluminum has lower strength but offers extremely high plasticity and ductility (typically with an elongation rate of ≥ 16%). It is the most suitable temper for parts requiring secondary cold deformation, such as deep bending, stamping, or flanging.

 

 

6060 T5 Aluminum (Artificially Aged)

 

It is cooled from an elevated temperature shaping process and then artificially aged. This temper is suitable for parts with standard strength requirements that need good dimensional stability and high surface quality (such as standard window frames).

 

 

6060 T6 Aluminum(Solution Heat Treated + Artificially Aged)

 

 It offers higher strength than T5. It generally requires a separate quenching process and can be used for structural components with moderate load-bearing requirements.

 

 

6060 T66  Aluminum (Enhanced T6)

 

 This is achieved by precisely controlling extrusion temperatures and cooling rates. It provides the highest yield strength for the 6060 alloy without sacrificing formability.T66 has become the preferred choice for high-performance curtain walls and precision industrial aluminum.

 

 

 

Physical Properties of 6060 Aluminum

 

The physical properties of 6060 aluminum alloy are not affected by heat treatment.  Its physical properties include:

 

• Density: 2.70 g/cm³
  
• Melting Range: 600 - 655 °C
  
• Thermal Conductivity: 200 - 220 W/(m·K)
  
• Electrical Resistivity: 0.030 - 0.035 μΩ·m

 

 

 

 

6060 Aluminum Alloy Manufacturability

 

 

From Profile to Part : Extrusion and CNC Machining 

 

 

While most products start as 6060 aluminum extrusion profiles (windows, rails, frames), they often require CNC Machining to become finished components.

 

• Why 6060 for Extrusion：It has the highest "extrudability" rating, allowing for wall thicknesses under 1mm and features like screw ports, snap-fits, and internal hollows.
• CNC Machining Role: Even the best extrusion has relative high tolerances compared to high precision aluminum CNC machining. And CNC milling and drilling can also be used to create precise mounting holes (6H thread accuracy), finish mating surfaces, and add complex 3D details to the profiles. If your part requires heavy machining, specify 6060 T6 or T66. The higher hardness ensures cleaner chips and prevents "gumming" on the cutting tool.

 

 

 

 

Surface Finishing: The Anodizing Standard

 

 

 

 

6060 aluminum alloy is an ideal 6xxx-series grade for anodizing due to its low iron (Fe) content and strictly controlled impurities to gain a good surface. It is an electrochemical process that converts the aluminum surface into a uniform aluminum oxide layer in a sulfuric acid electrolyte. Because this oxide layer is integrated with the substrate at a molecular level, it eliminates risks of peeling or flaking common with physical coatings. The resulting film provides good transparency, clearly displaying the metal's natural texture while allowing for stable color absorption through its microporous structure.

 

 

Surface Protection and Visual Performance

 

Anodizing improves the surface hardness and wear resistance of 6060 alloy components. By combining this process with mechanical treatments such as brushing, sandblasting, or polishing, parts can achieve various industrial finishes ranging from matte to high-gloss with various colors options. This method maintains the metallic feel of the aluminum, making it suitable for electronic components and architectural segments that require both dimensional precision and surface durability.

 

 

Other Treatment Options and Cost Considerations 

 

While anodizing is the standard choice for aluminum 6060, other treatments offer specific advantages:

• Powder coating provides a wide range of colors and hides material imperfections, making it suitable for outdoor architectural applications but not that durable like anodizing.
• PVDF (Fluorocarbon) coating offers high weather resistance, often used for curtain walls in landmark buildings.

In terms of cost, anodizing typically sits between powder coating and PVDF coating.

 

 

 

 

Welding 6060 Aluminum

 

 

6060 aluminum has good weldability. When welding 6060 aluminum, both MIG and TIG welding provide reliable results. However, filler metal selection depends on whether the part will undergo further surface treatment:

 

• For Parts Without Anodizing: In their raw, as-welded state, ER4043 is often preferred as it produces a bright silver weld bead and offers excellent fluidity at a lower cost. In contrast, ER5356 produces a slightly darker weld seam and more soot during the welding process.
• But for Parts Will Anodizing: ER5356 (AlMg5) becomes the essential choice. Its magnesium content ensures a consistent color match with the 6060 base metal after the electrochemical process. Using ER4043 in this scenario is problematic; the silicon in the filler does not oxidize like the aluminum, resulting in a prominent "black seam" that compromises the visual integrity of the part.

 

 

 

 

6060 Aluminum vs. 6061: Which should you choose?

 

 

Aluminum alloy 6060 is a common grade under the European Standard (EN), whereas 6063 is the primary grade under the American Standard (ASTM). Both are widely used for architectural extrusions and are very similar in application. Although they are often interchangeable due to shared properties—such as good corrosion resistance, excellent formability, medium strength, and suitability for anodizing—there are still some differences in these characteristics:

 

 

Table 3: Comparison of 6060 Aluminum Vs 6061 Aluminum

 

 

 

 

  

 

Common Applications of 6060 Aluminum

 

 

Due to its excellent extrusion performance and superior anodizing aesthetics, 6060 aluminum alloy is widely used in industries that require high surface precision and complex structural configurations. Here are a few of its use examples:

 

• Architecture: High-end window/door frames, curtain walls, and shelving.
• Modern Furniture: Office desk frames, modular partitions, and designer lighting tracks. 
• Automotive: Decorative trim, roof rails, and interior dashboard frames.

 

• Electronics: Heat sinks, hard drive cases, and audio panels.
• Industrial: Automation line frameworks (T66 temper) and pneumatic cylinders.

 

 

 

Conclusion

 

6060 aluminum alloy is the perfect synthesis of form and function. Whether you are designing a sleek architectural facade or a precision electronic casing, understanding extrusion aluminum 6060, properties and its compatibility with CNC machining and anodizing can elevate your product's quality.

 

 

 

 

 

VMT CNC Machining Case Study: 6060 Aluminum Motor Housing

 

 

A premium smart home manufacturer required a 0.8mm thin-wall motor housing for an automated curtain system. The component serves as both a structural frame and a heat sink, requiring a high-precision matte titanium-gray finish with high surface uniformity and no visible machining marks.

 

 

 

VMT CNC Machining Factory Solutions:

 

• Material Selection: We utilized custom E6060 extrusions with strictly controlled low-iron content to ensure optimal anodizing clarity and color consistency.
  
• Precision Machining: Using 4-axis CNC centers equipped with diamond tooling, we maintained a dimensional tolerance of ±0.02mm. This approach effectively managed the thermal and mechanical stresses on the thin walls to prevent deformation.
  
• Surface Treatment: The parts underwent automated 120# glass bead blasting followed by a 15μm sulfuric acid anodizing process to achieve a durable, high-texture metallic finish.
  
• Efficiency Gains: By transitioning from solid 6061 bar stock to near-net-shape 6060 extrusions combined with precision CNC finishing, the client achieved a 45% reduction in material costs and a 60% improvement in production cycle efficiency.
  

 

 

 

FAQs

 

 

Q1: What are the equivalent grades for Aluminum 6060? 

 

The closest equivalent is 6063. In the ISO system, it is known as Al-Mg-Si0.5.

 

 

Q2: What is the typical 6060 aluminum price? 

 

It is generally very cost-effective due to high production speeds. However, prices vary based on the complexity of the extrusion and the specific temper (T66 usually carries a small premium).

 

 

Q3: Can I get 6060 aluminum plate? 

 

While 6060 aluminum plate exists, this alloy is predominantly used for extrusions. If you need a sheet for machining, 6061 or 5052 are often more readily available in plate form.

 

 

Q4: Is 6060 aluminum good for saltwater environments? 

 

It has good corrosion resistance, but for direct marine contact, 5083 or 6061 with high-thickness anodizing are usually preferred.

 

 

Q5: What is E6060 aluminum sheet? 

 

The "E" prefix often designates "Electronic" or "Exquisite" grade, signifying a material with even higher purity and tighter tolerances for premium decorative anodizing.

 

 

Q6: Why use T66 instead of T6 for 6060?

 

 T66 is the "super-charged" version of T6. Choose T66 if your part is a load-bearing architectural component that needs maximum stiffness without increasing wall thickness.