Aluminum 6101
AA 6101 · UNS A96101 · EN AW-6101, AW 6101 · also 91E
6101 (A96101, 91E) is a low-copper, low-impurity heat-treatable Al-Mg-Si alloy developed for electrical conductor extrusions, with Cu, Cr and Mn deliberately restricted to protect conductivity.
Values for the T6 condition
6101 tempers and conditions
6101 is supplied in 6 conditions, soft to hard. T6 is the default FabDigit quotes; the values on this page are for it.
Compare all 6 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
Slightly strain hardened | Soft, non-age-hardened 6101 with only incidental strain hardening from forming — low strength but maximum ductility and near-peak electrical conductivity, used where conductors are bent or formed before aging/service. | 55 | 105 | 25 | 28 HB | 57 % IACS |
Solution heat treated and under-aged for maximum… | Lowest-strength, highest-conductivity bus temper for tight bends and stamped conductive parts. | 90 | 130 | 24 | 40 HB | 59.5 % IACS |
T6 variant, underaged | Choose when 57 % IACS minimum conductivity and good bendability matter more than strength (heavy bus bar, formed connectors). | 110 | 150 | 20 | 48 HB | 58.5 % IACS |
Solution heat treated and artificially aged | Balanced bus-bar temper: near-T6 strength with 55 % IACS minimum and better bend performance than T65. | 175 | 200 | 14 | 65 HB | 56.5 % IACS |
Solution heat treated and artificially aged to maximum strength | Highest-strength 6101 bus temper for structurally loaded conductor profiles; least formable. | 185 | 220 | 12 | 72 HB | 56 % IACS |
T6Default Solution heat treated and artificially aged | Standard high-strength conductor temper for extruded bus bar and electrical profiles where 55 % IACS minimum is acceptable. | 195 | 220 | 15 | 71 HB | 57 % IACS |
What is 6101?
6101 (A96101, 91E) is a low-copper, low-impurity heat-treatable Al-Mg-Si alloy developed for electrical conductor extrusions, with Cu, Cr and Mn deliberately restricted to protect conductivity. It delivers 55-60% IACS (57% IACS at the default condition) alongside moderate strength — 195 MPa yield, 220 MPa tensile, 15% elongation, 71 HB — and 218 W/m·K thermal conductivity, so it is used for extruded busbar, conductor bar and electrical structural sections. Compared with 6063/6061 the composition window is tighter and peak strength is lower; welding or prolonged heat above the 150 °C service limit over-ages the material and loses strength. 6101 has a density of 2.7 g/cm³ (0.0975 lb/in³), lighter than 59% of aluminum grades. It melts at 621°C (1,150 °F). 6101 has a yield strength of 195 MPa (28.3 ksi) and a tensile strength of 220 MPa (31.9 ksi) — stronger than 51% of aluminum grades. Elongation at break is 15% and the elastic modulus is 69 GPa (10 Msi).
What is 6101 used for?
- Busbars
- Electrical conductors
- Heat sinks
Advantages
- High electrical conductivity — 57 % IACS, better than 94% of aluminum grades
- Conducts heat well — 218 W/m·K (126 BTU/hr·ft·°F), better than 93% of aluminum grades
- Ductile — tolerates forming and impact — 15%, better than 82% of aluminum grades
- Polishes to a fine finish — 65/100, better than 82% of aluminum grades
- Readily welded — 85/100, better than 79% of aluminum grades
6101 properties
Typical room-temperature values for 6101-T6; bars are the position among aluminum grades.
Physical3
6101 has a density of 2.7 g/cm³ (0.0975 lb/in³), lighter than 59% of aluminum grades. It melts at 621°C (1,150 °F).
Mechanical11
6101 has a yield strength of 195 MPa (28.3 ksi) and a tensile strength of 220 MPa (31.9 ksi) — stronger than 51% of aluminum grades. Elongation at break is 15% and the elastic modulus is 69 GPa (10 Msi).
Thermal6
6101 is rated for continuous service to 150°C (302 °F). It conducts heat at 218 W/m·K (126 BTU/hr·ft·°F), better than 93% of aluminum grades. Thermal expansion is 23.5 µm/m·K (13.1 µin/in·°F).
Electrical3
6101 conducts electricity at 57 % IACS, better than 94% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is good (65/100), better than 71% of aluminum grades.
Sustainability4
Producing a kilogram of 6101 takes about 205 MJ of energy and emits 12 kg of CO₂ — more than 76% of aluminum grades. Typical recycled content is 20%.
Manufacturability7
6101's machinability is good (55/100, worse than 59% of aluminum grades); weldability excellent (85/100); formability good (55/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the aluminum family
Yield strength against density for every aluminum grade FabDigit runs. 6101 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with 6101
Is 6101 easy to machine?
Machines easily but gummy in soft tempers — use sharp polished-flute carbide, high speed, generous coolant; T6/T65 give the cleanest chips.
Can 6101 be welded?
Readily GTAW/GMAW welded with 4043 (lower conductivity joint) or 5356; HAZ loses temper, so bolted or exothermically welded joints are preferred for busbar ampacity.
Can 6101 be formed, bent or molded?
Extrudes very well into thin-web conductor profiles; bend in T61/T64 (typ. 1–2 t radius) rather than T6/T65 to avoid cracking.
Manufacturability
The process limits FabDigit's quote engine applies to 6101. Design inside these and the part quotes instantly; outside them it routes to an engineer.
CNC machining
| Machinability | Better55 / 100 |
|---|---|
| ISO material group | N.1 |
| Cutting speed (rough / finish) | 340 / 410 m/min |
| Minimum wall | 0.5 mm |
| Minimum internal radius | 1 mm |
| Drill depth limit | 8× diameter |
| Best surface (machined / polished) | Ra 0.8 / 0.4 µm |
| Hardenable after machining | No |
Sheet metal
| Formability | Better55 / 100 |
|---|---|
| Weldability | Excellent85 / 100 |
6101 chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| Si | 0.3 – 0.7 | 0.5 |
| Fe | ≤ 0.5 | 0.25 |
| Culimited to protect conductivity | ≤ 0.1 | 0.03 |
| Mn | ≤ 0.03 | |
| Mg | 0.35 – 0.8 | 0.6 |
| Cr | ≤ 0.03 | |
| Zn | ≤ 0.1 | |
| Bboron treatment removes Ti/V for higher conductivity | ≤ 0.06 | |
| Others (each) | ≤ 0.03 | |
| Others (total) | ≤ 0.1 | |
| Al | balance |
What surface finishes work on 6101?
Bare surfaces are usually brushed and tin- or silver-plated at contact faces; clear/hard anodize is possible but insulating, so mask joint areas.
Surface treatments FabDigit runs on aluminum parts — pick them in the quote configurator or call them out on the drawing. Each links to its datasheet in the surface-finish library (thickness, specs, call-out, material verdicts).
Passivation
Conversion Coating
PVD Coating
Equivalent designations
Standards and trade names that resolve to Aluminum 6101 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- UNS
- A96101
- Aluminum Association
- AA6101
- EN / DIN / Werkstoff-Nr.
- AW-6101AW 6101
- Trade names
- 91E
- Also called
- E-AlMgSi
How much does 6101 cost?
6101 is a standard-cost aluminum ($$), cheaper than about 80% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
6101 — frequently asked
What is 6101 used for?
6101 is typically used for busbars, electrical conductors and heat sinks. In short: maximum electrical conductivity.
What is the yield strength of 6101?
6101 has a typical yield strength of 195 MPa (28.3 ksi) and a tensile strength of 220 MPa (31.9 ksi) — stronger than 51% of aluminum grades. Strength varies by condition: see the 6 listed tempers.
Is 6101 easy to machine?
Reasonably — machinability is rated good (55/100, worse than 59% of aluminum grades). Machines easily but gummy in soft tempers — use sharp polished-flute carbide, high speed, generous coolant; T6/T65 give the cleanest chips.
Can 6101 be welded?
Yes — weldability is rated excellent (85/100). Readily GTAW/GMAW welded with 4043 (lower conductivity joint) or 5356; HAZ loses temper, so bolted or exothermically welded joints are preferred for busbar ampacity.
What surface finishes work on 6101?
Bare surfaces are usually brushed and tin- or silver-plated at contact faces; clear/hard anodize is possible but insulating, so mask joint areas.
Can 6101 be formed, bent or molded?
Extrudes very well into thin-web conductor profiles; bend in T61/T64 (typ. 1–2 t radius) rather than T6/T65 to avoid cracking.
What is the maximum service temperature of 6101?
6101 is rated for continuous use to about 150°C (302 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between 6101-T6 and 6101-H111?
T6 is the default condition — standard high-strength conductor temper for extruded bus bar and electrical profiles where 55 % IACS minimum is acceptable. H111: soft, non-age-hardened 6101 with only incidental strain hardening from forming — low strength but maximum ductility and near-peak electrical conductivity, used where conductors are bent or formed before aging/service. Yield strength is 195 MPa in T6 versus 55 MPa in H111.
How much does 6101 cost?
6101 is a standard-cost aluminum ($$), cheaper than about 80% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Can FabDigit make parts in 6101?
Yes — 6101 is available for CNC machining and sheet metal with instant online pricing. Upload a STEP file to get a price and a DFM check.
Sources
- Aluminum Association Teal Sheets — International Alloy Designations and Chemical Composition Limits for Wrought Aluminum — The Aluminum Association (2018)
- ASTM B317/B317M — Aluminum-Alloy Extruded Bar, Rod, Tube, Pipe, Structural Profiles and Profiles for Electrical Purposes (Bus Conductor) — ASTM International (2019)
- EN 573-3 / EN 755-2 — Aluminium and aluminium alloys, chemical composition and mechanical properties of extruded products — CEN (2019)
- ASM Handbook Vol. 2 — Properties and Selection: Nonferrous Alloys — ASM International (1990)
- GB/T 3190 / GB/T 5585.2 (2020)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.