Aluminum 6101 · precip hard
Aluminum 6101-T65
Properties of the T65 condition, compared with the other 6101 tempers.
Highest-strength 6101 bus temper for structurally loaded conductor profiles; least formable.
What is 6101-T65?
6101-T65 is 6101 in the T65 condition — highest-strength 6101 bus temper for structurally loaded conductor profiles; least formable. 6101-T65 has a yield strength of 185 MPa (26.8 ksi) and a tensile strength of 220 MPa (31.9 ksi) — weaker than 53% of aluminum grades. Elongation at break is 12% and the elastic modulus is 69 GPa (10 Msi). 6101-T65 has a density of 2.7 g/cm³ (0.0975 lb/in³), lighter than 60% of aluminum grades. It melts at 621°C (1,150 °F). T6 is the default condition FabDigit quotes; T65 is available on request or by drawing note.
Advantages
- Conducts heat well — 214 W/m·K (123.6 BTU/hr·ft·°F), better than 93% of aluminum grades
- High electrical conductivity — 56 % IACS, better than 93% 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-T65 properties
Typical room-temperature values for 6101-T65 — 11 properties are specific to this condition; the rest are grade-level values shared by every 6101 temper. Each bar shows where the value sits among the aluminum grades in FabDigit's library — further right is higher.
Physical3
6101-T65 has a density of 2.7 g/cm³ (0.0975 lb/in³), lighter than 60% of aluminum grades. It melts at 621°C (1,150 °F).
Mechanical11
6101-T65 has a yield strength of 185 MPa (26.8 ksi) and a tensile strength of 220 MPa (31.9 ksi) — weaker than 53% of aluminum grades. Elongation at break is 12% and the elastic modulus is 69 GPa (10 Msi).
Thermal6
6101-T65 is rated for continuous service to 150°C (302 °F). It conducts heat at 214 W/m·K (123.6 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-T65 conducts electricity at 56 % IACS, better than 93% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is good (65/100), better than 71% of aluminum grades.
Sustainability4
Producing a kilogram of 6101-T65 takes about 205 MJ of energy and emits 12 kg of CO₂ — more than 75% of aluminum grades. Typical recycled content is 20%.
Manufacturability7
6101-T65's machinability is good (57/100, worse than 55% of aluminum grades); weldability excellent (85/100); formability fair (50/100).
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Other 6101 tempers and conditions
6101 is also supplied in 5 other conditions. The full side-by-side table is on the 6101 overview.
- T6DefaultStandard high-strength conductor temper for extruded bus bar and electrical profiles where 55 % IACS minimum is acceptable.195 MPa yield · 71 HB
- T65Highest-strength 6101 bus temper for structurally loaded conductor profiles; least formable.185 MPa yield · 72 HB
- T63Balanced bus-bar temper: near-T6 strength with 55 % IACS minimum and better bend performance than T65.175 MPa yield · 65 HB
- T61Choose when 57 % IACS minimum conductivity and good bendability matter more than strength (heavy bus bar, formed connectors).110 MPa yield · 48 HB
- T64Lowest-strength, highest-conductivity bus temper for tight bends and stamped conductive parts.90 MPa yield · 40 HB
- H111Soft, 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 MPa yield · 28 HB
Working with 6101-T65
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.
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.
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 | — |
6101-T65 — frequently asked
What is 6101-T65 used for?
6101-T65 is typically used for busbars, electrical conductors and heat sinks. In short: maximum electrical conductivity.
What is the yield strength of 6101-T65?
6101-T65 has a typical yield strength of 185 MPa (26.8 ksi) and a tensile strength of 220 MPa (31.9 ksi) — weaker than 53% of aluminum grades. Strength varies by condition: see the 6 listed tempers.
Is 6101-T65 easy to machine?
Reasonably — machinability is rated good (57/100, worse than 55% 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-T65 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-T65?
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-T65 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-T65?
6101-T65 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.
Can FabDigit make parts in 6101-T65?
Yes — 6101-T65 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. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.