Aluminum Sintered 6061 AT4-T4-I
Precip hard
also MPIF 6061
AT4-T4-I = aT4-6061 Type I
Best strength/ductility compromise for parts that are still sized, staked or riveted after heat treatment.
Values for the AT4-T4-I condition
Other Sintered 6061 tempers and conditions
Sintered 6061 is listed in 6 conditions; see the grade overview at Sintered 6061.
Compare all 6 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
AT1-6061 Type I | Lowest-cost condition: softest, most ductile and easiest to size or coin after sintering. | 62 | 117 | 4 | 40 HB | 38 % IACS |
AT1-6061 Type II | Same soft T1 state but higher pressed density for better strength, stiffness and surface sealing. | 83 | 145 | 6 | 48 HB | 42 % IACS |
AT4-T4-IThis page AT4-6061 Type I | Best strength/ductility compromise for parts that are still sized, staked or riveted after heat treatment. | 96 | 148 | 3.5 | 55 HB | 34 % IACS |
AT4-6061 Type II | Higher-density T4 for load-bearing parts that must still tolerate some post-sinter deformation. | 110 | 179 | 5 | 62 HB | 38 % IACS |
AT6-T6-IDefault AT6-6061 Type I | Standard stocked condition: maximum strength and hardness for single-press/single-sinter PM 6061 parts. | 193 | 200 | 1 | 70 HB | 38 % IACS |
AT6-6061 Type II | Highest strength and stiffness variant of sintered 6061; specify for the most loaded PM aluminium parts. | 235 | 245 | 2 | 80 HB | 42 % IACS |
What is Sintered 6061 AT4-T4-I?
Sintered 6061 AT4-T4-I is Sintered 6061 in the AT4-T4-I condition — best strength/ductility compromise for parts that are still sized, staked or riveted after heat treatment. Sintered 6061 AT4-T4-I has a yield strength of 96 MPa (13.9 ksi) and a tensile strength of 148 MPa (21.5 ksi) — weaker than 85% of aluminum grades. Elongation at break is 3.5% and the elastic modulus is 60 GPa (8.7 Msi). Sintered 6061 AT4-T4-I has a density of 2.55 g/cm³ (0.0921 lb/in³), lighter than 99% of aluminum grades. It melts at 582°C (1,080 °F). AT6-T6-I is the default condition FabDigit quotes; AT4-T4-I is available on request or by drawing note.
Limitations
- Low stiffness — 60 GPa (8.7 Msi), worse than 100% of aluminum grades
- Hard to polish — 40/100, worse than 91% of aluminum grades
- Low strength — 96 MPa (13.9 ksi), worse than 85% of aluminum grades
- Limited service temperature — 120°C (248 °F), worse than 79% of aluminum grades
- Limited ductility — 3.5%, worse than 76% of aluminum grades
Sintered 6061 AT4-T4-I properties
Typical room-temperature values for Sintered 6061 AT4-T4-I; 35 are specific to this condition. Other listed values are Sintered 6061 reference data and may not represent this condition. Bars are the position among aluminum grades.
Physical3
Sintered 6061 AT4-T4-I has a density of 2.55 g/cm³ (0.0921 lb/in³), lighter than 99% of aluminum grades. It melts at 582°C (1,080 °F).
Mechanical13
Sintered 6061 AT4-T4-I has a yield strength of 96 MPa (13.9 ksi) and a tensile strength of 148 MPa (21.5 ksi) — weaker than 85% of aluminum grades. Elongation at break is 3.5% and the elastic modulus is 60 GPa (8.7 Msi).
Thermal6
Sintered 6061 AT4-T4-I is rated for continuous service to 120°C (248 °F). It conducts heat at 130 W/m·K (75.1 BTU/hr·ft·°F), worse than 65% of aluminum grades. Thermal expansion is 23.4 µm/m·K (13 µin/in·°F).
Electrical3
Sintered 6061 AT4-T4-I conducts electricity at 34 % IACS, worse than 52% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is good (55/100), worse than 51% of aluminum grades.
Sustainability4
Producing a kilogram of Sintered 6061 AT4-T4-I takes about 220 MJ of energy and emits 13.5 kg of CO₂ — more than 95% of aluminum grades. Typical recycled content is 25%.
Manufacturability7
Sintered 6061 AT4-T4-I's machinability is very good (70/100, better than 72% of aluminum grades); weldability fair (35/100); formability fair (35/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with Sintered 6061 AT4-T4-I
Is Sintered 6061 easy to machine?
Machines like soft wrought 6061 but pores break chips and can smear — use sharp polished-flute carbide, high speed, light feeds and flood coolant; deburr and blow out pores before assembly.
Can Sintered 6061 be welded?
Fusion welding is generally avoided: trapped gas and lubricant residue cause weld porosity; join by adhesive bonding, mechanical fastening, staking or brazing of impregnated parts.
Can Sintered 6061 be formed, bent or molded?
Formed by die compaction of admixed 6061 powder (typically 200–500 MPa), delubrication and nitrogen sintering near 595–620 °C, then optional repressing/sizing (Type II) and T4/T6 heat treatment; net shrinkage/growth must be built into tooling.
What surface finishes work on Sintered 6061?
Anodizing gives a duller, mottled film unless resin or steam impregnation seals the porosity; chromate/trivalent conversion coating, e-coat or resin impregnation followed by paint are the usual routes, and polishing is limited by open pores.
Sintered 6061 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 |
|---|---|---|
| Mg | 0.8 – 1.2 | 1 |
| Si | 0.4 – 0.8 | 0.6 |
| Cu | 0.15 – 0.4 | 0.25 |
| Cr | 0.04 – 0.35 | 0.2 |
| Fe | ≤ 0.7 | 0.2 |
| Mn | ≤ 0.15 | 0.05 |
| Zn | ≤ 0.25 | 0.05 |
| Ti | ≤ 0.15 | 0.05 |
| Cresidual from admixed lubricant (PM-specific, burn-off dependent) | ≤ 0.3 | 0.1 |
| Albalance; each other element ≤0.05, total ≤0.15 | balance | — |
Sintered 6061 AT4-T4-I — frequently asked
What is Sintered 6061 AT4-T4-I used for?
Sintered 6061 AT4-T4-I is typically used for P/M structural brackets, small housings, automotive components and consumer electronics parts. In short: corrosion-resistant P/M aluminum; heat-treatable to T6; near-net shape cost saving.
What is the yield strength of Sintered 6061 AT4-T4-I?
Sintered 6061 AT4-T4-I has a typical yield strength of 96 MPa (13.9 ksi) and a tensile strength of 148 MPa (21.5 ksi) — weaker than 85% of aluminum grades. Strength varies by condition: see the 6 listed tempers.
Is Sintered 6061 AT4-T4-I easy to machine?
Yes — machinability is rated very good (70/100, better than 72% of aluminum grades). Machines like soft wrought 6061 but pores break chips and can smear — use sharp polished-flute carbide, high speed, light feeds and flood coolant; deburr and blow out pores before assembly.
Can Sintered 6061 AT4-T4-I be welded?
With care — weldability is rated fair (35/100). Fusion welding is generally avoided: trapped gas and lubricant residue cause weld porosity; join by adhesive bonding, mechanical fastening, staking or brazing of impregnated parts.
What surface finishes work on Sintered 6061 AT4-T4-I?
Anodizing gives a duller, mottled film unless resin or steam impregnation seals the porosity; chromate/trivalent conversion coating, e-coat or resin impregnation followed by paint are the usual routes, and polishing is limited by open pores.
Can Sintered 6061 AT4-T4-I be formed, bent or molded?
Formed by die compaction of admixed 6061 powder (typically 200–500 MPa), delubrication and nitrogen sintering near 595–620 °C, then optional repressing/sizing (Type II) and T4/T6 heat treatment; net shrinkage/growth must be built into tooling.
What is the maximum service temperature of Sintered 6061 AT4-T4-I?
Sintered 6061 AT4-T4-I is rated for continuous use to about 120°C (248 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
Sources
- MPIF Standard 35 — Materials Standards for PM Structural Parts (Aluminum P/M alloys) — Metal Powder Industries Federation (2016)
- ASM Handbook Vol. 7 — Powder Metallurgy (Aluminium PM alloys) — ASM International (2015)
- ASM Handbook Vol. 2 — Properties of Nonferrous Alloys (6061) — ASM International (1990)
- Aluminum Association Teal Sheets — Alloy 6061 chemical composition limits — The Aluminum Association (2018)
- Sintered aluminium P/M alloy property tables (density-dependent strength data) — FabDigit compilation (2026)
- Aluminium alloy powder spot price levels (SMM / 1688 wholesale listings) (2026)
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.