Key Takeaways:
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Strength Difference: 6061 offers higher tensile strength and is better for machined or heavy-duty parts.
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Finish Quality: 6063 delivers a smoother surface and is ideal for visible extrusions or decorative applications.
- Fabrication Fit: 6061 is preferred for machining, while 6063 is better suited for extrusion details and aesthetic finishes.
Aluminum is one of the most versatile materials used in manufacturing and fabrication, especially when lightweight properties and corrosion resistance are required. Within the 6000-series of aluminum alloys, 6061 and 6063 are two of the most widely used. While they may seem similar at first glance, they perform differently depending on how they’re fabricated and where they’re used. Choosing between them begins with understanding how each alloy behaves in real-world applications, including its strength, machinability, finish, and extrusion performance.
At Testrite Aluminum, we don’t just supply aluminum tubing and extrusion. We manufacture it in the USA and focus on supporting professionals who build with aluminum every day. We offer raw and pre-finished materials, available in full lengths or cut to length, for customers who prefer to handle fabrication in-house. Our products are used by digital printers, display fabricators, set builders, and manufacturers who need reliable aluminum materials for lightweight frames, fixtures, and custom structures.
In this piece, we’ll compare 6061 and 6063 aluminum and explain how to choose the right alloy for your project based on strength, finish, fabrication method, and application.
Understanding the Difference Between 6061 and 6063 Aluminum
When comparing 6061 vs 6063 aluminum, both fall under the 6000-series, meaning they share magnesium and silicon as primary alloying elements. Despite this, they are suited for different applications due to variations in strength, finish, and machinability.
6061 aluminum offers higher strength and good machinability. CNC shops and industrial manufacturers commonly use it for parts that require drilling, tapping, or welding. It’s a strong choice for those fabricating components in-house, especially when precision and strength are required.
6063 aluminum is softer and more easily extruded than other aluminum alloys. It provides a smoother surface finish, which makes it ideal for visible display elements, frames, and other lightweight applications where appearance is a key factor. It’s popular among manufacturers of retail displays, SEG frames, and decorative elements.
Testrite Aluminum supplies both alloys in raw or pre-finished material, with cut-to-length available. For fabricators comfortable handling their own cutting and assembly, choosing between these alloys depends on whether strength or finish is the priority.
To learn more about working with aluminum tubing, see Learn more about aluminum tubing.
6061 vs 6063 Strength: Which Alloy Handles More Load?
When strength is a deciding factor, 6061 aluminum clearly outperforms 6063. This alloy exhibits higher tensile and yield strengths, making it the superior option for applications where mechanical performance is crucial.
For companies that fabricate in-house, 6061 is often selected for parts that require support for weight, resistance to bending, or the ability to handle stress during use. It’s commonly used in heavy-wall aluminum tubing, where rigidity is more important than surface appearance. This makes it ideal for machining houses and industrial manufacturers that need aluminum that withstands cutting, welding, or post-processing.
6063, in contrast, is softer and more flexible. While it can be used for load-bearing applications in lightweight displays, it's not suitable where high mechanical strength is required. It's more commonly found in extrusions for SEG frames, retail displays, and decorative elements, where visual appeal and weight savings take precedence over structural performance.
Testrite Aluminum offers both 6061 and 6063 in cut-to-length options, allowing customers to select the ideal alloy for their specific strength requirements while maintaining in-house capabilities for drilling, mitering, and assembly.
To explore lightweight tubing options for telescoping or non-structural use, read Why thin-wall aluminum tubing
6061 vs 6063 Machinability: Which is Easier to Work With?
Machinability is a key factor when selecting aluminum, especially for customers who plan to handle fabrication in-house. In this case, 6061 aluminum is generally the better choice. It machines cleanly, holds tight tolerances, and responds well to tapping, drilling, and cutting processes. This makes it ideal for CNC machining houses and manufacturers who require precise results.
While 6063 can be machined, its softer nature often results in more clogging or surface deformation during the cutting process. It’s best suited for simpler fabrication tasks where tight tolerances aren’t critical. For example, 6063 works well in display systems and lightweight extrusions that are cut to length and assembled without requiring significant machining.
Testrite Aluminum supplies heavy-wall tubing in 6061 for customers needing material ready for further fabrication. For more appearance-driven applications with minimal machining, 6063 is available in standard and custom finishes.
If you're considering materials for telescopic systems, see our article on Benefits of .058 wall for telescopic tubing applications
6061 vs 6063 Corrosion Resistance for Aluminum Fabricators
Both 6061 and 6063 aluminum exhibit good corrosion resistance due to their magnesium-silicon composition. However, 6063 typically performs slightly better in environments where surface corrosion is a concern, especially when anodized. This makes it a strong option for displays, frames, and non-structural applications that require a clean, long-lasting finish.
6061, while still corrosion resistant, has a slightly higher copper content, which can reduce its resistance in harsh or marine environments. That said, for most indoor or general-use applications, 6061 holds up well, particularly when powder-coated or anodized.
Fabricators often choose 6063 for its superior surface finish and anodizing quality, while 6061 is selected when mechanical performance takes priority, and finishing is secondary.
Testrite Aluminum offers custom powder-coated aluminum tubing, available in both 6061 and 6063 alloys, providing customers with flexibility based on their performance and visual requirements.
For more information on finishing options, visit: Custom powder-coated aluminum tubing.
How 6061 vs 6063 Impacts Extrusion and Surface Finish
For aluminum extrusion, 6063 is the preferred alloy when surface finish and profile complexity are essential considerations. It offers better flow during extrusion, resulting in smoother finishes and cleaner details. This makes it ideal for applications such as SEG extrusion, retail display frames, and other visible structures where appearance is a top priority.
6061 can also be extruded, but it does not flow as easily as 6063. This can result in rougher surfaces and reduced precision in complex shapes. However, its higher strength makes it suitable for simpler profiles that will be machined, drilled, or welded after extrusion.
Fabricators who prioritize appearance often choose 6063 for its cleaner lines and better anodizing response. Those who need greater strength or plan to do post-processing may opt for 6061 instead.
Testrite Aluminum offers both 6061 and 6063 in raw or pre-finished options, including cut-to-length material for professionals handling their own fabrication.
Choosing Between 6061 and 6063 for SEG Extrusion Applications
For companies fabricating their own SEG frames, the choice between 6061 and 6063 aluminum directly affects both the appearance and functionality of the final product. 6063 is typically the preferred alloy for SEG extrusion due to its smooth surface finish and excellent extrudability. It produces clean, consistent profiles that are ideal for visual display systems.
Manufacturers in digital printing, event production, and retail display often opt for 6063 when a high-quality finish is crucial. It also performs well with anodizing and powder coating, helping produce frames that meet visual standards in branded environments.
6061 is a better fit for SEG frame systems that require greater strength or added rigidity. While it may not provide the same surface finish as 6063, it holds up better in demanding conditions or where frames may be reused or reconfigured regularly. It also machines well, making it a solid option for buyers who plan to drill, cut, or modify their extrusions post-purchase.
Testrite Aluminum offers cut-to-length SEG extrusion in both 6061 and 6063 alloys, allowing customers to select the alloy that best matches their project’s performance and fabrication requirements.
Best Uses for 6061 vs 6063 in Aluminum Tubing
Understanding how 6061 and 6063 perform in tubing applications helps fabricators choose the right alloy based on strength, machinability, and finish requirements.
6061 aluminum tubing is ideal for applications that require durability, rigidity, and post-processing. It’s frequently used by CNC machining shops and industrial manufacturers that handle operations such as drilling, mitering, and tapping in-house. Its strength makes it suitable for heavy wall tubing, where added support and dimensional stability are required during machining or fabrication.
On the other hand, 6063 aluminum tubing is a better choice for lightweight, decorative, or visible structures. It’s commonly used in telescoping tubing, store fixtures, retail displays, and non-load-bearing frames. Its excellent surface finish also makes it ideal for anodized or powder-coated finishes in customer-facing environments.
For projects where tubing needs to telescope smoothly, 6063 provides a better fit and slide due to its softness and uniform extrusion. When strength is more important than surface appearance or slide, 6061 is the better option.
Testrite Aluminum offers both alloys in various diameters and wall thicknesses, including .058 and .065 wall tubing. Tubes are sold in full lengths or cut to length, depending on your needs and fabrication setup.
Selecting the Right Alloy for Your In-House Fabrication Needs
When deciding between 6061 and 6063 aluminum, the best choice depends on your fabrication process, performance requirements, and the end-use application.
Choose 6061 if your application demands strength, durability, and compatibility with machining. It performs well in heavy-wall tubing, machined parts, and components that require post-processing, such as drilling or welding. It’s well-suited for manufacturers who prefer to handle all aspects of fabrication internally.
Choose 6063 if surface finish, appearance, or ease of extrusion is a priority. It’s the go-to alloy for SEG frames, retail displays, decorative tubing, and telescoping systems, especially when anodizing or powder coating will be applied.
At Testrite Aluminum, we supply both alloys in a wide range of tubing and extrusion profiles. Materials are available in raw or pre-finished form and can be cut to length to meet your specific production needs. All subsequent fabrication, including mitering, drilling, and assembly, is handled by the customer.
If you're unsure which alloy suits your project, review the product specifications and fabrication notes carefully. Accessories, bracket compatibility, and finishing options can all vary based on the alloy and profile selected.
Final Thoughts
Choosing between 6061 and 6063 aluminum ultimately depends on the specific needs of your project. For teams focused on high-strength parts and in-house machining, 6061 is often the right fit. For applications where appearance and extrusion quality matter more, 6063 delivers consistent results.
Testrite Aluminum offers both alloys in raw and pre-finished forms, with cut-to-length service to support your fabrication process. Whether you're building SEG frames, retail fixtures, or lightweight aluminum structures, selecting the right material is crucial to achieving efficiency and optimal performance.
Read also:
- Build Fast with 1" Square Tubing and Press‑Fit Plastic Corners
- Custom Powder Coated Aluminum Tubing
- Why Retailers Prefer Testrite’s 1” OC Aluminum Slatwall
Frequently Asked Questions About 6061 vs 6063 Aluminum
What is the primary chemical difference between 6061 and 6063 aluminum?
6061 contains slightly more magnesium and significantly more copper than 6063, which contributes to its higher strength but slightly reduces corrosion resistance.
Can 6061 and 6063 be welded together in the same frame or structure?
Yes, they can be welded together, but it's essential to match filler materials appropriately and understand that their post-weld characteristics may differ.
Is there a price difference between 6061 and 6063 aluminum?
6063 is generally less expensive than 6061 due to its softer composition and easier extrudability, but prices vary depending on finish, cut length, and wall thickness.
Which alloy is better suited for bending applications?
6063 is generally better suited for bending due to its higher ductility, whereas 6061 is more prone to cracking unless properly heat-treated or annealed.
Are 6061 and 6063 both suitable for anodizing?
Yes, both can be anodized, but 6063 yields a smoother and more uniform finish, making it preferable for visible or decorative applications.
Do 6061 and 6063 have the same availability in tubing and extrusion profiles?
6063 is more commonly used in custom extrusion profiles due to its extrudability, while 6061 is widely available in standard tubing and bar stock forms.
Can I use 6063 for load-bearing aluminum tubing in a display?
6063 can support light loads in display applications, but if strength is critical, 6061 is a safer choice due to its higher tensile strength.
How do I determine if I need a wall thickness of .058 vs. .065 with these alloys?
Wall thickness depends on load, span, and intended use. A wall thickness of .058 is better for telescoping and lightweight assemblies; a wall thickness of .065 offers more durability.
Are both alloys available in powder-coated finishes?
Yes, Testrite Aluminum offers both 6061 and 6063 in powder-coated finishes. 6063 provides a smoother finish, while 6061 offers better durability under stress.
Is heat treatment required for 6061 or 6063 before use?
Both are typically used in the T5 or T6 temper. 6061-T6 is common for maximum strength, while 6063-T5 is standard for extrusion and finishing applications.
