Aluminum Extrusion Alloys Guide
Choose the right alloy for your extruded profiles
Aluminum extrusion alloy selection revolves around the extrudability–strength tradeoff. Softer alloys flow through complex dies more easily (enabling thinner walls and tighter features) but have lower strength. Understanding this tradeoff is key to cost-effective extrusion design.
Key Selection Factors
Extrudability
How easily the alloy flows through the die — softer alloys allow more complex cross-sections.
Strength (T5 vs T6)
Post-extrusion temper affects mechanical properties. T6 is strongest but requires separate heat treatment.
Surface Quality
As-extruded surface finish and anodizing response. 6063 is the best for decorative finishes.
Weldability
Some alloys lose significant strength in the heat-affected zone after welding.
Dimensional Precision
Straightness, twist, and cross-section tolerances achievable.
Die Cost
Complex profiles need softer alloys. Harder alloys limit die complexity and increase die cost.
Recommended Materials
The most extruded alloy in the world. Best surface finish, highest extrudability, and excellent anodizing response. T5 (air-cooled at press) is standard; T6 adds 15–20% strength.
The structural extrusion standard. 40% stronger than 6063-T6 but harder to extrude through complex dies. Requires separate solution heat treatment + aging for T6 temper.
The "middle ground" between 6063 and 6061. Better extrudability than 6061 with close to 6061 strength. Growing in popularity for structural applications.
💡 Pro Tips
- ▸ 6063 for looks, 6061 for strength, 6005A when you need both. That covers 95% of extrusion projects.
- ▸ Minimum wall thickness: 6063 can go to 0.8mm, 6061 needs 1.2mm+ due to lower extrudability.
- ▸ Die costs range $500–5,000 depending on profile complexity. Amortize over expected volume.
- ▸ T5 temper is "free" — parts are cooled at the press. T6 requires a separate furnace step (adds cost).
- ▸ For anodized parts, always use 6063. 6061 anodizes with a slightly gray/uneven appearance.
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