Aluminum 6061

When machining, choose sharp carbide tools with coatings like TiN or TiAlN for durability. Optimize cutting speeds, balancing efficiency with tool life, and use coolants to dissipate heat and improve chip evacuation. Securely fixturing the workpiece is important to prevent vibrations and ensure accuracy. As aluminum generates long chips, effective chip control is necessary to prevent tool damage. Consider tool path strategies, favoring climbing milling for reduced tool deflection. A smooth finish may require post-machining and deburring, and optional heat treatment can enhance mechanical properties.

6061 is easily weldable through methods like Tungsten Inert Gas (TIG) or Metal Inert Gas (MIG), with post-weld properties resembling 6061-T4. Heat treatment restores the entire piece to near -T6 temper, while natural aging can regain some strength. Without proper treatment, design strength near the weld is recommended at 165 MPa/24000 PSI. This alloy is ideal for extrusions, producing elongated structural shapes. It's also suitable for hot forging, crafting automotive and industrial parts. Although not traditionally cast due to low silicon content, 6061 can be cast using centrifugal methods, which is ideal for larger rings and sleeves.