Cutting speed
Aluminium tolerates very high surface speeds; with carbide, several hundred metres per minute is normal. Machine rigidity and chip evacuation are usually the limit, not the tool.
Round rod for turned parts and shafts
6061 Aluminium Round Bar & Rod
6061 round bar is the most widely used aluminium rod for turned parts, shafts, pins and bushings: strong in T6, easy to machine and suitable for anodising and welding. Metline supplies 6061 rod from about 3 to 300 mm (1/8 to 12 in) diameter as extruded T6511, cold-finished T6 or turned and ground bar, cut to length and certified, to customers worldwide.
- Alloy
- 6061
- Tempers
- T6, T651, T6511, T4, O
- Diameter
- about 3 – 300 mm
- Standards
- ASTM B211 · B221 · EN 754-2 / 755-2
What makes 6061 round bar so widely used?
A turned part starts as a length of round bar, so the bar's diameter tolerance, straightness, internal stress and machinability decide how much work and scrap the part costs. 6061 performs well on all four: it is available in very tight cold-finished tolerances, it is straightened and often stress-relieved by stretching, and in T6 it cuts with short chips and a bright finish.
It is also a material that survives real service. 6061-T6 has a typical tensile strength of about 310 MPa, good resistance to atmospheric corrosion, and it anodises evenly, which matters for visible parts such as knobs, spacers, rollers and camera hardware. Free-machining alloys like 2011 cut faster, but they corrode more readily and cannot be welded; 7075 is stronger but costs more. 6061 sits in the middle and covers most jobs.
Round bar is produced three ways, and choosing the right one is the most useful decision a buyer can make: extruded bar for general machining and large diameters, cold-finished (drawn) bar for close-tolerance small diameters, and turned, peeled or precision-ground bar when the outside diameter is used as finished.
6061 composition (wt %)
Composition limits per the Aluminum Association registration, ASTM B211 / B221 and EN 573-3. Each lot's analysis is on the certificate.
| Element | Minimum | Maximum |
|---|---|---|
| Magnesium (Mg) | 0.80 | 1.20 |
| Silicon (Si) | 0.40 | 0.80 |
| Copper (Cu) | 0.15 | 0.40 |
| Chromium (Cr) | 0.04 | 0.35 |
| Iron (Fe) | — | 0.70 |
| Manganese (Mn) | — | 0.15 |
| Zinc (Zn) | — | 0.25 |
| Titanium (Ti) | — | 0.15 |
| Others, each / total | — | 0.05 / 0.15 |
| Aluminium (Al) | Remainder |
Mechanical properties of 6061 round bar
| Product, temper and standard | Tensile min. | Yield min. | Elongation min. |
|---|---|---|---|
| Cold-finished rod T6 / T651, ASTM B211 | 290 MPa / 42 ksi | 240 MPa / 35 ksi | 10 % |
| Extruded rod T6 / T6511, ASTM B221 | 260 MPa / 38 ksi | 240 MPa / 35 ksi | 8 – 10 % |
| Drawn round bar T6, EN 754-2 (≤ 80 mm) | 290 MPa | 240 MPa | 10 % |
| Extruded round bar T6, EN 755-2 (≤ 200 mm) | 260 MPa | 240 MPa | 8 % |
| Cold-finished T4, ASTM B211 | 207 MPa / 30 ksi | 110 MPa / 16 ksi | 18 % |
| Typical T6 | 310 MPa | 276 MPa | 12 – 17 % |
Minimums apply to the size bands in each standard; the certificate lists the values for your diameter. For very large diameters, quench rate limits through-thickness properties, and some standards allow reduced values.
Physical properties of 6061-T6
- Density
- 2.70 g/cm³ (0.0975 lb/in³)
- Modulus of elasticity
- 68.9 GPa (10,000 ksi)
- Shear strength (typical)
- 207 MPa (30 ksi)
- Thermal conductivity
- 167 W/m·K
- Electrical conductivity
- 43 % IACS
- Coefficient of thermal expansion
- 23.6 µm/m·°C (20 – 100 °C)
- Melting range
- 582 – 652 °C
Extruded, cold-finished or ground: which 6061 rod?
| Route | Typical diameters | Diameter tolerance | Surface | Best for |
|---|---|---|---|---|
| Extruded T6 / T6511 | about 10 – 300 mm | Standard extruded (wider) | Mill finish, may show die lines | Parts machined all over, large diameters |
| Cold-finished (drawn) T6 / T651 | about 3 – 50 mm | Close (cold-finished tables) | Bright, smooth | Screw-machine and CNC lathe parts |
| Peeled / turned | about 20 – 300 mm | Close, set by turning | Turned, free of extrusion skin | Large bar where skin defects must be removed |
| Precision ground | about 6 – 100 mm | ISO h9 or h8 class by agreement | Ground, very straight | Guide rods, shafts, pistons, rollers |
Tolerances for extruded and cold-finished rod are set in ANSI H35.2 for ASTM orders and in EN 755-3 (extruded round bar) and EN 754-3 (drawn round bar) for EN orders. Cold-finished rod is typically held to a small fraction of the extruded tolerance at the same diameter. If your drawing gives a fit class (for example h9), state it on the order so the bar can be ground or selected to suit.
6061 round bar sizes and weights
Weight per metre = 0.002121 × d² kg (d in mm, density 2.70 g/cm³). Theoretical values; use the bar weight calculator for any other size.
| Diameter (mm) | Approx. inch | kg per metre | kg per 3 m bar | lb per foot |
|---|---|---|---|---|
| 3 | 0.12 | 0.019 | 0.06 | 0.013 |
| 5 | 0.20 | 0.053 | 0.16 | 0.036 |
| 6 | 0.24 | 0.076 | 0.23 | 0.051 |
| 8 | 0.31 | 0.136 | 0.41 | 0.091 |
| 10 | 0.39 | 0.212 | 0.64 | 0.142 |
| 12 | 0.47 | 0.305 | 0.92 | 0.205 |
| 14 | 0.55 | 0.416 | 1.25 | 0.279 |
| 16 | 0.63 | 0.543 | 1.63 | 0.365 |
| 18 | 0.71 | 0.687 | 2.06 | 0.462 |
| 20 | 0.79 | 0.848 | 2.54 | 0.570 |
| 22 | 0.87 | 1.03 | 3.08 | 0.690 |
| 25 | 0.98 | 1.33 | 3.98 | 0.891 |
| 28 | 1.10 | 1.66 | 4.99 | 1.117 |
| 30 | 1.18 | 1.91 | 5.73 | 1.282 |
| 32 | 1.26 | 2.17 | 6.51 | 1.459 |
| 35 | 1.38 | 2.60 | 7.79 | 1.746 |
| 40 | 1.57 | 3.39 | 10.18 | 2.280 |
| 45 | 1.77 | 4.29 | 12.88 | 2.886 |
| 50 | 1.97 | 5.30 | 15.90 | 3.562 |
| 55 | 2.17 | 6.41 | 19.24 | 4.311 |
| 60 | 2.36 | 7.63 | 22.90 | 5.130 |
| 65 | 2.56 | 8.96 | 26.88 | 6.020 |
| 70 | 2.76 | 10.39 | 31.17 | 6.982 |
| 75 | 2.95 | 11.93 | 35.78 | 8.015 |
| 80 | 3.15 | 13.57 | 40.72 | 9.120 |
| 90 | 3.54 | 17.18 | 51.53 | 11.542 |
| 100 | 3.94 | 21.21 | 63.62 | 14.250 |
| 110 | 4.33 | 25.66 | 76.98 | 17.242 |
| 120 | 4.72 | 30.54 | 91.61 | 20.519 |
| 130 | 5.12 | 35.84 | 107.5 | 24.082 |
| 150 | 5.91 | 47.71 | 143.1 | 32.062 |
| 160 | 6.30 | 54.29 | 162.9 | 36.479 |
| 180 | 7.09 | 68.71 | 206.1 | 46.169 |
| 200 | 7.87 | 84.82 | 254.5 | 56.999 |
| 250 | 9.84 | 132.54 | 397.6 | 89.060 |
| 300 | 11.81 | 190.85 | 572.6 | 128.247 |
Inch diameters, as commonly ordered for ASTM and AMS work:
| Diameter (in) | Diameter (mm) | lb per foot | kg per metre |
|---|---|---|---|
| 1/4 | 6.35 | 0.057 | 0.086 |
| 3/8 | 9.52 | 0.129 | 0.192 |
| 1/2 | 12.70 | 0.230 | 0.342 |
| 5/8 | 15.88 | 0.359 | 0.534 |
| 3/4 | 19.05 | 0.517 | 0.770 |
| 7/8 | 22.22 | 0.704 | 1.05 |
| 1 | 25.40 | 0.919 | 1.37 |
| 1-1/4 | 31.75 | 1.436 | 2.14 |
| 1-1/2 | 38.10 | 2.068 | 3.08 |
| 1-3/4 | 44.45 | 2.815 | 4.19 |
| 2 | 50.80 | 3.677 | 5.47 |
| 2-1/2 | 63.50 | 5.746 | 8.55 |
| 3 | 76.20 | 8.274 | 12.31 |
| 3-1/2 | 88.90 | 11.262 | 16.76 |
| 4 | 101.60 | 14.709 | 21.89 |
| 5 | 127.00 | 22.983 | 34.20 |
| 6 | 152.40 | 33.096 | 49.25 |
| 7 | 177.80 | 45.047 | 67.04 |
| 8 | 203.20 | 58.837 | 87.56 |
| 10 | 254.00 | 91.933 | 136.81 |
| 12 | 304.80 | 132.383 | 197.01 |
Lengths and processing
- Standard lengths
- 3 – 3.66 m (10 – 12 ft); up to 6 m for extruded bar
- Cut pieces
- Saw-cut blanks to length, square ends, deburred
- Marking and packing
- End-marked with alloy, temper and lot; bundled or boxed, export cased
Turning and machining 6061 rod
Tool geometry
Use sharp, polished inserts with high positive rake and a large relief angle to prevent built-up edge and smearing.
Chip control
T6 gives short, curled chips; O and T4 produce long stringy chips that need chip breakers.
Distortion
For long slender parts or deep bores, use T6511 or T651 bar and rough-machine before finishing to release remaining stress.
Coolant
Water-soluble coolant with good lubricity improves finish and tool life; mist or MQL works for light cuts.
Finishing
Anodise after machining. Hard anodising adds wear resistance for shafts and pistons; allow for coating growth on fits.
Standards and equivalents for 6061 rod
| System | Designation | Round bar standard |
|---|---|---|
| ASTM / ASME | 6061 | ASTM B211 (cold-finished), ASTM B221 (extruded), SB-211 / SB-221 |
| SAE AMS | 6061-T6 / T651 / T6511 | AMS 4117 (cold-finished), AMS 4150 and AMS 4173 (extruded) |
| UNS | A96061 | — |
| European | EN AW-6061 (AlMg1SiCu) | EN 754-2 (drawn), EN 755-2 (extruded) |
| Germany | Werkstoff 3.3211 | DIN EN 754 / 755 |
| Japan | A6061 | JIS H4040 |
| China | 6061 | GB/T 3191 |
| India | 65032 | IS 733 |
Applications of 6061 round bar
- Shafts and rollers: conveyor rollers, idler shafts, light drive shafts and guide rods
- Turned components: bushings, spacers, knobs, pulleys, pistons for pneumatic cylinders
- Fasteners: pins, rivets, clevis pins and threaded studs
- Optics and electronics: lens barrels, sensor housings and heat-sink pins
- Transport and marine: fittings, hinge pins and brackets (anodised for marine use)
- Sports and leisure: bicycle axles and components, fishing reel parts, climbing hardware
6061 rod compared with 6082, 2011, 7075 and 5083 rod
| Alloy and temper | Typical yield | Machinability | Corrosion | Weldability |
|---|---|---|---|---|
| 6061-T6 | 276 MPa | Good | Good | Good |
| 6082-T6 | about 280 – 300 MPa | Good | Good | Good |
| 2011-T3 | about 295 MPa | Excellent | Fair | Poor |
| 7075-T6 | 505 MPa | Very good | Fair | Poor |
| 5083-H111 | about 165 MPa (min.) | Fair | Excellent (seawater) | Excellent |
Pick 6082 when a European standard names it, 7075 when strength governs, and 5083 for welded parts in seawater.
How to order 6061 round bar
- SpecifyAlloy and temper (for example 6061-T6511, 60 mm diameter), shape and size, length or cut pieces, quantity, and the governing standard (ASTM B211, ASTM B221, AMS 4117 or EN 754-2 / 755-2).
- QuoteWe confirm availability, tolerance class, certification and delivery terms (EXW, FOB, CIF or DAP) for your destination.
- ProcessBars are cut to length or to blanks on request, end-marked with alloy, temper and lot number, and inspected for size, straightness and surface.
- DocumentEach shipment carries a mill test certificate to EN 10204 3.1 with chemistry and tensile results, plus the packing list; third-party inspection on request.
- ShipBundles are wrapped and packed in seaworthy wooden cases or on pallets and sent by sea or air to your port or door.
References and standards
- ASTM B211/B211M – Aluminum and Aluminum-Alloy Rolled or Cold Finished Bar, Rod, and Wire
- ASTM B221 – Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
- SAE AMS 4117 – 6061-T6 / T651 rolled or cold-finished bars, rods and wire
- EN 755-3 – Extruded round bars: tolerances on dimensions and form
- The Aluminum Association – Aluminum Standards and Data (ANSI H35.1 / H35.2)
6061 aluminium (aluminum) round bar: frequently asked questions
What is the weight of a 6061 aluminium round bar?
Weight per metre is 0.002121 × d² kg with d in mm. A 20 mm bar weighs about 0.85 kg/m, a 50 mm bar 5.30 kg/m and a 100 mm bar 21.2 kg/m. In inch units, a 1 in bar weighs about 0.92 lb/ft.
Should I buy cold-finished or extruded 6061 rod?
Cold-finished rod has a tighter diameter tolerance and brighter surface and suits parts where the bar OD is used as-is. Extruded rod is cheaper, available in larger diameters and, in T6511, stress-relieved for heavy machining.
Is 6061-T6 round bar strong enough for shafts?
For light and medium duty, yes: typical yield is about 276 MPa and fatigue strength about 96 MPa at 5×10⁸ cycles. For heavily loaded or high-cycle shafts, steel or 7075 may be needed; check deflection too, as aluminium is about one-third as stiff as steel.
Can 6061 round bar be anodised?
Yes. 6061 gives an even clear or coloured anodised finish and accepts hard anodising for wear resistance. Allow for coating build-up on toleranced diameters.
What is the largest 6061 round bar available?
Extruded bar is commonly available up to about 300 mm. Larger diameters are supplied as forged rounds or cut from forged blocks, with properties agreed per order.
Do you supply precision-ground 6061 rod?
Yes, on request. Tell us the diameter, the fit class or tolerance (for example h9) and the straightness you need, and we will confirm what can be supplied.
Need 6061 round bar?
Send diameter, production route, temper, length and quantity. We will reply with availability, certification and a delivered price.
