2011-T3 / T8
Free-machining alloy with lead and bismuth that break chips into small pieces. The first choice for high-volume screw-machine parts such as fittings and nuts. Poor corrosion resistance and not weldable.
Long products
Aluminium Hexagonal Bar
Aluminium hexagonal bar is extruded or cold-drawn bar with six equal flats, sized by the distance across the flats. It is the starting stock for nuts, fittings, standoffs and turned parts, where the hex form saves a milling operation. Metline supplies hex bar in free-machining, structural and high-strength grades, cut and certified, to customers worldwide.
- Size basis
- Across flats (AF)
- Common grades
- 6061, 6082, 2011, 7075
- Routes
- Extruded or cold drawn
- Standards
- ASTM B211 · B221 · EN 754 / 755
What is aluminium hex bar?
Hex bar is a long product whose cross-section is a regular hexagon. Its nominal size is the distance across the flats (AF), which matches the spanner size of the finished part. The distance across the corners is always about 1.155 times larger, a detail that matters when you check whether the bar will pass through a lathe collet or bar feeder.
Buyers choose hex rather than round bar when the finished part needs flats for a spanner, a locking feature or an anti-rotation face. Starting from hex removes the milling step on every part, which on high-volume screw-machine work saves more than the small premium hex bar carries over round bar. Typical products are hydraulic and pneumatic fittings, hex nuts and spacers, electrical standoffs, couplings, valve bodies and knurled knobs.
Hex bar is made in two ways. Extruded bar is pushed through a hexagonal die and covers the widest size range. Cold-drawn (cold-finished) bar is extruded first and then drawn through a die to tighten tolerances, sharpen corners and improve surface finish. Drawn bar is preferred for automatic lathes and bar feeders, where consistent size keeps collets gripping evenly.
Hex bar grades and what each is for
6061-T6 / T6511
General-purpose structural alloy with good machinability, corrosion resistance and anodising response. Weldable. The most widely stocked hex grade outside Europe.
6082-T6
European structural equivalent of 6061, slightly stronger in thicker sections. Common for fittings and machined parts across Europe and the Middle East.
2014-T6 / 2017-T4
High-strength copper alloys for heavily loaded machined parts and fasteners. Machine well; need protection against corrosion.
7075-T6 / T651
Highest-strength common hex grade for aerospace fittings, motorsport parts and tooling. Excellent machinability, limited weldability.
5083-H111 / H112
Non-heat-treatable marine alloy for fittings and fasteners exposed to seawater. Lower strength, excellent corrosion resistance.
Lead-containing free-machining grades such as 2011 are restricted in some markets. Where RoHS or end-of-life vehicle rules apply, ask about lead-free free-machining alternatives such as 6026, or use 6061/6082 with chip-breaking tooling.
Chemical composition of common hex bar grades (wt %)
Limits follow the Aluminum Association registrations and EN 573-3. Maximums are shown where there is no minimum.
| Element | 2011 | 6061 | 6082 | 7075 |
|---|---|---|---|---|
| Silicon (Si) | ≤ 0.40 | 0.40 – 0.80 | 0.70 – 1.30 | ≤ 0.40 |
| Iron (Fe) | ≤ 0.70 | ≤ 0.70 | ≤ 0.50 | ≤ 0.50 |
| Copper (Cu) | 5.0 – 6.0 | 0.15 – 0.40 | ≤ 0.10 | 1.2 – 2.0 |
| Manganese (Mn) | — | ≤ 0.15 | 0.40 – 1.0 | ≤ 0.30 |
| Magnesium (Mg) | — | 0.80 – 1.20 | 0.60 – 1.20 | 2.1 – 2.9 |
| Chromium (Cr) | — | 0.04 – 0.35 | ≤ 0.25 | 0.18 – 0.28 |
| Zinc (Zn) | ≤ 0.30 | ≤ 0.25 | ≤ 0.20 | 5.1 – 6.1 |
| Lead (Pb) / Bismuth (Bi) | 0.20 – 0.6 each | — | — | — |
| Aluminium | Remainder | Remainder | Remainder | Remainder |
Mechanical properties of hex bar by grade and temper
Typical values are what the material usually achieves; specified minimums are what the standard guarantees and should be used for design. Minimums vary with section size, so the governing value is the one on the mill certificate for your size.
| Grade / temper | Tensile strength | Yield strength (0.2 %) | Elongation | Machinability |
|---|---|---|---|---|
| 2011-T3 | 379 MPa | 296 MPa | 15 % | Excellent (free machining) |
| 2011-T8 | 407 MPa | 310 MPa | 12 % | Excellent |
| 2014-T6 | 483 MPa | 414 MPa | 13 % | Good |
| 2017-T4 | 427 MPa | 276 MPa | 22 % | Good |
| 6061-T6 | 310 MPa | 276 MPa | 12 – 17 % | Good |
| 6082-T6 (EN 755-2 min., ≤ 20 mm) | 295 MPa | 250 MPa | 8 % | Good |
| 7075-T6 | 572 MPa | 503 MPa | 11 % | Very good |
| 5083-H111 (EN 755-2 min.) | 270 MPa | 110 MPa | 12 % | Fair (gummy) |
Typical values from Aluminum Association and ASM data unless marked as EN 755-2 minimums. Density is 2.70 g/cm³ for 6061 and 6082, 2.81 g/cm³ for 7075 and 2.83 g/cm³ for 2011.
Hex bar standards and tolerances
| Standard | Scope | Use it for |
|---|---|---|
| ASTM B211 / ASME SB-211 | Cold-finished bar, rod and wire | Drawn hex for screw machines (2011, 2024, 6061, 7075) |
| ASTM B221 / ASME SB-221 | Extruded bar, rod, wire, profiles and tubes | Extruded hex in all common grades |
| ANSI H35.2 | Dimensional tolerances for aluminium mill products | Tolerances for ASTM orders |
| EN 754-2 / EN 755-2 | Mechanical properties, drawn and extruded bar | European orders |
| EN 754-6 | Tolerances for cold-drawn hexagonal bar | Drawn hex to EN |
| EN 755-6 | Tolerances for extruded hexagonal bar | Extruded hex to EN |
| SAE AMS (various) | Aerospace bar specifications | Aerospace hex in 2024, 6061, 7075 |
Drawn hex bar holds noticeably tighter across-flats tolerances and sharper corners than extruded bar. Extruded hex has slightly rounded corners and a wider tolerance band, but it is available in larger sizes. For automatic lathes and collet-fed machines, drawn bar is worth the small premium; for manual machining and large sizes, extruded is usually fine.
Hex bar sizes and weight per metre
Supply range
- Metric sizes
- From about 6 mm to 100 mm across flats; larger sizes extruded on request
- Imperial sizes
- From 1/4 in to 4 in across flats
- Lengths
- Random mill lengths of about 3 – 4 m, fixed lengths, or cut pieces
- Tempers
- T3, T351, T4, T6, T651, T6511, T8, H111, H112 depending on alloy
- Surface
- Mill finish, drawn bright finish, or anodised on request
The cross-sectional area of a hexagon is 0.866 × AF². Multiply by the density to get weight: for 6061 or 6082 at 2.70 g/cm³, weight in kg/m = 0.002338 × AF² (AF in mm). For 7075, multiply the figures below by 1.04; for 2011, by 1.05.
| Across flats (mm) | Across corners (mm) | Area (mm²) | Weight 6061 / 6082 (kg/m) |
|---|---|---|---|
| 6 | 6.9 | 31 | 0.084 |
| 8 | 9.2 | 55 | 0.150 |
| 10 | 11.5 | 87 | 0.234 |
| 12 | 13.9 | 125 | 0.337 |
| 13 | 15.0 | 146 | 0.395 |
| 14 | 16.2 | 170 | 0.458 |
| 17 | 19.6 | 250 | 0.676 |
| 19 | 21.9 | 313 | 0.844 |
| 22 | 25.4 | 419 | 1.132 |
| 24 | 27.7 | 499 | 1.347 |
| 27 | 31.2 | 631 | 1.705 |
| 30 | 34.6 | 779 | 2.104 |
| 32 | 37.0 | 887 | 2.394 |
| 36 | 41.6 | 1122 | 3.030 |
| 41 | 47.3 | 1456 | 3.931 |
| 46 | 53.1 | 1833 | 4.948 |
| 50 | 57.7 | 2165 | 5.846 |
| 55 | 63.5 | 2620 | 7.073 |
| 60 | 69.3 | 3118 | 8.418 |
| 70 | 80.8 | 4244 | 11.458 |
| 80 | 92.4 | 5543 | 14.965 |
| 100 | 115.5 | 8660 | 23.383 |
Machining, anodising and fabrication notes
Turning
Use sharp, polished carbide or HSS tools with high positive rake. 2011 and 7075 give short chips; 6061 and 6082 benefit from chip-breaker geometry to avoid long strings on bar feeders.
Threading
Hex bar is often made into threaded fittings. 2011, 2014 and 7075 hold fine threads well; for 6061 use roll-formed threads where possible for better fatigue strength.
Anodising
6061 and 6082 anodise to a clear, even finish. 2011 and 2014 anodise poorly because of their copper content; 7075 anodises well, including hard anodising.
Welding
6061, 6082 and 5083 weld readily with 4043 or 5356 filler. 2011 and 7075 are not recommended for fusion welding.
Corrosion
Copper-bearing 2011, 2014 and 7075 need anodising or coating outdoors. 5083 and 6082 suit marine and humid service.
Collet fit
Size collets by across-flats dimension. Remember across-corners is 1.155 × AF when checking spindle bore and bar feeder clearance.
Where hex bar is used
- Fluid power: hydraulic and pneumatic fittings, adaptors, manifolds and valve bodies
- Fasteners: hex nuts, spacers, standoffs and coupling nuts
- Electrical and electronics: PCB standoffs, terminal posts and earthing fittings
- Automotive and motorsport: AN fittings, brake and fuel line connectors, suspension parts
- Marine: deck hardware and fittings in 5083 or anodised 6082
- Instruments and consumer products: knobs, handles, pen bodies and camera accessories
How to order aluminium hex bar
- SpecifyGrade and temper, size across flats with unit, extruded or drawn, length (mill, fixed or cut), quantity and the governing standard (ASTM B211, B221, EN 754 or EN 755).
- QuoteWe confirm alloy, temper, tolerances, certification, packing and delivery terms (EXW, FOB, CIF or DAP) for your destination.
- ProcessBars are cut to length, checked for across-flats size, straightness and surface, and bundled with end identification.
- DocumentEach delivery carries a mill test certificate to EN 10204 3.1 with the cast analysis and mechanical results; third-party inspection can be arranged on request.
- ShipBundled, interleaved or crated for export and shipped by sea or air on EXW, FOB, CIF or DAP terms.
References and standards
- ASTM B211 – Standard Specification for Aluminum and Aluminum-Alloy Rolled or Cold-Finished Bar, Rod, and Wire
- ASTM B221 – Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
- EN 754-6 – Cold drawn rod/bar and tube: hexagonal bars, tolerances on dimensions and form
- EN 755-6 – Extruded rod/bar, tube and profiles: hexagonal bars, tolerances on dimensions and form
- The Aluminum Association – International Alloy Designations and Chemical Composition Limits for Wrought Aluminum (Teal Sheets)
Aluminium (aluminum) hex bar: FAQ
How is aluminium hex bar measured?
Across the flats (AF), the distance between two opposite parallel faces. This equals the spanner size of the finished part. The across-corners dimension is about 1.155 × AF.
How much does aluminium hex bar weigh?
For 6061 or 6082, weight in kg per metre is 0.002338 × AF² with AF in mm. A 24 mm AF bar weighs about 1.35 kg/m and a 50 mm AF bar about 5.85 kg/m.
Which aluminium hex bar is easiest to machine?
2011-T3 is the classic free-machining grade, producing small broken chips at high speeds. 7075-T6 also machines very well. 6061-T6 and 6082-T6 machine well but produce longer chips unless chip-breaking tools are used.
What is the difference between drawn and extruded hex bar?
Drawn bar has tighter across-flats tolerances, sharper corners and a brighter surface, which suits automatic lathes. Extruded bar has slightly rounded corners and wider tolerances but comes in larger sizes.
Which hex bar grade should I use in seawater?
5083 or a well-anodised 6082 / 6061. Avoid 2011, 2014 and 7075 in marine service unless they are fully protected, because their copper content lowers corrosion resistance.
Can you supply hex bar cut to length?
Yes. Metline supplies aluminium hex bar in mill lengths or cut to your length, with mill test certificates, packed for export to customers worldwide.
Need aluminium hex bar?
Send the grade, temper, size across flats and quantity. We will reply with availability, tolerances, certification and a delivered price.
