Bending
T61 and T64 bend tightly with little cracking risk; T6 and T63 need larger radii. Bend across the rolling or extrusion direction where possible.
Electrical conductor alloy
6101 Aluminium Sheet & Plate
6101 is a heat-treatable Al-Mg-Si alloy designed for electrical conductors: it combines 55 – 60 % IACS conductivity with far more strength than pure EC aluminium. It is best known as busbar extrusion, and 6101 sheet and plate are used for connection plates, flat conductors and switchgear parts cut from flat stock. Metline supplies 6101 in conductor tempers, cut to size, worldwide.
- Alloy
- 6101 (Al-Mg-Si, high purity)
- Tempers
- T6, T61, T63, T64, T65
- Conductivity
- 55 – 60 % IACS
- Busbar standard
- ASTM B317
What is 6101 aluminium?
6101 contains roughly 0.5 % magnesium and 0.5 % silicon, with very tight limits on the elements that hurt conductivity: manganese and chromium are held to 0.03 % maximum, and boron may be added to tie up trace transition metals. After ageing, almost all of the magnesium and silicon is out of solution as fine Mg2Si precipitates, so the aluminium matrix conducts nearly as well as pure metal while the precipitates provide strength.
This makes 6101 the standard choice where a conductor must also carry mechanical load: busbars that span between supports, bolted joints that must not creep, and connection plates in switchgear, transformers and battery systems. Pure 1350 aluminium conducts better (about 61 % IACS) but has little strength; 6101 trades a few points of conductivity for three to four times the yield strength.
The temper is the main specification decision. Each 6101 temper is aged to a different point on the strength–conductivity curve, so specify both the temper and the minimum conductivity on the order.
6101 chemical composition (wt %)
| Element | Minimum | Maximum |
|---|---|---|
| Silicon (Si) | 0.30 | 0.70 |
| Iron (Fe) | — | 0.50 |
| Copper (Cu) | — | 0.10 |
| Manganese (Mn) | — | 0.03 |
| Magnesium (Mg) | 0.35 | 0.80 |
| Chromium (Cr) | — | 0.03 |
| Zinc (Zn) | — | 0.10 |
| Boron (B) | — | 0.06 |
| Others, each / total | — | 0.03 / 0.10 |
| Aluminium (Al) | Remainder |
Aluminum Association limits. EN AW-6101B, used for European busbar, has slightly different limits; tell us which designation your drawing uses.
6101 strength and conductivity by temper
Approximate minimum values for bus conductor product (ASTM B317 basis). Values for sheet and plate cut from rolled stock are agreed against the same targets; the certificate states tested strength and conductivity.
| Temper | Tensile (min) | Yield (min) | Conductivity (min, 20 °C) | Character |
|---|---|---|---|---|
| T6 | 200 MPa | 172 MPa | 55 % IACS | Highest strength |
| T63 | about 185 MPa | about 150 MPa | about 56 % IACS | Strength-biased balance |
| T65 | about 170 MPa | about 140 MPa | about 56.5 % IACS | Intermediate |
| T61 | about 140 MPa | about 105 MPa | about 57 % IACS | Conductivity-biased; good bendability |
| T64 | about 115 MPa | about 60 MPa | about 59.5 % IACS | Highest conductivity; easiest bending |
Physical properties
- Density
- 2.70 g/cm³
- Thermal conductivity
- about 218 W/m·K (T6)
- Resistivity (55 % IACS)
- about 0.0313 Ω·mm²/m at 20 °C
- Modulus of elasticity
- about 69 GPa
- Coefficient of thermal expansion
- 23.4 µm/m·°C
6101 supply range and weights
Supply
- Forms
- Sheet, plate and flat strip; busbar, rod and tube as extrusions
- Thickness
- 2 – 50 mm for flat stock
- Sizes
- Cut-to-size plates, strips and blanks to drawing
- Surface
- Mill finish; tin or silver plating of contact areas arranged on request
| Thickness (mm) | kg per m² | 1250 × 2500 mm (kg) | 1500 × 3000 mm (kg) |
|---|---|---|---|
| 2 | 5.40 | 16.9 | 24.3 |
| 3 | 8.10 | 25.3 | 36.5 |
| 4 | 10.80 | 33.8 | 48.6 |
| 5 | 13.50 | 42.2 | 60.8 |
| 6 | 16.20 | 50.6 | 72.9 |
| 8 | 21.60 | 67.5 | 97.2 |
| 10 | 27.00 | 84.4 | 121.5 |
| 12 | 32.40 | 101.3 | 145.8 |
| 16 | 43.20 | 135.0 | 194.4 |
| 20 | 54.00 | 168.8 | 243.0 |
| 25 | 67.50 | 210.9 | 303.8 |
| 30 | 81.00 | 253.1 | 364.5 |
Bending, joining and design notes
Bolted joints
Clean and abrade contact faces, apply contact grease and use spring washers or Belleville washers to keep pressure as the joint heats and cools. 6101 creeps much less than 1350, which is why it suits bolted joints.
Welding
TIG and MIG weldable with 4043 filler; welds have lower conductivity and strength than the parent metal, so most conductor joints are bolted or friction-welded.
Temperature
Continuous operating temperatures above about 100 – 120 °C slowly over-age the alloy; check the busbar temperature rise in your design.
Sizing a conductor by resistance alone is not enough: joint resistance, skin effect at higher currents and allowable temperature rise usually decide the final cross-section.
Where 6101 is used
- Switchgear and panels: busbars, connection plates and droppers
- Substations: rigid bus conductors and tubular bus
- Transformers and rectifiers: terminals and flat conductors
- EV and battery systems: busbars and interconnects
- Data centres: busway and power distribution conductors
How to order 6101
- SpecifyAlloy and temper (for example 6101-T61, minimum 57 % IACS), thickness, width and length or a drawing, quantity, and the governing standard (ASTM B317 targets or your drawing).
- QuoteWe confirm availability, tolerances, certification and delivery terms (EXW, FOB, CIF or DAP) for your destination.
- ProcessPlate is saw-cut or waterjet-cut to size where required, film-protected on request and inspected for dimensions and surface.
- DocumentEach shipment carries a mill test certificate to EN 10204 3.1 with chemistry and mechanical results, plus the packing list; third-party inspection can be arranged.
- ShipSeaworthy wooden cases or fumigated pallets, dispatched by sea or air to your port or door.
References and standards
- ASTM B317/B317M – Aluminum-Alloy Extruded Bar, Rod, Pipe and Structural Shapes for Electrical Purposes (Bus Conductor)
- The Aluminum Association – International Alloy Designations and Chemical Composition Limits
- The Aluminum Association – Aluminum Electrical Conductor Handbook
- EN 573-3 – Chemical composition and form of wrought products
6101 aluminium (aluminum): FAQ
What is the conductivity of 6101 aluminium?
Between about 55 % IACS (T6) and about 59.5 % IACS (T64), depending on temper. Pure 1350 aluminium is about 61 % IACS.
Which 6101 temper should I choose for busbar?
T6 or T63 where the bar must carry mechanical load; T61 or T64 where conductivity and tight bends matter more than strength.
Is 6101 better than 6063 for busbar?
6101 is made to tighter impurity limits and is certified for conductivity, so it reaches higher guaranteed conductivity. 6063 is sometimes used where cost matters and lower conductivity is acceptable.
Can 6101 plate be supplied as sheet rather than extrusion?
Yes, flat 6101 sheet and plate can be supplied to order and cut into connection plates and conductors.
Can 6101 be plated?
Yes. Contact areas are often tin- or silver-plated to lower and stabilise contact resistance.
Need 6101 conductor plate or busbar?
Send the temper, minimum conductivity, size and quantity. We will confirm availability and a delivered price.
