6061 Aluminium Wire Rod for Rivets and Cold-Headed Fasteners
6061 rivet wire is drawn, precision-sized aluminium wire made for cold heading into solid rivets, blind-rivet bodies, screws and pins. After heat treatment to T6, 6061 rivets combine a typical shear strength of about 207 MPa with very good corrosion resistance, which makes them a standard choice for structural aluminium, marine and transport assemblies. This guide covers tempers, sizes, tolerances, heading practice and how 6061 compares with other rivet alloys.
- Alloy
- 6061 (A96061)
- Tempers
- O, T4, T6
- Diameter
- About 1.6 – 10 mm
- Standard
- ASTM B316
What makes good rivet wire?
A rivet is formed by cold heading: a length of wire is cut and upset in a die to form the head, sometimes in several blows. The wire must flow without cracking, so it needs consistent chemistry, a fine and uniform grain, an accurate diameter and a surface free of seams, laps and scratches that would open during upsetting.
6061 is a heat-treatable alloy, which gives the fastener maker a choice: head the wire in a soft condition and heat-treat the finished parts to T6, or use pre-treated wire where the head form is simple. Either way, the finished rivet has far higher strength than 1100 or 3003 rivets, and better corrosion resistance than copper-bearing 2xxx aerospace rivets. It is compatible with 6xxx and 5xxx structures, so it avoids galvanic problems in aluminium assemblies.
Tempers, diameters and supply forms
| Temper | Condition | Typical use |
|---|---|---|
| O | Annealed, softest | Complex or large heads; parts heat-treated to T6 after heading |
| T4 | Solution treated, naturally aged | Moderate heading, then artificial ageing to T6 |
| T6 | Solution treated and artificially aged | Simple heads and machined pins; highest as-supplied strength |
Supply range
- Diameter
- About 1.6 – 10 mm; larger rod for bolts and pins on request
- Form
- Coils for automatic headers, or straight cut lengths
- Surface
- Bright drawn, clean, lightly lubricated for heading
- Standard
- ASTM B316 / B316M; equivalent national rivet-wire standards on request
Composition and mechanical properties
| Element | Min % | Max % |
|---|---|---|
| Silicon (Si) | 0.40 | 0.80 |
| Iron (Fe) | — | 0.70 |
| Copper (Cu) | 0.15 | 0.40 |
| Manganese (Mn) | — | 0.15 |
| Magnesium (Mg) | 0.80 | 1.20 |
| Chromium (Cr) | 0.04 | 0.35 |
| Zinc (Zn) | — | 0.25 |
| Titanium (Ti) | — | 0.15 |
| Others, each / total | — | 0.05 / 0.15 |
| Aluminium (Al) | Remainder |
| Property (6061-T6) | Typical value |
|---|---|
| Shear strength | About 207 MPa (30 ksi) |
| Tensile strength | About 310 MPa (45 ksi) |
| Yield strength | About 276 MPa (40 ksi) |
| Hardness | About 95 HB |
| Density | 2.70 g/cm³ |
Typical values. Specified minimum shear strengths are set by the order standard and are tested by double shear to ASTM B565 on wire or on finished rivets in the T6 condition.
Diameter tolerance and surface quality
Diameter control matters because rivets must fill their holes and head consistently. Rivet wire is drawn to much closer tolerances than general wire, typically a few hundredths of a millimetre in the 1.6 – 10 mm range, with tolerances widening slightly as diameter increases. Many fastener makers specify a one-sided (minus only) tolerance so that the shank never exceeds the hole size.
- No cracks, seams, laps, blisters, inclusions or corrosion on the surface
- Scratches and handling marks shallower than half the permitted negative tolerance
- Light lubricant or oil residue is acceptable and often helpful for heading
- Upsetting (heading) test on samples to confirm the wire forms without cracking
From wire to finished 6061 rivet
- Cut and headWire is fed from the coil, cut to length and upset in one or more blows to form the head.
- Heat treatParts headed in O or T4 are solution treated, quenched and aged, or simply aged from T4, to reach T6.
- FinishRivets are cleaned and may be anodised or chemically treated for colour and corrosion protection.
- InspectDimensions, head soundness and shear strength are checked by batch.
Unlike 2017 and 2024 "icebox" rivets, 6061-T6 rivets are driven in their final condition and do not need refrigeration before use, which simplifies site work.
6061 vs other rivet alloys
| Alloy | Strength | Corrosion resistance | Typical use |
|---|---|---|---|
| 1100 / 1050A | Low | Excellent | Light sheet, decorative and electrical |
| 5052 / 5056 | Medium | Excellent, marine | Marine, magnesium-compatible joints |
| 6061-T6 | Medium-high (shear about 207 MPa) | Very good | Structural aluminium, transport, marine |
| 2117-T4 | Medium-high (shear about 195 MPa) | Fair | Aircraft general rivets |
| 2017 / 2024-T4 | High | Fair–poor | Aircraft high-strength, refrigerated before driving |
| 7050-T73 | Very high | Good | Aerospace structural rivets |
References and standards
- ASTM B316/B316M – Aluminum and Aluminum-Alloy Rivet and Cold-Heading Wire and Rods
- ASTM B565 – Shear Testing of Aluminum and Aluminum-Alloy Rivets and Cold-Heading Wire and Rods
- The Aluminum Association – Aluminum Design Manual
- ASM International – Properties of Wrought Aluminum and Aluminum Alloys
6061 rivet wire: frequently asked questions
What is the shear strength of a 6061-T6 rivet?
Typical shear strength is about 207 MPa (30 ksi). Design to the specified minimum in your rivet or wire standard, which is lower.
Which temper of 6061 wire is best for cold heading?
O or T4 for complex or large heads, followed by heat treatment to T6. T6 wire suits simple heads and pins.
Do 6061 rivets need refrigeration like 2024 rivets?
No. 6061-T6 rivets are driven in their final temper and can be stored at room temperature.
Can 6061 aluminum rivets be used in marine structures?
Yes. They resist seawater atmospheres well and are compatible with 5xxx and 6xxx hull and superstructure alloys.
In what form is the wire supplied?
In coils for automatic headers or in straight lengths, with mill test certificates.
Need 6061 cold-heading wire?
Send diameter, temper, tolerance, coil or length format and quantity. We will reply with availability and a delivered price.
