T6
Highest strength. For bus pipe and rigid bars spanning long distances.
Alloy guide
6101 Aluminium Alloy: the Conductor Grade of the 6xxx Series
6101 is a heat-treatable aluminium-magnesium-silicon alloy designed for electrical conductors. Its tempers give a guaranteed minimum conductivity of 55 – 59.5 % IACS with tensile strengths from about 100 to 200 MPa, which is why it is the standard aluminium for busbar, tubular bus pipe and strong conductor parts. This guide explains how it works, how to choose a temper and where it is used.
- Family
- Al-Mg-Si (6xxx), heat-treatable
- Conductivity
- 55 – 59.5 % IACS min by temper
- Key standard
- ASTM B317 / B317M
- UNS
- A96101
What makes 6101 different
6101 is essentially 6063 re-engineered for electricity: similar magnesium and silicon, but with the elements that hurt conductivity pushed close to zero.
In an ordinary structural alloy, small amounts of manganese, chromium, titanium and vanadium are tolerated or even added for grain control. Each of these elements, when dissolved in aluminium, scatters conduction electrons far more strongly than magnesium or silicon do. 6101 caps manganese and chromium at 0.03 % and adds a little boron, which combines with titanium, vanadium and chromium to form insoluble borides that no longer affect conductivity.
Magnesium and silicon are kept because, once precipitated as fine Mg2Si particles during ageing, they add strength while removing themselves from solid solution. That is the key idea behind 6101: precipitation hardening gives strength without the conductivity cost of solid-solution hardening. By choosing how far to age the alloy, the producer can move along a curve from high strength and lower conductivity (T6) to lower strength and higher conductivity (T64).
6101 equivalent designations
| System | Designation | Notes |
|---|---|---|
| Aluminum Association / ASTM | 6101 | ASTM B317/B317M for extruded conductors |
| UNS | A96101 | |
| European (EN 573-3) | EN AW-6101 (EN AW-E-AlMgSi) | Variants 6101A and 6101B have slightly different limits |
| German Werkstoff (former) | 3.3207, E-AlMgSi0.5 | |
| Japan (JIS) | A6101 | JIS H4040 / H4080 for bar and tube |
| India (IS) | 63401 | Electrical grade in IS 5082 |
| IEC | Al-Mg-Si busbar material | IEC 60114 recommendation for heat-treated busbar |
6101 chemical composition (wt %)
Aluminum Association registered limits. Note the very low manganese and chromium and the boron allowance, which separate 6101 from 6063.
| Element | Minimum | Maximum | Why it is limited |
|---|---|---|---|
| Silicon (Si) | 0.30 | 0.70 | Forms Mg2Si with magnesium |
| Iron (Fe) | — | 0.50 | Impurity; lowers conductivity |
| Copper (Cu) | — | 0.10 | Impurity |
| Manganese (Mn) | — | 0.03 | Very strong conductivity penalty, so held far below normal 6xxx limits |
| Magnesium (Mg) | 0.35 | 0.80 | Main strengthening element |
| Chromium (Cr) | — | 0.03 | Very strong conductivity penalty |
| Zinc (Zn) | — | 0.10 | Impurity |
| Boron (B) | — | 0.06 | Added to tie up dissolved Ti, V and Cr as borides, raising conductivity |
| Others, each / total | — | 0.03 / 0.10 | Tighter than the usual 0.05 / 0.15 |
| Aluminium (Al) | Remainder | About 97.9 – 99.4 % |
6101 tempers and their minimum properties
Every 6101 temper for extruded conductors is solution heat-treated and then aged; the difference is how long and how hot the ageing is. Peak ageing (T6) gives maximum strength; over-ageing (T61, T63, T64, T65) coarsens the precipitates, lowering strength but raising conductivity and ductility.
| Temper | Thickness | Tensile min | Yield min | Conductivity min (20 °C) |
|---|---|---|---|---|
| T6 | 3.2 – 12.7 mm | 200 MPa (29 ksi) | 172 MPa (25 ksi) | 55.0 % IACS |
| T61 | 3.2 – 19 mm | 138 MPa (20 ksi) | 103 MPa (15 ksi) | 57.0 % IACS |
| T61 | 19 – 38 mm | 124 MPa (18 ksi) | 76 MPa (11 ksi) | 57.0 % IACS |
| T61 | 38 – 50.8 mm | 103 MPa (15 ksi) | 55 MPa (8 ksi) | 57.0 % IACS |
| T63 | 3.2 – 25.4 mm | 186 MPa (27 ksi) | 152 MPa (22 ksi) | 56.0 % IACS |
| T64 | 3.2 – 25.4 mm | 103 MPa (15 ksi) | 55 MPa (8 ksi) | 59.5 % IACS |
| T65 | 3.2 – 19 mm | 172 – 221 MPa (25 – 32 ksi) | 138 – 186 MPa (20 – 27 ksi) | 56.5 % IACS |
| H111 | 6.3 – 50.8 mm | 83 MPa (12 ksi) | 55 MPa (8 ksi) | 59.0 % IACS |
Specified minimums for extruded rod, bar, tube, pipe and profiles for electric conductors, from the Aluminum Association property-limit table that ASTM B317/B317M follows (inch values converted). T65 has both minimum and maximum limits so that bending behaviour is repeatable. Confirm against the current edition of the standard for contract use.
T61
The most common busbar temper: good conductivity with moderate strength.
T63
A middle option with near-T6 strength and better conductivity.
T64
Highest conductivity of the aged tempers and easiest to bend, including edgewise.
T65
Controlled maximum and minimum strength for consistent, repeatable bending in production.
H111
Lightly worked, non-aged condition with high conductivity and low strength.
Typical physical properties
6101 typical values
- Density
- 2.69 – 2.70 g/cm³
- Resistivity at 20 °C
- About 29 – 31 nΩ·m depending on temper (55 % IACS = 31.3 nΩ·m; 59.5 % = 29.0 nΩ·m)
- Thermal conductivity
- About 218 W/m·K (T6, typical)
- Coefficient of thermal expansion
- About 23 µm/m·°C
- Modulus of elasticity
- About 69 GPa
- Typical T6 strength
- About 220 MPa tensile, 195 MPa yield, 15 % elongation
Because conductivity varies by temper, the fair way to compare 6101 with other conductors is resistance per metre at the operating temperature, not alloy name alone.
Forms 6101 is supplied in
Busbar
Extruded flat and shaped bar for switchgear, busways and panels. See the 6101 busbar guide.
Bus pipe
Round tube for outdoor substations and switchyards. See 6101 bus pipe.
Wire rod and wire
Rod for drawing into conductor wire and drawn wire for cables and braids. See wire rod and wire.
Sheet and plate
Rolled 6101 for stamped connectors and plate-cut busbar. See 6101 sheet and plate.
Rod and shapes
Round and shaped conductors, angles and channels for earthing and bus supports.
Forged terminals
Connectors and fittings forged from 6101 stock and then heat-treated.
Where 6101 is used
- Power distribution: switchgear and switchboard busbar, busway (bus duct) conductors, transformer leads.
- Substations: rigid tubular bus, jumpers and connection bars in outdoor switchyards.
- Industry: electrolytic cells, furnaces, rectifier buses and other high-current DC systems.
- Transport and EV: battery interconnects, traction busbar and charging equipment where weight matters.
- Renewables: inverter and combiner busbar in solar and wind installations.
- Earthing: ground bars and lightning-protection conductors that also need stiffness.
6101 compared with 1350 and 6063
| Property | 1350 (EC) | 6101 | 6063 |
|---|---|---|---|
| Conductivity | 61.0 – 61.8 % IACS min | 55 – 59.5 % IACS min by temper | Not guaranteed; ≈ 53 – 55 % typical |
| Strength | Low (H111 tensile min 59 MPa) | Medium (T6 tensile min 200 MPa) | Medium (T6 tensile min 215 MPa, EN) |
| Creep under bolt load | Highest tendency | Lower | Lower |
| Typical forms | Wire, rolled and extruded bar | Extruded bar, tube, pipe, rod | Profiles, bar, tube |
| Main use | Maximum-conductivity conductors | Strong conductors with guaranteed conductivity | General extrusions; low-cost busbar |
Choose 1350 when the conductor is well supported and losses must be minimal; 6101 when it must also carry mechanical load or bolt clamping force; and 6063 only when conductivity does not need to be guaranteed.
References and standards
- ASTM B317/B317M – Aluminum-Alloy Extruded Bar, Rod, Tube, Pipe, Structural Profiles, and Profiles for Electrical Purposes (Bus Conductor)
- The Aluminum Association – Property Limits for Electric Conductors (Table 16.3)
- IEC 60114 – Recommendation for heat-treated aluminium alloy busbar material of the aluminium-magnesium-silicon type
- EN 573-3 – Chemical composition and form of wrought products
- IS 5082 – Wrought aluminium and aluminium alloy bars, rods, tubes, sections, plates and sheets for electrical purposes
6101 aluminium (aluminum) alloy: FAQ
What is 6101 aluminium used for?
Mainly electrical conductors that also need strength: busbar, tubular bus pipe, conductor rod and wire, connectors and earthing bars.
What is the conductivity of 6101?
ASTM B317 sets minimums of 55.0 % IACS for T6, 56.0 % for T63, 56.5 % for T65, 57.0 % for T61 and 59.5 % for T64. Production material often measures a little above these minimums.
Is 6101 the same as 6063?
No. They have similar magnesium and silicon, but 6101 holds manganese and chromium to 0.03 % and allows boron, giving higher and guaranteed conductivity.
Which 6101 temper is best for busbar?
T61 is the usual default. Use T6 or T63 for stiffer bars and long spans, and T64 or T65 where the bar will be bent tightly or edgewise.
Can 6101 be welded?
Yes, by TIG or MIG, usually with ER4043 filler. Welding locally lowers strength and slightly changes conductivity at the joint, so many conductor joints are bolted or use welded fittings designed for the purpose.
Specifying a 6101 conductor?
Send the form, temper, size and conductivity requirement. Metline will reply with availability, certificates and a delivered price.
