Extruded aluminium bar is solid stock made by pushing a heated billet through a die, which gives round, square, hexagonal, flat and shaped sections in long lengths at low tooling cost. This guide explains which alloys and tempers to choose, the standards that govern extruded bar, how it compares with drawn and rolled bar, and how to specify sizes, tolerances and certificates when you buy. Metline supplies extruded bar in every common alloy to customers worldwide.
An extruded bar is a solid aluminium section produced in one pass through an extrusion die. A cylindrical billet is heated to roughly 400 – 500 °C, loaded into a press container and pushed by a ram through a steel die whose opening has the shape of the finished bar. The metal emerges as a continuous length with that cross-section, is cooled, stretched straight, cut and, for heat-treatable alloys, aged to its final temper.
Because the shape comes from the die opening rather than from rolls or machining, extrusion can make almost any solid cross-section: plain rounds, squares and hexagons, flat bars with sharp or rounded corners, and shaped bars such as angles, tees, channels, half-rounds and triangles. Die cost for a simple solid section is low, so even non-standard sizes are economical once quantities reach a few hundred kilograms.
The term "rod" is normally used for round solid sections and "bar" for square, rectangular, hexagonal or octagonal ones, although buyers and catalogues use the words loosely. ASTM B221 covers extruded bar, rod, wire, profiles and tube under one specification, while the European EN 755 series splits the same products into separate parts for round bar, square bar, rectangular bar, hexagonal bar, tube and profiles.
Extruded bar is the starting stock for a huge range of parts: turned shafts and fittings, CNC-machined brackets, fasteners, busbars, frames, rails and trim. Choosing well means getting four things right: the alloy, the temper, the production route (extruded, drawn or rolled) and the tolerance standard. The sections below cover each one.
Extruded bar falls into two groups: standard geometric bars that are used as machining stock, and shaped (structural or decorative) bars that are used close to their extruded form.
The most common form. Small diameters are often drawn after extrusion for tighter tolerance; large diameters (above about 100 mm) are usually supplied as extruded. Used for shafts, pins, turned fittings, hydraulic parts and fastener blanks.
Sharp-cornered or radiused squares, typically 6 – 150 mm across flats. Used for machined blocks, frames, spacers and fixtures.
Hex bar reduces machining for nuts, couplings, fittings and fastener heads because the flats are already formed. Sizes are specified across flats (A/F).
Rectangular sections from thin strips to heavy bars, with square or rounded edges. Used for busbars, wear strips, framing, brackets and base plates. See our flat bar range.
Semi-circular and half-oval bars used for edging, handrails, trims and decorative details.
Less common geometric bars for special supports, tooling and decorative work, produced from simple solid dies.
Equal and unequal angles and tee bars for frames, edge protection, supports and stiffeners.
Open channel sections for tracks, glazing, edging and pipe supports. Channel guide.
Special connection, framing and support sections, often produced to the customer's drawing.
Beyond plain geometry, extrusion also makes functional bars: T-slot framing bars for machine guarding and automation, conductive bars in 1350, 6101 or 6060 for electrical busbars, and precision ground rods for bushings and guides. Each is described in the related pages at the end of this guide.
Almost every wrought alloy can be extruded, but they differ greatly in extrusion speed, achievable shape complexity and cost. Soft 6xxx alloys flow easily and can be pushed fast through complex dies; hard 2xxx and 7xxx alloys need slower speeds, higher pressures and simpler shapes, which is why they cost more per kilogram.
| Group | Typical alloys | Character | Typical uses |
|---|---|---|---|
| General purpose | 6060, 6063, 3003, 1100 | Very easy to extrude, excellent surface and anodising, moderate strength | Architectural bars, trim, handrails, electrical parts, low-load components |
| Structural / engineering | 6061, 6082, 6005A, 6351 | Good strength after T6 ageing, weldable, machines well | Machined parts, frames, transport, marine fittings, structural members |
| Marine / non-heat-treatable | 5083, 5052, 5754, 5086 | Excellent seawater resistance, weldable without heat treatment; harder to extrude | Boat fittings, offshore parts, welded marine structures |
| High strength | 7075, 7050, 7049, 2024, 2014, 2219 | Highest strength, good fatigue; slower to extrude, limited weldability | Aerospace fittings, defence parts, high-load machine components, sports equipment |
| Free-machining | 2011, 6262, 6026 | Lead-free or low-lead chip-breaking additions for automatic lathes | High-volume turned parts, screw-machine products |
| Conductor | 1350, 6101, 6060 | High electrical conductivity | Busbars, connectors, earthing bars |
For most engineering buyers the decision comes down to three candidates. 6061 is the default in the Americas and Asia; 6082 fills the same role in Europe and is slightly stronger in thick sections; and 7075 is chosen when strength matters more than weldability or cost. 6063 is not a machining alloy, but it is the right choice for bars that will be anodised for appearance or bent.
The table lists typical room-temperature values from the Aluminum Association and ASM handbooks. Typical values show what material usually achieves; for design, use the specified minimums in ASTM B221 or EN 755-2, which vary with temper and section size. Every Metline delivery carries a mill test certificate with the actual results for the lot.
| Alloy and temper | Typical tensile strength | Typical yield strength | Typical elongation | Brinell hardness |
|---|---|---|---|---|
| 6063-T5 | 186 MPa / 27 ksi | 145 MPa / 21 ksi | 12 % | 60 HB |
| 6063-T6 | 241 MPa / 35 ksi | 214 MPa / 31 ksi | 12 % | 73 HB |
| 6061-T6 / T6511 | 310 MPa / 45 ksi | 276 MPa / 40 ksi | 12 – 17 % | 95 HB |
| 2024-T3 / T3511 | 483 MPa / 70 ksi | 345 MPa / 50 ksi | 18 % | 120 HB |
| 7075-T6 / T6511 | 572 MPa / 83 ksi | 503 MPa / 73 ksi | 11 % | 150 HB |
ASTM B221 specified minimums for common grades: 6061-T6 extrusions 260 MPa (38 ksi) tensile and 240 MPa (35 ksi) yield; 6063-T6 205 MPa (30 ksi) tensile and 170 MPa (25 ksi) yield; 6063-T5 up to 12.5 mm 150 MPa (22 ksi) tensile and 110 MPa (16 ksi) yield. Higher-strength alloys have thickness-dependent minimums; check the standard or the certificate.
Two points are often missed. First, the extrusion minimums in ASTM B221 are lower than the typical values, so a bar can pass the specification while testing well below the handbook figure; if your design relies on higher strength, write it into the order. Second, large-diameter bars cool more slowly at the centre during quenching, so strength falls as diameter rises, especially in 7xxx and 2xxx alloys. For critical parts above about 150 mm diameter, ask for test results taken from the bar centre or consider a forged bar instead.
Extruded bar is supplied in a smaller set of tempers than sheet and plate. The suffix tells you how the bar was cooled, treated and stress-relieved, which affects strength, straightness and how it behaves when machined. Our temper designation guide explains the full system.
| Temper | What it means | When to order it |
|---|---|---|
| F / H112 | As extruded, no controlled treatment; H112 has minimum properties guaranteed | Non-heat-treatable bars (5083, 3003) and stock for later forging |
| O | Fully annealed, softest condition | Severe bending, cold heading or forming before heat treatment |
| T4 | Solution heat-treated and naturally aged | Parts that will be formed and then aged to T6 |
| T5 | Cooled from the extrusion temperature and artificially aged | Economical 6060/6063 bars where moderate strength is enough |
| T6 | Solution heat-treated and artificially aged | Full strength in 6061, 6082, 7075 and 2014 |
| T6511 / T6510 | T6 plus controlled stretching to relieve stress (T6511 allows minor straightening) | Bar that will be heavily machined; stays straight and dimensionally stable |
| T3511 | 2024 solution treated, stretched, naturally aged | Aerospace and high-fatigue 2024 parts |
| T73511 / T76511 | Over-aged 7xxx tempers, stretched | Aerospace parts needing resistance to stress-corrosion cracking |
For machined parts, the stretched tempers (T6511, T3511, T73511) are worth the small extra cost. Stretching by 1 – 3 % after quenching removes most of the residual stress that otherwise makes long parts bow when one side is machined away.
The same alloy and temper can reach you by three routes, and the route affects tolerance, surface, straightness and price. ASTM B221 covers extruded products; ASTM B211 covers cold-finished (drawn) and rolled bar, rod and wire; in Europe, drawn bar falls under EN 754 and extruded bar under EN 755.
| Feature | Extruded bar | Cold-drawn (cold-finished) bar | Rolled bar |
|---|---|---|---|
| Process | Hot extruded through a die, stretched straight | Extruded, then drawn cold through a finishing die | Hot rolled from ingot or cut from plate |
| Diameter tolerance | Commercial extrusion tolerances (wider) | Tight; typically a fraction of the extruded tolerance | Variable; often sawn from plate |
| Surface | Mill finish, may show light die lines | Bright, smooth, sharp corners | Rolled or sawn surface |
| Size range | Small to very large (over 300 mm) | Small sizes, usually up to about 75 – 100 mm | Large square and rectangular sizes |
| Shapes | Any solid section, including angles, tees, custom | Round, square, hex, rectangle | Mainly rectangular |
| Typical use | General machining stock, large parts, shaped sections | Screw-machine parts, precision pins, fasteners | Large blocks and thick flat bar |
| Relative cost | Lowest | Higher (extra operation) | Depends on size |
The practical rule: if the bar goes into an automatic lathe or collet chuck, or needs a finished surface without machining, buy cold-drawn bar. If it will be machined all over, or the size or shape is beyond the drawing range, extruded bar does the job at lower cost. For very large solid sections where through-thickness properties matter, compare extruded bar with rolled or forged bar.
Quote the governing standard on every order. It defines chemistry, minimum properties, tolerances and testing, so it is the basis for acceptance. The main ones are listed below; projects in a given region usually follow that region's system, and one bar can be certified to several standards when the limits overlap.
| Standard | Scope |
|---|---|
| ASTM B221 / B221M | Extruded bar, rod, wire, profiles and tube: chemistry, tempers, mechanical properties |
| ANSI H35.2 / H35.2M | Dimensional tolerances for aluminium mill products, referenced by ASTM |
| SAE AMS-QQ-A-200 series, AMS 4150, AMS 4154 and others | Aerospace extruded bar, rod and shapes by alloy and temper |
| EN 755-1 / 755-2 | Technical delivery conditions and mechanical properties of extruded rod, bar, tube and profiles |
| EN 755-3 / -4 / -5 / -6 | Tolerances for round, square, rectangular and hexagonal extruded bar |
| EN 755-9 | Tolerances for extruded profiles (shaped bars) |
| EN 573-3 | Chemical composition of wrought alloys |
| ISO 6362 | International equivalent for extruded rod, bar, tube and profiles |
| JIS H4040 | Japanese standard for aluminium bar, rod and wire |
| GB/T 3191 and GB/T 3190 | Chinese standards for extruded bar and chemistry |
| IS 733 | Indian standard for wrought aluminium bars, rods and sections |
EN 755-3 covers round bars from 8 mm to 320 mm diameter and sets tolerances on diameter, ovality and straightness; EN 755-5 covers rectangular bars from 2 mm to 240 mm thick and 10 mm to 600 mm wide, including corner radii, squareness and twist. Tolerances widen as size increases and are tighter for "easy" alloys such as 6060 and 6063 than for hard alloys such as 7075, so the alloy you pick changes the tolerance you get.
Size availability depends on alloy and temper; very large or very small sections in hard alloys need checking against the mill's range.
Theoretical weight is cross-sectional area × length × density (2.70 g/cm³ for most 6xxx alloys). For a round bar, weight per metre in kg = 0.7854 × d² × 0.0027, with d in millimetres. 7075 (2.81 g/cm³) and 2024 (2.78 g/cm³) are about 3 – 4 % heavier. Use the bar weight calculator for other sizes.
| Size (mm) | Round bar kg/m | Hex bar (A/F) kg/m | Square bar kg/m |
|---|---|---|---|
| 6 | 0.076 | 0.084 | 0.097 |
| 8 | 0.136 | 0.150 | 0.173 |
| 10 | 0.212 | 0.234 | 0.270 |
| 12 | 0.305 | 0.337 | 0.389 |
| 16 | 0.543 | 0.599 | 0.691 |
| 20 | 0.848 | 0.935 | 1.08 |
| 25 | 1.33 | 1.46 | 1.69 |
| 30 | 1.91 | 2.10 | 2.43 |
| 40 | 3.39 | 3.74 | 4.32 |
| 50 | 5.30 | 5.85 | 6.75 |
| 60 | 7.63 | 8.42 | 9.72 |
| 80 | 13.57 | 14.96 | 17.28 |
| 100 | 21.21 | 23.38 | 27.00 |
| 120 | 30.54 | 33.67 | 38.88 |
| 150 | 47.71 | 52.61 | 60.75 |
| 200 | 84.82 | 93.53 | 108.00 |
| 250 | 132.54 | 146.14 | 168.75 |
| 300 | 190.85 | 210.44 | 243.00 |
Commercial extruded bar is supplied to the standard tolerance tables of the order specification. If your drawing needs more, state it explicitly, or allow a machining margin and specify cold-drawn or precision-ground bar.
A common source of rejection is ordering bar to "drawing tolerance" when the drawing shows finished-part tolerances. Extruded bar is a raw material; specify the stock size and the standard, and leave the finished tolerance to machining.
6061-T6, 6082-T6, 7075-T6 and 2024-T3 all machine well with sharp carbide tools, high speeds and flood coolant. Soft tempers (O, F, 6063-T5) are gummy and form built-up edge; for high-volume turning choose 2011, 6262 or 6026.
6xxx bars weld readily by MIG and TIG with ER4043 or ER5356 filler, although the heat-affected zone loses part of its T6 strength. 5083 welds without heat treatment. 7075 and 2024 are generally not fusion welded; use mechanical fastening.
Bend in T4 or O and age afterwards for tight radii. T6 bars need generous radii and are best bent across the extrusion direction with care.
6060 and 6063 give the most uniform decorative anodising; 6061 and 6082 anodise well for protection. 7075 and 2024 accept hard anodising for wear surfaces.
Powder coating, wet painting, brushing and mirror polishing are all applied to extruded bar; specify the finish standard on the order.
Bars can be supplied cut to length, chamfered, drilled or machined to drawing, which reduces handling and scrap at your plant.
| Industry | Typical alloys | Typical shapes and parts |
|---|---|---|
| Aerospace | 2024, 7075, 7050, 6061 | Round, square and hex bar for fittings, brackets and machined components; see aerospace |
| Marine | 5083, 5052, 6061, 6082 | Round and flat bar, angles and tees for fittings, frames and deck hardware |
| Defence | 7075, 2024, 7050, 2219 | High-strength bar for machined components; material certificates to military specifications |
| Automotive and EV | 6061, 6082, 5754, 7075 | Bars and shaped sections for brackets, suspension parts, battery structures |
| Building and architecture | 6063, 6060, 6061 | Flat, half-round and custom bars for trims, handrails, balustrades and decoration |
| Power and electrical | 1350, 6101, 6063 | Flat and rectangular busbars, earthing and connector bars |
| Machinery and automation | 6061, 6082, 7075 | Round, square and hex bar for shafts, fixtures and T-slot framing |
| Rail and road transport | 6082, 6061, 6005A | Bars and shaped sections for frames, floors and fittings |
| Medical equipment | 6061, 5052 | Round and rectangular bar for equipment frames and machined parts, usually anodised |
Extruded rod is formed hot through a die and supplied with commercial tolerances and a mill finish. Drawn (cold-finished) rod is extruded first and then pulled cold through a finishing die, which gives tighter diameter tolerances, a brighter surface and sharper corners. Drawn rod costs more and is limited to smaller sizes.
6061-T6511 or 6082-T6 for general engineering parts, 7075-T6511 when high strength is needed, and 2011 or 6262 for high-volume automatic turning. Avoid 6063 and annealed tempers for precision machining, as they are soft and gummy.
Multiply cross-sectional area by length and density. For a round bar, kg per metre = 0.7854 × d² × 0.0027 with d in mm. A 50 mm round bar weighs about 5.30 kg/m and a 100 mm bar about 21.2 kg/m in 6061.
Standard extruded round bar is widely available up to about 300 mm diameter, and large presses can produce bars around 500 mm. Very large diameters are slower to source and have lower centre properties, so forged bar is sometimes preferred for critical parts.
In the same alloy and temper, extruded bar meets the same type of minimum properties, with some directionality along the extrusion axis. Forging gives better through-thickness properties and grain flow, which matters for highly stressed aerospace or rotating parts.
T6511 is the T6 condition plus controlled stretching after quenching to relieve residual stress, with minor straightening allowed after stretching. It keeps bars straight and stable during machining.
Tell us the alloy, temper, shape, size and quantity. Metline will confirm availability, certification and delivery to your port or door.
