T4
Solution treated and naturally aged. Used for stretch- or press-bent members that are aged to T6 after forming.
High-strength structural extrusions
6082 T5 and T6 Aluminium Automotive Extrusions
6082 is the strongest of the mainstream 6xxx extrusion alloys and the European standard for load-bearing aluminium sections. In vehicles it is used for bumper beams and crash boxes, sills, sub-frame members, battery-tray frames, seat structures and commercial-vehicle bodies and chassis. Metline supplies 6082 profiles, tubes and bars to drawing in T4, T5, T6 and crash-optimised tempers, cut, machined, bent and finished, to customers worldwide.
- Alloy
- 6082 (EN AW-AlSi1MgMn)
- Tempers
- O, T4, T5, T6, T7-type
- Min. yield (T6)
- 250 – 260 MPa
- Standards
- EN 755-2 · EN 755-9 · EN 573-3
Why 6082 is used for structural vehicle extrusions
6082 has the highest magnesium and silicon content of the common 6xxx extrusion alloys, plus 0.4 – 1.0 % manganese. The extra alloying gives a T6 yield strength of at least 250 – 260 MPa, and the manganese keeps a fine, fibrous grain structure that improves toughness and crash behaviour. The price is extrudability: 6082 needs higher pressure and lower speeds than 6060 or 6063, and very thin walls are harder to achieve.
For vehicle structures those trade-offs are usually worth it. Bumper beams, crash boxes and sill sections must absorb energy by folding progressively without cracking; sub-frame and battery-frame members must carry high static and fatigue loads; commercial-vehicle bodies must stay stiff over long service lives. 6082 meets all of these and is readily welded, machined and bent.
In Europe 6082 largely replaced 6061 for structural extrusions, and the two are close equivalents in strength. Specialist crash alloys such as 6008 or 7003 are used on some programmes, but 6082 remains the reference against which they are compared.
6082 chemical composition (wt %)
Composition per EN 573-3 and the Aluminum Association registration. Extruders often use narrower internal windows, especially for magnesium, silicon and manganese, to balance strength against extrusion speed and grain control.
| Element | Minimum | Maximum | Role |
|---|---|---|---|
| Silicon (Si) | 0.7 | 1.3 | Forms Mg2Si; excess Si adds strength |
| Iron (Fe) | — | 0.50 | Impurity |
| Copper (Cu) | — | 0.10 | Kept low for corrosion resistance |
| Manganese (Mn) | 0.40 | 1.0 | Controls grain structure and recrystallisation; raises toughness |
| Magnesium (Mg) | 0.6 | 1.2 | Main strengthening element |
| Chromium (Cr) | — | 0.25 | Grain structure control |
| Zinc (Zn) | — | 0.20 | Impurity |
| Titanium (Ti) | — | 0.10 | Grain refiner |
| Others, each / total | — | 0.05 / 0.15 | |
| Aluminium (Al) | Remainder |
Mechanical properties of 6082 profiles
Specified minimums for extruded profiles from EN 755-2. Note that the standard gives T6 walls over 5 mm slightly higher minimums than thin walls; design to the band that matches your section.
| Temper | Wall thickness (mm) | Rm min (MPa) | Rp0.2 min (MPa) | A / A50 min (%) | Typical hardness (HBW) |
|---|---|---|---|---|---|
| O | all | ≤ 160 | ≤ 110 | 14 / 12 | 35 |
| T4 | ≤ 25 | 205 | 110 | 14 / 12 | 70 |
| T5 | ≤ 5 | 270 | 230 | 8 / 6 | 90 |
| T6 | ≤ 5 | 290 | 250 | 8 / 6 | 95 |
| T6 | > 5 – 25 | 310 | 260 | 10 / 8 | 95 |
Typical T6 values are about 310 – 340 MPa tensile and 270 – 300 MPa yield. Tubes and bars have their own tables in EN 755-2. Some trade sheets quote only "290 MPa tensile, 250 MPa yield, 6 %" for 6082 without stating temper or wall thickness; those are the thin-wall T6 minimums.
Physical properties (T6, typical)
- Density
- 2.70 g/cm³
- Modulus of elasticity
- about 70 GPa
- Thermal conductivity
- about 170 – 180 W/m·K
- Electrical conductivity
- about 40 – 45 % IACS
- Coefficient of thermal expansion
- 23.4 µm/m·°C (20 – 100 °C)
- Melting range
- about 575 – 650 °C
T4, T5, T6 and crash tempers
T5
Press-quenched and aged. Economical for thin-walled sections where press quenching reaches enough strength.
T6
Fully solution treated (or water press-quenched) and aged. The standard for highly loaded profiles.
T7-type (over-aged)
Aged beyond peak strength to improve ductility and crash folding, and to reduce sensitivity to stress corrosion. Specified for some crash boxes and bumper beams.
For crash parts, the drawing usually adds axial crush or three-point bend tests on sample lengths, because tensile results alone do not show whether a section folds cleanly or cracks.
Section types, sizes and processing
Typical 6082 automotive extrusion range
- Profiles
- Multi-cell hollows for crash management and sills; open and semi-hollow sections; T, U, Z, angle and channel shapes
- Tube and bar
- Round, square and rectangular tube; round and flat bar
- Wall thickness
- Typically from about 1.5 – 2 mm in hollows; heavier for bars and solid sections
- Length
- Mill lengths about 3 – 7 m, longer by agreement, or cut to part length
- Finishes
- Mill finish, anodising, electrocoat-ready, powder coat
- Processing
- Precision cutting, CNC machining, punching, stretch bending, welding of sub-assemblies
6082 has lower extrudability than 6060 or 6063; send the section for review so wall thickness and cavity design can be confirmed.
Standards and international equivalents
| System | Designation |
|---|---|
| European (EN) | EN AW-6082 / EN AW-AlSi1MgMn |
| German Werkstoff | 3.2315 (formerly AlMgSi1) |
| British (former) | HE30 (extrusions), HP30 / H30 |
| ISO | AlSi1MgMn |
| UNS | A96082 |
| Aluminum Association | 6082 |
Mechanical properties are governed by EN 755-2 and tolerances by EN 755-9 for profiles (EN 755-8 for porthole tubes). 6082 is less common in North American standards, so US programmes often specify 6061-T6 instead; Metline can certify to either.
Welding, bending, machining and joining
- MIG and TIG welding: use ER5356 or ER5183 for strength, or ER4043 to reduce hot-cracking risk; the heat-affected zone falls to roughly half of T6 strength unless re-aged
- Friction-stir welding: common for battery-tray floors and wide panels made from joined extrusions
- Bending: tight bends in T4 or freshly quenched condition; T6 needs generous radii and stretch bending
- Machining: T6 gives short chips and good finish; slightly more abrasive than 6061 due to higher silicon
- Mechanical joining: flow-drill screws and self-pierce rivets join profiles to castings and sheet; check rivetability in T6 by trial
- Corrosion: good resistance; isolate steel fasteners and use sealants at mixed-material joints
Where 6082 extrusions are used in vehicles
| Part | Typical temper | Why 6082 |
|---|---|---|
| Bumper beams and crash boxes | T6 or T7-type | Strength with controlled folding |
| Sills (rockers) and side-impact members | T6 | High section stiffness and energy absorption |
| Sub-frame and cradle members | T6 | Fatigue strength and weldability |
| Battery-tray frames and cross-members | T6 | Load capacity and side-impact protection |
| Seat structures and cross-car beams | T6 | Strength in compact sections |
| Truck bodies, tipper bodies and trailer chassis | T6 | Stiffness, durability and corrosion resistance |
Pistons, cylinders and connecting rods are not made from 6082 extrusions, and brake discs are not aluminium extrusions at all. Wheels in 6082 are forged, not extruded.
6082 compared with 6061, 6005A and 7003
| Property | 6082-T6 | 6061-T6 | 6005A-T6 | 7003-T5 |
|---|---|---|---|---|
| Rp0.2 min (thin wall) | 250 MPa | 240 MPa | 225 MPa | 290 MPa |
| Extrudability | Fair | Fair–good | Good | Fair |
| Crash behaviour | Good (better in T7-type) | Good | Good | Good with correct ageing |
| Weldability | Good | Good | Good | Good (self-ageing welds) |
| Typical use | Structural, crash | Structural (Americas) | Thin-walled structural | High-strength bumper beams |
6005A extrudes thinner, more complex hollows at slightly lower strength, which suits battery-tray rails. 7003 and other 7xxx alloys give more strength for bumper beams but need careful control of stress-corrosion behaviour.
How to order 6082 extrusions from Metline
- SpecifySection drawing, alloy and temper (e.g. 6082-T6), length, finish, machining or bending, crush or bend test requirements, and annual volume.
- Confirm the standardEN 755-2 for properties and EN 755-9 or your drawing for tolerances; OEM specifications for crash and corrosion tests.
- QuoteWe confirm availability, tolerances, certification and delivery terms (EXW, FOB, CIF or DAP) for your plant or port.
- Process and inspectProfiles are dimensionally checked, tensile and hardness tested per lot, and packed with interleaving to protect surfaces.
- Document and shipEach lot ships with an EN 10204 3.1 mill test certificate, lot traceability and a packing list, in seaworthy export packing. Third-party inspection can be arranged on request.
References and standards
- EN 755-2 – Extruded rod/bar, tube and profiles: mechanical properties
- EN 755-9 – Extruded rod/bar, tube and profiles: tolerances on dimensions and form for profiles
- EN 573-3 – Aluminium and aluminium alloys: chemical composition and form of wrought products
- EN 515 – Aluminium and aluminium alloys: wrought products, temper designations
- The Aluminum Association – International Alloy Designations and Chemical Composition Limits (Teal Sheets)
- IATF 16949 – Quality management system requirements for automotive production and relevant service parts organisations
6082 aluminium (aluminum) automotive extrusions: frequently asked questions
What are the minimum properties of 6082-T6 extrusions?
EN 755-2 requires 290 MPa tensile and 250 MPa yield for profile walls up to 5 mm, and 310 MPa and 260 MPa for walls over 5 up to 25 mm, with 8 – 10 % elongation.
Is 6082 better than 6061 for automotive profiles?
They are near-equivalents. 6082 is slightly stronger in thicker walls and is the European standard; 6061 is common in North America and Asia. Use the alloy your design standard specifies.
Can 6082 be used for crash boxes?
Yes. 6082 is widely used for crash boxes and bumper beams, often in an over-aged T7-type temper to improve folding behaviour. Axial crush tests confirm the performance.
What filler wire should be used to weld 6082?
ER5356 or ER5183 give higher weld strength; ER4043 reduces hot-cracking risk. Expect strength loss in the heat-affected zone unless the assembly is re-aged.
What is the difference between 6082-T5 and T6?
T5 is cooled at the press and aged, giving 270 MPa tensile and 230 MPa yield minimum in thin walls. T6 is fully solution treated and aged, reaching 290 – 310 MPa tensile and 250 – 260 MPa yield.
Do you supply 6082 extrusions worldwide?
Yes. Metline ships 6082 profiles, tube and bar worldwide with EN 10204 3.1 certificates and export packing on EXW, FOB, CIF or DAP terms.
Need 6082 extrusions for a vehicle structure?
Send the drawing, temper, test requirements and volume. Our team will reply with feasibility and delivered pricing.
