Stamping
Aluminium has lower formability limits and higher springback than mild steel. Generous radii, optimised draw beads and simulation with the actual 6111 forming-limit curve keep splits and wrinkles under control.
Automotive body sheet
6111 T4 / T6 Auto Body Aluminium Sheet
6111 is a copper-bearing 6xxx body sheet alloy, developed in North America for outer panels that need high dent resistance after paint baking. Delivered in T4 or T4P for stamping, it gains strongly in the paint oven, and it can be supplied in T6 for structural parts. Metline supplies 6111 sheet and coil with mill, EDT or pre-treated surfaces to stampers and vehicle makers worldwide.
- Alloy
- 6111 (Al-Mg-Si-Cu)
- Tempers
- T4, T4P, T6
- Thickness
- About 0.7 – 3.5 mm
- Standards
- ASTM B209 · EN 485 · GB/T 33227
What is 6111 body sheet?
6111 was introduced in the early 1980s as an outer-panel alloy offering better formability and less springback than the 2xxx alloys then in use, with a strong paint-bake response. Its 0.50 – 0.9 % copper accelerates and strengthens precipitation hardening, so a 6111 panel reaches higher post-bake strength than copper-free 6016 or 6022 at the same thickness.
That higher strength lets designers down-gauge bonnets, doors and boot lids, or meet dent targets on flatter panels. 6111 has been widely used on North American vehicles for outer skins, and in T6 or as thicker gauge for structural reinforcements.
The trade-off is corrosion: copper makes the alloy more sensitive to filiform corrosion at cut edges and hems if the paint system is damaged. European makers have therefore tended to prefer 6016, and some programmes now use 6111 mainly for inner or structural parts where its strength counts most.
6111 chemical composition (wt %)
Limits per the Aluminum Association registration of 6111. The copper range is what sets 6111 apart from 6016, 6022 and 6181, which hold copper at 0.25 % or below.
| Element | 6111 (wt %) |
|---|---|
| Silicon (Si) | 0.6 – 1.1 |
| Iron (Fe) | 0.40 max |
| Copper (Cu) | 0.50 – 0.9 |
| Manganese (Mn) | 0.10 – 0.45 |
| Magnesium (Mg) | 0.50 – 1.0 |
| Chromium (Cr) | 0.10 max |
| Zinc (Zn) | 0.15 max |
| Titanium (Ti) | 0.10 max |
| Others, each / total | 0.05 / 0.15 |
| Aluminium (Al) | Remainder |
6111 mechanical properties
Body sheet is sold on property ranges agreed with the OEM, not on a single standard table. The figures below are typical for 1 mm 6111 and show the scale of the paint-bake gain; use the values in your material specification for design.
| Condition | Tensile strength Rm | Proof strength Rp0.2 | Elongation A50 |
|---|---|---|---|
| T4 / T4P as delivered (typical) | about 260 – 300 MPa | about 140 – 180 MPa | about 24 – 28 % |
| After 2 % pre-strain and paint-bake cycle (typical) | — | about 230 – 270 MPa | — |
| T6, fully aged (typical) | about 340 – 380 MPa | about 290 – 330 MPa | about 10 – 12 % |
Formability and physical data (typical)
- Strain-hardening exponent n
- about 0.22 – 0.26 in T4
- Plastic strain ratio r
- about 0.5 – 0.7
- Density
- 2.71 g/cm³
- Modulus of elasticity
- about 70 GPa
- Thermal conductivity
- about 165 W/m·K (T4)
Some older data sheets list much lower T4 or T6 strengths for 6111. Those figures do not reflect the alloy; ask for the certificate of the actual coil.
T4, T4P and the paint-bake response
6xxx body sheet is delivered soft enough to stamp and gains most of its in-service strength in the paint shop. After the body is e-coated, the bake oven (typically 170 – 190 °C for 20 – 30 minutes) acts as an artificial ageing treatment: fine Mg-Si precipitates form and the yield strength of the panel rises. Strain from stamping adds a further work-hardening increment. This is the bake-hardening or paint-bake response, and it is why a door skin can be pressed easily yet resist dents on the road.
| Condition | What it means | Why it matters for 6111 |
|---|---|---|
| T4 | Solution heat-treated and naturally aged at room temperature | Natural ageing continues for weeks; formability slowly falls and bake response weakens |
| T4P (T4 pre-aged) | Solution treated, then given a short pre-ageing treatment (roughly 70 – 100 °C) immediately after quenching | Stabilises properties during storage and gives a stronger, faster bake response |
| T6B / T8X test state | T4P sheet pre-strained about 2 % and baked in the laboratory (for example 185 °C for 20 minutes) | Simulates the painted panel; used to verify dent resistance |
| T6 | Fully artificially aged to peak strength | For structural parts that need maximum strength and little forming |
Suffix letters such as T4Pa or T6Bb are supplier or OEM sub-codes for a specific pre-ageing or bake cycle. Always state the cycle and test method in the order.
Surface texture, pre-treatment and lubricant
Body sheet is ordered not just by alloy and temper but by surface texture, pre-treatment and lubricant, because these decide how the coil behaves in the press shop, the adhesive line and the paint shop. The codes below are the ones most purchase specifications use; your OEM specification may use its own names for the same options.
| Option | Code | What it does | Where it is used |
|---|---|---|---|
| Mill finish | MF | Roll-ground surface straight from cold rolling, with a fine directional pattern | Inner panels and structural parts |
| Electro-discharge textured | EDT | Surface printed from work rolls textured by spark erosion; a random, isotropic micro-pattern holds lubricant and gives an even paint appearance | Visible outer panels: bonnets, doors, roofs, tailgates |
| Ti/Zr conversion pre-treatment | P / TiZr | Thin titanium-zirconium conversion layer applied on the finishing line; stabilises the oxide for durable adhesive bonding | Bonded and riveted body structures |
| Cleaned only | NP | Degreased and pickled surface, no pre-treatment film | Parts pre-treated by the customer |
| Dry lubricant (hot-melt) | DO | Wax-type lubricant that is solid at room temperature; clean handling and good deep-drawing performance | Complex outer panels and automated lines |
| Wet oil (electrostatic) | EO | Thin, even film of forming oil laid down electrostatically, typically about 0.5 – 1.5 g/m² per side | General stamping |
Lubricant type and coating weight must be compatible with your adhesives, sealers and pre-treatment chemistry. Confirm both with the paint shop before the first trial coil of 6111.
6111 sheet and coil sizes and tolerances
Typical supply range
- Thickness
- About 0.7 – 1.5 mm for closures and outer panels; up to about 3 – 4 mm for structural parts
- Width
- About 800 – 2400 mm
- Form
- Coil (for blanking lines) or cut sheet and blanks, typically 800 – 5500 mm long
- Tempers
- T4, T4P; T6 on request for structural parts
- Standards
- EN 485 / EN 573-3, ASTM B209, GB/T 33227, JIS H4000, or the OEM specification
Body sheet tolerances are tighter than general-purpose sheet because blanks feed automated presses and lasers. The schedule below is typical for cut sheet and coil in the 0.7 – 1.5 mm range used for closures; the governing figures are those of your order standard (EN 485-4, ASTM B209 or GB/T 33227) or the OEM specification, whichever is tighter.
| Thickness (mm) | Width 800 – 1600 mm | Width 1600 – 1800 mm | Width 1800 – 2400 mm |
|---|---|---|---|
| 0.70 – 1.00 | ±0.03 | ±0.05 | ±0.08 |
| 1.00 – 1.20 | ±0.04 | ±0.06 | ±0.09 |
| 1.20 – 1.50 | ±0.05 | ±0.07 | ±0.10 |
Other dimensional and quality checks
- Width and length
- Plus-only tolerances on slit width and cut length, typically a few millimetres on blanks over 2 m
- Squareness
- Diagonal difference controlled so that blanks register correctly in the press
- Flatness
- Measured as wave height per metre; outer-panel sheet is levelled to avoid surface distortion after stamping
- Surface
- No cuts, roll marks or pick-up on the exposed face of outer-panel sheet; minor cosmetic marks allowed on inner and structural grades
- Paint-brush lines (roping)
- Graded by stretching and stoning a sample; outer panels need the best grade
- Hemming
- Flat-hem test graded on cracking at the bend, usually after pre-straining and ageing
Stamping, hemming and joining 6111
Hemming
Outer panels are hemmed around inner panels at doors, bonnets and tailgates. Good flat-hem performance depends on low iron-particle content and a fine grain; roller hemming is common for tight radii.
Joining
Bodies are joined by self-piercing rivets, clinching, adhesive bonding, resistance spot welding with special electrodes, laser and friction stir welding. Ti/Zr pre-treated surfaces give the most durable adhesive joints.
Shelf life
T4-type sheet ages at room temperature. Use coils within the shelf life agreed with the supplier, and store them cool and dry.
Corrosion
With phosphate or zirconium pre-treatment and e-coat, 6xxx panels perform well. Copper-bearing alloys need good coating integrity to avoid filiform corrosion at edges.
Recycling
Press-shop offcuts are segregated by alloy and returned for closed-loop recycling into new body sheet.
For 6111 in particular, protect cut edges and hems with sealer, and check that the pre-treatment line handles copper-bearing aluminium; this is the best defence against filiform corrosion.
Where 6111 sheet is used
- Outer closures: bonnets, door skins, boot lids and tailgates where dent resistance at low gauge matters
- Roof panels and wings (fenders)
- Inner panels and reinforcements: door inners, hinge and latch reinforcements
- Structural parts in T6: brackets, cross-members and pillar reinforcements
- Truck cabs and commercial vehicle panels
6111 compared with other body sheet alloys
| Property | 6111 | 6016 | 6022 | 6181 |
|---|---|---|---|---|
| Copper | 0.50 – 0.9 % | 0.20 % max | 0.01 – 0.11 % | 0.10 % max |
| Bake-hardened strength | Highest | Moderate | Moderate–high | Moderate–high |
| Hemming / formability | Good | Excellent | Very good | Very good |
| Filiform corrosion resistance | Fair | Very good | Good | Good |
| Main market | North America | Europe | North America | Europe |
Choose 6111 when post-bake strength and down-gauging are the priority and the paint system is robust; choose 6016 or 6181 for the best hemming and corrosion margin.
How to order 6111 body sheet
- SpecifyAlloy and temper (e.g. 6111-T4P), outer, inner or structural grade, surface (MF/EDT, Ti/Zr), lubricant and weight, thickness, width, coil ID/OD or blank size, and annual volume.
- Confirm the standardYour OEM material specification, or EN 485 / ASTM B209 / GB/T 33227, with the bake-test cycle and formability tests to be reported.
- QuoteWe confirm availability, tolerances, certification and delivery terms (EXW, FOB, CIF or DAP) for your plant or port.
- Process and inspectCoils are slit or blanked, checked for dimensions, surface and properties, and packed eye-to-sky or eye-to-wall in sealed, desiccated export cases.
- 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
- The Aluminum Association – International Alloy Designations and Chemical Composition Limits (Teal Sheets)
- ASTM B209 – Aluminum and Aluminum-Alloy Sheet and Plate
- EN 485-2 – Sheet, strip and plate: mechanical properties
- GB/T 33227 – Aluminium and aluminium alloy sheet and strip for automobiles
- SAE 830096 – An Optimized Aluminum Alloy (X6111) for Auto Body Sheet Applications
6111 automotive body sheet (aluminum): frequently asked questions
What makes 6111 different from 6016?
6111 contains 0.50 – 0.9 % copper, which gives a stronger paint-bake response and higher final strength. 6016 has very little copper, so it hems better and resists filiform corrosion better.
What temper is 6111 delivered in?
Usually T4 or T4P (pre-aged) for stamping. T6 can be supplied for structural parts that need peak strength.
How much strength does 6111 gain in the paint bake?
Typically the proof strength rises by about 80 – 100 MPa after 2 % pre-strain and a standard bake cycle, depending on pre-ageing and bake conditions.
Is 6111 suitable for hemmed outer panels?
Yes, it is used for outer closures, though hemming radii need more care than with 6016. Roller hemming and good process control help.
Does 6111 sheet have a shelf life?
Yes. Natural ageing continues after delivery, so coils should be used within the period agreed with the supplier, typically a few months.
Do you ship 6111 sheet worldwide?
Yes. Metline supplies 6111 sheet and coil worldwide with mill certificates and sealed export packing.
Need 6111 body sheet?
Send the grade, surface, size and volume. We will reply with availability, certification and delivered pricing.
