Substations and switchgear
Support frames for bus systems and insulators, switchgear and control-panel skeletons, cable trays and walkways. Non-magnetic aluminium avoids induced heating near high-current runs.
Structural extrusions for power systems
6005 / 6005A Aluminium Extrusions for Electrical & Energy Structures
6005 and 6005A are medium-strength Al-Mg-Si extrusion alloys that sit between 6063 and 6061/6082: stronger than 6063, yet able to form thin-walled hollow profiles that 6061 cannot. In power and energy work they are used for structures rather than conductors: substation supports, cabinet frames, solar mounting rails, battery enclosures and rail power hardware. Metline supplies 6005 and 6005A profiles in T5 and T6 to drawing, worldwide.
- Alloys
- 6005, 6005A (EN AW-6005A)
- Tempers
- T5, T6
- Min. strength (6005A-T6)
- Rm 270 · Rp0.2 225 MPa
- Standards
- EN 755-2 · ASTM B221
Why 6005 alloys suit power-sector structures
Electrical installations need many structural members that are light, non-magnetic, corrosion resistant and quick to install: bus support frames, insulator brackets, switchgear and cabinet skeletons, cable trays, solar tracker beams and battery racks. Steel can do these jobs but must be galvanised or painted and is heavy and magnetic. 6005 and 6005A extrusions deliver structural-grade strength at one third of the weight of steel and can be extruded into complex shapes that integrate slots, screw ports and snap fits.
The two alloys are close relatives. 6005 is the North American registration (ASTM B221), most often supplied in T5 temper. 6005A, the European variant (EN AW-6005A), allows wider manganese and chromium additions that refine the grain and give more consistent strength in thicker and hollow sections, and it is normally supplied in T6. Both age-harden through magnesium silicide precipitation, like 6061 and 6063.
A point worth stating clearly: 6005 is not a conductor alloy. Its conductivity of roughly 47 – 50 % IACS is acceptable for structures that also serve as earthing paths, but current-carrying bus bars and conductors should be 1350, 6101 or 6201, which are made for conductivity.
6005 and 6005A chemical composition (wt %)
| Element | 6005 | 6005A |
|---|---|---|
| Silicon (Si) | 0.60 – 0.90 | 0.50 – 0.90 |
| Magnesium (Mg) | 0.40 – 0.60 | 0.40 – 0.70 |
| Iron (Fe) | ≤ 0.35 | ≤ 0.35 |
| Copper (Cu) | ≤ 0.10 | ≤ 0.30 |
| Manganese (Mn) | ≤ 0.10 | ≤ 0.50 |
| Chromium (Cr) | ≤ 0.10 | ≤ 0.30 |
| Mn + Cr | — | 0.12 – 0.50 |
| Zinc (Zn) | ≤ 0.10 | ≤ 0.20 |
| Titanium (Ti) | ≤ 0.10 | ≤ 0.10 |
| Others, each / total | 0.05 / 0.15 | 0.05 / 0.15 |
| Aluminium | Remainder | Remainder |
Limits per the Aluminum Association registrations and EN 573-3. Some sources quote 6005A limits under the name 6005; check which alloy your drawing specifies.
Mechanical and physical properties
Specified minimums depend on temper, wall thickness and whether the profile is open or hollow. Design to the minimum values, not typical results.
| Alloy, temper and section | Tensile Rm min | 0.2 % proof Rp0.2 min | Elongation A min | Standard |
|---|---|---|---|---|
| 6005A-T6 open profile, wall ≤ 5 mm | 270 MPa | 225 MPa | 8 % | EN 755-2 |
| 6005A-T6 open profile, 5 – 10 mm | 260 MPa | 215 MPa | 8 % | EN 755-2 |
| 6005A-T6 open profile, 10 – 25 mm | 250 MPa | 200 MPa | 8 % | EN 755-2 |
| 6005A-T6 hollow profile, wall ≤ 5 mm | 255 MPa | 215 MPa | 8 % | EN 755-2 |
| 6005-T5, thickness ≤ 12.5 mm | 262 MPa (38 ksi) | 241 MPa (35 ksi) | 8 % | ASTM B221 |
Physical properties (typical, T5/T6)
- Density
- 2.70 g/cm³
- Modulus of elasticity
- ≈ 69 GPa
- Electrical conductivity
- ≈ 47 – 50 % IACS
- Thermal conductivity
- ≈ 180 – 190 W/m·K
- Coefficient of thermal expansion
- 23.4 µm/m·°C
- Magnetic behaviour
- Non-magnetic: no eddy-current heating around high-current conductors
6005 compared with 6063, 6061 and 6101
| Property | 6063-T6 | 6005A-T6 | 6061-T6 | 6101-T6 |
|---|---|---|---|---|
| Min. tensile (thin profile) | 215 MPa | 270 MPa | 260 MPa | 200 MPa |
| Min. proof stress | 170 MPa | 225 MPa | 240 MPa | 170 MPa |
| Extrudability of thin hollows | Excellent | Very good | Fair | Very good |
| Electrical conductivity | ≈ 53 % IACS | ≈ 47 – 50 % IACS | ≈ 43 % IACS | ≈ 55 – 57 % IACS |
| Anodised appearance | Excellent | Good | Good | Good |
| Typical power-sector role | Enclosures, trim, light frames | Load-bearing frames, rails, brackets | Machined fittings, heavy brackets | Bus bars and conductors |
Values are indicative minimums or typical figures from EN 755-2, ASTM B221 and ASTM B317. The practical rule: choose 6063 where appearance and conductivity matter more than load, 6005A where a hollow or thin profile must carry structural load, 6061/6082 for thick or machined parts, and 6101 when the section itself carries current.
Applications in power, renewable and rail systems
Distribution cabinets and bus ducts
Frame and housing profiles for low-voltage distribution boards and the casing of bus-duct (busway) systems, often with integral slots for mounting rails.
Solar mounting and trackers
Rails, purlins, clamps and tracker torque members. 6005-T5 is a common choice because it combines structural strength with good corrosion resistance in unpainted outdoor service.
Energy storage
Battery rack uprights, module frames and enclosure profiles where weight, stiffness and fire behaviour matter.
Wind and EV charging
Control-cabinet frames, cable-management profiles and charging-post housings and brackets.
Rail power systems
Brackets and support members for overhead line equipment and onboard electrical equipment, where low weight reduces installation and vehicle loads.
Design, welding and finishing
- Welding: MIG and TIG weld well with ER4043 or ER5356 filler. The heat-affected zone loses a large part of its T6 strength (EN 1999-1-1 uses a reduction factor of roughly 0.5 – 0.6 for 6005A-T6), so place welds away from highly stressed regions or use bolted joints.
- Machining: machines cleanly in T5 and T6; use sharp, positive-rake tools.
- Bending: moderate bends are possible in T6; tighter bends are made in T4 and the part aged afterwards.
- Corrosion: good resistance to rural, industrial and moderate coastal atmospheres; anodise or powder coat for aggressive sites and isolate from copper and carbon steel.
- Earthing: remove the oxide and use bimetallic connectors or contact compound where copper earthing conductors are bonded to aluminium frames.
- Finishing: anodising, powder coating and painting are all suitable.
Supply range and ordering
What we supply
- Profiles
- Custom open, hollow and multi-void sections to drawing; standard angles, channels, tubes and bars
- Tempers
- 6005-T5, 6005A-T6 (others on request)
- Lengths
- Mill lengths or cut to size
- Tolerances
- EN 755-9 or ANSI H35.2 as specified
- Finishes
- Mill, anodised, powder coated
- Processing
- Cutting, punching, drilling, CNC machining and bending on request
- Documents
- EN 10204 3.1 mill certificate; RoHS and REACH declarations on request
- Send the drawingSection drawing, alloy, temper, length, quantity and design standard.
- ReviewWe check extrudability, wall-thickness ratios and tolerances and propose changes if needed.
- Approve samplesFor new dies, sample lengths are approved before production.
- ShipBundled and crated for export with certificates, on EXW, FOB, CIF or DAP terms.
References and standards
- EN 755-2 – Extruded rod/bar, tube and profiles: mechanical properties
- EN 573-3 – Chemical composition and form of wrought products
- ASTM B221 – Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles and Tubes
- EN 1999-1-1 (Eurocode 9) – Design of aluminium structures: general structural rules
- The Aluminum Association – Aluminum Design Manual
6005 aluminium (aluminum) extrusions: frequently asked questions
What is the difference between 6005 and 6005A aluminum?
6005A is the European variant with wider manganese and chromium limits (Mn + Cr 0.12 – 0.50 %) and slightly wider silicon and magnesium ranges. The additions refine the grain and give steadier properties in thicker and hollow sections. 6005 is common in North America in T5; 6005A is normally supplied in T6.
Is 6005 stronger than 6063?
Yes. 6005A-T6 has a specified minimum proof stress of about 225 MPa in thin profiles, against 170 MPa for 6063-T6, roughly 30 % higher, while still extruding into complex hollow shapes.
Can 6005 be used for bus bars?
It is not recommended. Its conductivity of about 47 – 50 % IACS is well below 6101 (about 55 – 57 %) and 1350 (about 61 %). Use 6005 for supporting structures and 6101 or 1350 for current-carrying bars.
Is 6005 suitable for solar panel mounting?
Yes. 6005-T5 and 6005A-T6 are among the most widely used alloys for solar rails, purlins and tracker parts because they combine structural strength, good outdoor corrosion resistance and efficient extrusion.
Can 6005A-T6 be welded?
Yes, by MIG or TIG with 4043 or 5356 filler, but the heat-affected zone loses roughly 40 – 50 % of its strength. Designs should apply HAZ reduction factors from EN 1999-1-1 or the Aluminum Design Manual.
Do you supply custom 6005 profiles worldwide?
Yes. Metline supplies 6005 and 6005A profiles to customer drawings with mill certificates and export packing, to destinations worldwide.
Need 6005 profiles for an energy project?
Send your drawings, temper and quantities. We will review extrudability and reply with a delivered quotation.
