ALUMINUM MACHINING 6061-T651
Aluminum Alloy 6061-T651
6061-T651 is the premium, stress-relieved version of the popular 6061-T6 aluminum alloy. By adding a controlled stretch after solution heat treatment, 6061-T651 delivers superior flatness, tighter thickness tolerances, and minimal residual stress—making it the go-to choice for precision parts, anodized enclosures, and large-format plates that must stay flat after machining.
Material Characteristics
- Composition: Al-Mg-Si alloy (Mg 0.8–1.2 %, Si 0.4–0.8 %) with Cr, Cu, Mn micro-additions.
- Density: 2.70 g/cm³—lightweight yet strong.
- Mechanical Properties (T651): Tensile 310 MPa, Yield 276 MPa, Elongation 12 %.
- Heat-Treatable: Achieves properties via solution + aging + stretch.
- Corrosion Resistance: Excellent in marine and industrial atmospheres.
- Weldability: Good with ER4043/5356 filler; post-weld re-aging recommended.
- Machinability: Chips cleanly; low residual stress prevents distortion during heavy machining.
- Surface: 400-grit polished, blemish-free—ready for clear anodizing without pre-polish.
Material Advantages
- Ultra-tight thickness tolerance (±0.05 mm) reduces CNC set-up time.
- Flatness down to 0.1 mm/m²—ideal for skeleton-cut or fully-lasered parts.
- Residual stress < 10 MPa; large plates stay flat after 2 m long milling passes.
- Mirror-ready surface eliminates sanding before decorative anodizing.
- Up to 2 m × 6 m plate sizes cut material waste versus welded sub-plates.
- Stable at 340 °C short-term exposure—perfect for oven-test fixtures.
Material Disadvantages
- Premium price: typically 8–15 % above standard 6061-T6.
- Thin gauges (<6 mm) may have limited stock; lead times longer.
- Lower fatigue strength versus 6082-T6 in dynamic loading applications.
- Stretching process reduces elongation slightly—avoid deep drawing.
Processing Precautions
- Heat Treatment: Do NOT re-solutionize; use artificial aging only (160 °C / 8 h max) to regain properties after welding.
- Surface Protection: Store vertically to prevent scratches on pre-polished faces; use plastic separators.
- Welding: Preheat to 100 °C for thick sections; post-weld stretch not required but re-age to T6/T651 temper.
- Machining: Use PCD or polished carbide tools for mirror finishes; flood coolant to evacuate chips and prevent galling.
- Anodizing: Can be Type II or Type III; racking marks should be planned outside cosmetic zones.
Main Uses
- Precision jigs & fixtures: semiconductor trays, phone test nests, 5-axis vacuum chucks.
- Anodized architectural panels: large-format façades, LED light-box frames.
- Aerospace & automotive: wing ribs, bulkheads, battery enclosures requiring tight flatness.
- Medical equipment: CT-gantry plates, robotic arm bases needing dimensional stability.
- Oven-test & reflow carriers: 2 m long PCBA carriers that survive 340 °C reflow cycles.
- Sports equipment: bicycle suspension links where fatigue life and flatness coexist.
Cost Guide
Expect a 10–15 % premium over standard 6061-T6 plate. However, eliminating skim cuts, stress-relief cycles, and pre-anodize polishing often delivers a lower total part cost.
For up-to-date 6061-T651 pricing, plate sizes, and cut-to-size services, contact Krosino manufacturing today.

