In the aviation industry, 6061 and 6063 aluminum alloys have become key materials due to their excellent comprehensive performance. These two alloys belong to the 6xxx series of aluminum-magnesium-silicon alloys, but due to differences in composition and heat treatment status, their application scenarios in the aviation field are significantly differentiated.
6061 aluminum sheet is known for its high content of alloying elements. Its typical composition is silicon (0.4-0.8%), magnesium (0.8-1.2%), and copper (0.15-0.4%). The higher magnesium-silicon ratio (about 1.5:1) allows it to form more Mg₂Si strengthening phases, giving the material higher strength. The AW 6063 has lower silicon (0.2-0.6%) and magnesium (0.45-0.9%) contents, and the copper content is limited to less than 0.1%. This composition design makes it more focused on processing performance and surface quality.
From the perspective of mechanical properties, the tensile strength of 6061-T6 is ≥260MPa, the yield strength is ≥240MPa, and the Brinell hardness is HB90-95; the tensile strength of 6063-T6 exceeds 205MPa, the yield strength exceeds 180MPa, and the Webster hardness is 11.5HW. The strength advantage of 6061 makes it more suitable for structural parts that bear high loads, while the medium strength and good ductility of 6063 are suitable for the manufacture of complex shapes.
The commonly used heat treatment states in the aviation field include T4 (solution treatment + natural aging) and T6 (solution treatment + artificial aging).
6061-T6 significantly improves strength through artificial aging and is widely used in parts with high rigidity requirements, such as the floor structure of the Boeing 737. Its typical specifications include plates with a thickness of 0.8mm to 150mm, and the tensile strength meets the AMS-QQ-A-250/11 standard.
6063-T6 balances strength and surface quality by optimizing the aging process. For example, the wing skin of the Airbus A380 uses 6063-T6 aluminum, which ensures structural strength while achieving good anodizing effect.
For scenarios that require higher processability, the 6061-T4 state (natural aging) performs well. The elongation of the material in this state can reach 16%, which is suitable for manufacturing parts that require cold forming, such as aircraft fuel pipes. The 6063-T5 state (air-cooled quenching + artificial aging) is used for interior parts with high corrosion resistance requirements. Its Webster hardness of 8HW makes it easy to surface treat while maintaining a certain strength.
With a tensile strength of 260MPa, 6061-T6 has become the core material for aircraft fuselage frames and wing beams. Its high fatigue resistance (cycle life of 10⁷ times) also makes it suitable for landing gear support structures.
Traditional rust-proof aluminum alloys (such as LF2-M) are gradually being replaced by 6061-T4. 6061-T4's corrosion resistance (corrosion depth ≤0.05mm in 1000 hours of salt spray test) and thin-walling capability (tube wall thickness reduced by 30%) make it an ideal choice for hydraulic pipelines and air conditioning systems.
With a yield strength of 240MPa, 6061-T6 can be used to manufacture engine compartment brackets, seat rails and other components that are subject to dynamic loads. Its welding performance (conventional argon arc welding can be used) further expands its application range.
The thickness of the anodized film of 6063-T6 can reach 25μm, with high surface finish and low color difference. It is widely used in interior parts such as cabin handrails and luggage rack frames. The ladder used for aircraft maintenance uses 6063-T5 extruded profiles, which are both corrosion-resistant and easy to clean after sandblasting oxidation.
6063 has excellent thermoplasticity and can be extruded into thin-walled hollow profiles. For example, the door frame of the Airbus A320 uses 6063-T6 extrusions, and its complex cross-sectional design achieves lightweight while meeting strength requirements.
The medium strength of 6063-T6 (tensile strength 205MPa) makes it suitable for non-critical parts such as ventilation ducts and cable racks. Its low sensitivity to stress corrosion cracking is particularly suitable for parts in hot and humid environments.
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