Yes, 6063 aluminum is highly bendable, making it one of the most versatile medium-strength alloys available for forming applications. This material balances good mechanical strength with excellent formability compared to other common aluminum alloys. The ease with which 6063 can be shaped allows manufacturers and builders to achieve intricate designs without sacrificing structural integrity. Its bendability is conditional on the specific thermal treatment it has received, known as its temper.
Defining the Architectural Alloy
The 6063 aluminum alloy is classified within the 6000-series, which primarily uses magnesium and silicon as its alloying elements. Magnesium contributes to the alloy’s moderate strength profile, while silicon helps to lower the melting temperature, enhancing its extrudability. This chemical makeup provides a material that is relatively strong, yet remains highly workable, distinguishing it from higher-strength, less-ductile grades.
This alloy is often nicknamed the “architectural alloy” because of its unique combination of properties. It exhibits good resistance to general corrosion and accepts a very smooth, aesthetic surface finish, often enhanced through anodizing. The ability to be easily formed into complex, thin-walled profiles through the extrusion process solidifies its standing as a preferred material for visible structural and decorative elements in building design.
How Temper Affects Ductility
The ability of 6063 to be successfully bent depends most heavily on its temper, which is defined by its heat treatment process. Tempering dictates the material’s mechanical properties, creating a trade-off between strength and ductility, which is the material’s ability to undergo plastic deformation without fracturing. For example, the T6 temper, which involves solution heat treatment followed by artificial aging, maximizes the alloy’s strength, resulting in a yield strength that can exceed 214 MPa.
This maximum strength comes at the cost of ductility, with elongation values often dropping to around 5%, making T6 more prone to cracking during tight bending. Conversely, the T5 temper provides a better balance, achieved by cooling the material from the extrusion press and then artificially aging it. T5 material is approximately 20–25% weaker than T6, but its increased ductility makes it more suitable for bending and forming operations. For maximum bendability, the material can be annealed to the “O” temper, though this sacrifices nearly all strength.
Techniques for Successful Bending
Successful bending of 6063 material requires careful consideration of the forming method and the material’s physical limits. The most common techniques utilized are press brake forming for sheet or plate, roll forming for large-radius curves, and mandrel bending for tubes and pipes. Each method must respect the minimum bend radius, which is the tightest curve the material can withstand before the outer surface causes cracking.
This minimum radius is directly proportional to the material’s thickness and inversely related to its ductility; a T5 temper will tolerate a smaller radius than a T6 temper. During the bending process, the aluminum will exhibit springback, which is the tendency of the material to partially return to its original shape after the forming pressure is released. Fabricators must compensate by over-bending the part by a calculated amount to achieve the desired final angle. Proper tooling and internal support, such as mandrels for tubing, are essential to prevent the profile from collapsing or wrinkling during deformation.
Primary Uses of Bent 6063
The ease of bending 6063 aluminum, combined with its favorable surface finish, makes it a staple in numerous commercial and architectural applications. Its formability is utilized in the production of curved window frames, door frames, and architectural trim where both visual appeal and moderate structural support are necessary. The ability to create intricate, curved profiles allows designers to incorporate smooth, flowing lines into building facades and interiors.
The alloy is also widely used for bent components in consumer goods, such as furniture, railings, and lighting fixtures. In the transportation industry, bent 6063 tubing and extrusions are found in custom automotive and marine components. These applications benefit from the alloy’s light weight and corrosion resistance. The alloy’s bendability translates directly into complex, functional, and aesthetically pleasing end products.