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Aluminum alloys have captured most industries due to their high strength and low densities. Among them, 2024 and 6061 Aluminum are two commercially popular alloys in their respective industries.
If you’ve heard about them and want to know the difference. Read through this – 2024 Aluminum vs. 6061 Aluminum – comparison guide. We’ll be comparing them in terms of their physical properties and mechanical strengths.
An Overview of 2024 Aluminum
2024 Aluminum belongs to the Aluminum 2000 series, having copper as the principle alloying element. Copper adds high strength and fatigue resistance, making the alloy suitable for structural applications in aerospace.
Although copper’s presence is beneficial for strength, it compromises corrosion resistance – a trait common to aluminum. To counter that, 2024 aluminum is cladded with other more corrosion-resistant aluminum alloys.
An Overview 6061 Aluminum
6061 Aluminum is a versatile general-purpose alloy, largely popular in the automotive and construction sectors. The alloy has over 96% Aluminum and 4% other elements, including magnesium and silicone.
6061 Aluminum’s well-rounded attributes include good strength, which can be enhanced through appropriate heat treatments, great corrosion resistance, and excellent weldability.
2024 Aluminum vs. 6061 Aluminum: Detailed Comparison
Besides Aluminum’s presence, the other similarity between the two alloys is their popularity in aerospace and automotive industries. The rest are differences, laid out in detail in this section.
| Property | Aluminum 2024-T4 | Aluminum 6061-T6 |
|---|---|---|
| Composition | Al: 90.7-94.7% | Al: 95.8-98.6% |
| Cu: 3.8-4.9% | Cu: 0.15-0.4% | |
| Mg: 1.2-1.8% | Mg: 0.8-1.2% | |
| Mn: 0.3-0.9% | Mn: Max 0.15% | |
| Density | 2.78 g/cc | 2.7 g/cc |
| Tensile Strength | 469 MPa | 310 MPa |
| Hardness, Brinell | 120 | 95 |
| Modulus of Elasticity | 73.1 GPa | 68.9 GPa |
| Machinability | Moderate | Good |
| Corrosion Resistance | Poor | Good |
| Weldability | Poor | Excellent |
| Cost | ~$4.3/ sq, ft | ~$3.3/ sq. ft |
| Industries Served | Aerospace | Automotive, Construction, Electronics |
Chemical Composition
2024 Aluminum is primarily alloyed with copper (3.8-4.9%), magnesium (1.2-1.8%), and manganese (0.3-0.9%). On the other hand, 6061 Aluminum includes magnesium (0.8-1.2%) and silicon (0.4-0.8%) as its main alloying elements.You may observe that 6061 has a higher percentage of aluminum than 2024. So, aluminum’s inherent characteristics are more prevalent here. Whereas, in Aluminum 2024, just a small proportion of copper has more influence on mechanical properties.
Weight-to-Strength Ratio
The weight-to-strength ratio is an important factor in materials used for structural applications. 2024 aluminum has an edge here. It has a higher ultimate tensile strength, 469 MPa, compared to 6061 aluminum, which has a strength of 310 MPa.
2024 Aluminum has high density (2.78 g/cc) against 6061’s 2.7 g/cc. But the greater strength makes up for its density, providing a better overall weight-to-strength performance.
Hardness
Hardness measures a metal’s resistance to deformation and indentation. Naturally, aluminum is relatively soft, but alloying elements like copper in 2024 increase its hardness.
On the Brinell hardness scale, 2024 aluminum scores 120, indicating more resistance to deformation compared to 6061, which has a lower score of 95.
Machinability
Machinability measures how easily a material can be cut into a desired shape with minimal wear on tools. Both 2024 and 6061 aluminum alloys machine easier than many metals, which simplifies manufacturing. Among the two, 6061 is notably easier to machine than 2024. This ease comes from aluminum’s softer nature. On the other hand, 2024 work hardens quickly and its higher hardness presents more challenges during machining.
Corrosion Resistance
Aluminum alloys are generally praised for their corrosion resistance. However, 2024 aluminum is an outlier because of its copper content. This copper content, though small, makes the alloy more prone to localized corrosion.
In contrast, 6061 aluminum shows much better corrosion resistance. In fact, 6061 is often used as a cladding material to protect 2024 aluminum.
Weldability
6061 aluminum is well-known for its good weldability. It can be welded using various techniques, including TIG, MIG, and resistance welding. This makes it versatile for multiple applications.In comparison, 2024 aluminum has poor weldability due to its high copper content. Copper enhances thermal conductivity, which makes it challenging to concentrate heat in a specific area during welding. Only friction welding is an effective way to weld 2024 Aluminum.
Costs
There is also a noticeable difference in cost between these two aluminum types. Aluminum 2024 is generally 20 to 25% more expensive than 6061.
A comparison from Aircraft Spruce shows that a 6061-T6 aluminum sheet costs about $3.37 per square foot, while a 2024 aluminum sheet of the same thickness costs about $4.35 per square foot. It’s also one of the reasons why Aluminum 6061 is widely used in local industries.
2024 Aluminum vs. 6061 Aluminum: Which One to Choose and When
Now, it all comes down to the bigger question: which one to choose and when? The applications for both alloys are quite distinct.
2024 Aluminum excels in environments that require high strength and fatigue resistance, making it ideal for:
- Aerospace components i.e. wings and fuselage sections
- Military vehicles and armament structures
- High-stress mechanical parts (gears, pistons, couplings)
Aluminum 6061 is preferred for its good strength, excellent corrosion resistance, and great weldability, suitable for general-purpose applications:
- Automotive components like bike frames and wheels
- Infrastructure uses including bridges and railings
- Architectural elements, doors, windows
- Electrical fittings and housings
How Richconn Can Help?
Once you have chosen an aluminum alloy for your project, you will need a reliable service partner to bring your designs to life. Richconn is the CNC machining partner you can trust for all your metal CNC machining needs. Whether it’s aluminum 2024 or 6061, we are equipped to handle precise specifications and complex designs.
Ready to start? Reach out to Richconn and let’s create something great together!
