A380 vs 6061-T6
A380 and 6061-T6 sit on opposite sides of the same decision: die-cast a complex shape or machine/extrude a wrought billet. The right pick is dictated less by the alloys themselves than by volume, geometry complexity, and whether the part is structural or cosmetic.
The verdict
Choose A380 (die cast) when you need high-volume, geometrically complex parts (housings, brackets, enclosures) at the lowest per-piece cost and can amortize tooling. Choose 6061-T6 when you need real structural integrity, ductility, weldability, a clean anodized finish, or low-to-medium volumes where machining or extrusion beats cutting a die. A380 wins on cost-at-scale; 6061-T6 wins on performance and flexibility.
Side-by-side data
| Property | A380 | 6061-T6 |
|---|---|---|
| Category | Aluminum | Aluminum |
| Density (g/cm³) | 2.71 | 2.7 |
| Tensile strength (MPa) | 324 | 310 |
| Yield strength (MPa) | 159 | 276 |
| Elongation (%) | 3 | 12 |
| Hardness | 80 HB | 95 HB |
| Max service temp (°C) | 170 | 170 |
| Machinability | ●●●●● | ●●●●● |
| Corrosion resistance | ●●●●● | ●●●●● |
| Relative cost | ●●●●● | ●●●●● |
| Thermal cond. (W/m·K) | 96 | 167 |
| Typically used for | High-volume die-cast housings | All-round structural & machined parts — the default aluminum |
Which should you choose?
Choose A380 (die cast) if…
- You're producing high volumes and can amortize die tooling across thousands of parts.
- The geometry is complex — thin walls, integral bosses, ribs, fins — that would be expensive to machine.
- The part is a non-critical housing or enclosure rather than a fatigue- or impact-loaded structural member.
- You want near-net-shape parts with minimal secondary machining and good as-cast dimensional repeatability.
- Surface finish will be painted or powder-coated, not anodized.
Choose 6061-T6 if…
- The part is structural, fatigue-loaded, or impact-prone and needs ductility plus porosity-free integrity.
- You need to weld the part (accepting heat-affected-zone softening).
- A clean, uniform anodized finish or hard-anodized wear surface is required.
- Volumes are low to medium, or geometry is simple enough to extrude or machine without die tooling.
- You want a well-characterized, traceable wrought alloy with predictable mechanical properties.
Key differences that matter
- Process drives the choice. A380 is a casting alloy and 6061-T6 a wrought alloy — the real decision is die casting vs. machining/extrusion, not just two metals on a spec sheet.
- Ductility and integrity: 6061-T6 is far more ductile and free of casting porosity, so it's preferred for structural, impact, and fatigue-critical parts; A380's low elongation means it can crack rather than yield.
- Weldability splits them. 6061 welds readily (expect HAZ softening near the weld), whereas A380's high silicon and gas porosity make it a poor structural welding candidate.
- Finishing: 6061 anodizes cleanly for cosmetic or wear surfaces; A380's high silicon gives a dull, uneven anodize, so cast parts are usually painted or powder-coated.
- Cost crossover is volume-dependent: A380 wins per-part at high volume once tooling is amortized; 6061-T6 wins at low volume and when you'd otherwise machine away most of a billet.
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Open the Material SelectorGet a Quote →Frequently asked questions
Is A380 stronger than 6061-T6?
Roughly comparable in ultimate tensile strength, but 6061-T6 has higher yield strength and dramatically better ductility. A380 is strong as-cast but brittle, with low elongation and casting porosity that hurts fatigue and impact performance, so 6061-T6 is the better structural choice.
Which is cheaper?
It depends on volume. A380 die casting has high upfront tooling cost but very low per-part cost at scale, so it's cheaper for large runs of complex parts. 6061-T6 has no tooling cost and wins for low-to-medium volumes or simple machined geometries.
Can I weld A380 or 6061?
6061 is readily weldable, though the heat-affected zone softens and may need re-aging or design allowance. A380 is generally considered non-weldable for structural purposes due to its high silicon content and trapped gas porosity, which cause cracking and blowholes.
Can I anodize A380 die castings?
Not well. A380's high silicon content produces a dark, blotchy, non-uniform anodized layer, so cast parts are usually painted or powder-coated. 6061 anodizes cleanly and uniformly, making it the choice when finish appearance or hard-anodized wear resistance matters.
Can A380 be machined like 6061?
Both machine well, but differently. 6061-T6 gives clean chips and excellent surface finish, ideal for fully machined parts. A380 machines fine for secondary operations like drilling and tapping cast bosses, but its silicon is abrasive on tooling and porosity can expose voids on cut surfaces.
Property values are typical/nominal figures for early-stage guidance only and vary by temper, grade, supplier and heat treatment. Confirm critical specifications against a certified datasheet or with an mfgiq engineer before production.