6061 vs 6082 vs 7075 Aluminium Alloy Comparison 2025

Aluminium alloys have become essential in modern industries due to their:
High strength-to-weight ratio
Excellent machinability
Corrosion resistance
Thermal conductivity
Recyclability

But three aluminium alloys dominate engineering applications today:
6061 – The most versatile alloy
6082 – The strongest member of the 6000 series
7075 – The high-strength aerospace alloy

Each grade performs differently in terms of strength, weight, weldability, machinability, fatigue resistance, and cost. Choosing the wrong alloy can lead to early failure, high maintenance costs, or poor machining performance. This guide will help you choose the best aluminium alloy for your 2025 application.

Chemical Composition — What Makes Each Alloy Unique?

Alloy	Major Elements	Summary
6061	Mg + Si	Balanced strength + weldability
6082	Mg + Si (higher Mg)	Higher strength than 6061
7075	Zn + Mg + Cu	Ultra high strength (aerospace grade)

✔ 6061 & 6082 are very similar — both belong to the 6000 series. 6082 has more magnesium → stronger than 6061.
✔ 7075 belongs to the 7000 series — much stronger but less weldable and more expensive.

Mechanical Properties Comparison

Property	6061-T6	6082-T6	7075-T6
Tensile Strength	290 MPa	330 MPa	570 MPa
Yield Strength	240 MPa	280 MPa	505 MPa
Hardness	Medium	Medium–High	High
Fatigue Strength	Good	Very Good	Excellent
Density	Same	Same	Same

Summary:
• 7075 is almost 2× stronger than 6082 and 3× stronger than 6061
• 6082 is slightly stronger than 6061
Best strength overall → 7075

Weldability Comparison

✔ 6061 — Excellent weldability
✔ 6082 — Good weldability
✔ 7075 — Poor weldability (risk of cracking)

Winner: 6061

Machinability Comparison

Alloy	Machinability
6061	⭐⭐⭐⭐⭐ Excellent
6082	⭐⭐⭐⭐ Good
7075	⭐⭐⭐ Very Good (higher tool wear)

Summary:
• Best machinability → 6061
• 7075 machines well but needs harder tools
• 6082 is slightly gummy compared to 6061

Corrosion Resistance

✔ 6061 — Very Good for marine/outdoor use
✔ 6082 — Very Good due to grain structure
✔ 7075 — Moderate (stress corrosion cracking risk)

⭐ Winner: 6082 ≈ 6061
7075 should be coated in marine environments.

Weight Comparison

All three alloys have nearly identical density: 2.70 g/cm³
The difference lies in strength-to-weight ratio:
7075 > 6082 > 6061

Cost Comparison (2025 Market Trend)

Alloy	Cost	Why
6061	Low	Easy availability
6082	Medium	Higher strength
7075	High	Aerospace-grade alloy

Applications — Where Each Alloy Is Used

6061 Aluminium Applications

Frames & structures
Marine fittings
Heat exchangers
Automotive components
Bicycle frames
CNC machined parts

6082 Aluminium Applications

Bridges
Cranes
Trusses
Pressure vessels
Transport applications
Engineering structures

7075 Aluminium Applications (High Strength)

Aircraft parts
Aerospace fittings
Motorsport components
High-performance gears
Defence applications
High-strength bolts

Which Alloy Should You Choose?

✔ Choose 6061 if:
You need good strength + low cost
Excellent weldability
Marine/outdoor use
Easy machining

✔ Choose 6082 if:
You need stronger aluminium than 6061
Structural or load-bearing applications
Need weldability + strength

✔ Choose 7075 if:
Strength is the top priority
Aerospace, defence, motorsport
Need steel-like performance
No welding required
Maximum fatigue resistance

6061 vs 6082 vs 7075 — Final Comparison Chart

Category	6061	6082	7075
Strength	⭐⭐	⭐⭐⭐	⭐⭐⭐⭐⭐
Weldability	⭐⭐⭐⭐⭐	⭐⭐⭐⭐	⭐
Machinability	⭐⭐⭐⭐⭐	⭐⭐⭐⭐	⭐⭐⭐
Corrosion Resistance	⭐⭐⭐⭐	⭐⭐⭐⭐	⭐⭐
Cost	⭐⭐	⭐⭐⭐	⭐⭐⭐⭐⭐
Aerospace Suitability	⭐	⭐	⭐⭐⭐⭐⭐
Best For	General use	Structural use	High strength

Conclusion

Choosing between 6061, 6082, and 7075 aluminium alloys depends entirely on project requirements. ✔ 6061 → Best for machining, welding, low-cost components ✔ 6082 → Best for structural strength + corrosion resistance ✔ 7075 → Best for aerospace-level ultra-high strength

Each alloy has its own strengths. Selecting the right one improves performance, durability, and cost-efficiency. Moksh Tubes & Fittings LLP supplies all major aluminium alloys in sheets, plates, bars, tubes, and custom-engineered components with global standards.

FAQ's

Is 7075 stronger than steel?

7075-T6 is stronger than many mild steels and close to some alloy steels.

Which aluminium alloy is best for welding?

6061 is the easiest and safest to weld.

Can 7075 be used in marine environments?

Not recommended without protective coating — it can develop stress corrosion cracks.

Which aluminium alloy is best overall for engineering?

6082 gives the best balance of strength, corrosion resistance, and load-bearing performance.

Which grade is cheapest?

6061 — widely available and economical.