T-Slot Aluminum Extrusion Profiles – 6063-T5 & 6105-T5
Comprehensive technical specification for T-slot aluminum extrusion profiles (6063-T5 and 6105-T5 alloys) used in Canadian fabrication, jig building, machine guarding, and workstations. Covers standard stock sizes, tolerances, machinability, common defects, and storage guidelines.
Material Overview & Common Uses
T-slot aluminum extrusions are the backbone of modular industrial framing in Canada. Typically extruded from 6063-T5 (for intricate shapes and good surface finish) or 6105-T5 (for higher strength structural applications), these profiles feature a continuous slot that accepts standard T-nuts, bolts, and accessories. Common uses include: machine safety guarding, workbenches, conveyor supports, robot cells, material handling carts, and custom jigs/fixtures. The modular nature allows for rapid reconfiguration without welding, making them ideal for lean manufacturing environments. Standard finishes include mill finish (as-extruded) and clear anodized (for corrosion resistance in wet or food-grade areas).
Core Technical Properties & Sizing
| Property | Value (6063-T5 / 6105-T5) |
|---|---|
| Tensile Strength | 150 MPa (22 ksi) / 260 MPa (38 ksi) min |
| Yield Strength | 110 MPa (16 ksi) / 240 MPa (35 ksi) |
| Hardness | ~60 HB / ~95 HB |
| Density | 2.70 g/cm³ (0.0975 lb/in³) |
Standard Profile Sizing & Tolerances
| Parameter | Standard / Tolerance |
|---|---|
| Standard Profile Lengths | 12 ft (3.66 m) & 20 ft (6.10 m) |
| Common Cross-section Sizes (Metric) | 20x20, 30x30, 40x40, 45x45, 50x50, 80x80, 40x80, 40x120, 80x160 mm |
| Slot Widths | 6 mm, 8 mm, 10 mm (metric); 5/16" (8 mm), 3/8" (9.5 mm) (inch) |
| Cross-section Tolerance (≤ 50 mm) | ±0.2 mm |
| Cross-section Tolerance (50-100 mm) | ±0.3 mm |
| Cross-section Tolerance (> 100 mm) | ±0.5 mm |
| Wall Thickness Tolerance | ±0.15 mm |
| Straightness Tolerance | 0.5 mm / 1 m |
| Twist Tolerance | 1° / 1 m |
| Cut Length Tolerance (Standard Saw) | ±0.5 mm |
| Cut Length Tolerance (CNC Precision) | ±0.2 mm |
| Surface Finish (Mill) | Ra 0.8-1.6 µm |
| Anodized Finish (Clear) | Class AA10, 10 µm min (MIL-A-8625) |
Machinability, Tooling & Feeds
T-slot aluminum extrusions are highly machinable with standard carbide tooling. Use sharp, polished carbide end mills with 2-3 flutes for optimal chip evacuation. Avoid climb milling on thin walls to prevent chatter. Common issues include built-up edge (BUE) at low speeds and stringy chips – use air blast or vacuum chip extraction. For anodized profiles, take care to avoid chipping the anodic layer during deburring.
| Operation | Recommended Tooling | Speed (RPM) | Feed Rate |
|---|---|---|---|
| Milling / Drilling | Sharp polished carbide end mills (2-3 flutes) | 8,000 – 12,000 | 0.002-0.005 in/tooth |
| Drilling | 118° point angle HSS or carbide drills | 3,000 – 5,000 | Pecking cycle |
| Tapping | Spiral point taps (roll form preferred) | 1,000 – 2,000 | Cutting fluid (WD-40 or light oil) |
| Sawing | Carbide-tipped blade (10-14 teeth per inch) | 3,000 – 4,000 | 10-20 in/min |
Common Defects & Quality Control
Incoming inspection should check for the following defects to ensure material quality and dimensional integrity before committing to production.
| # | Defect | Inspection Criteria / Acceptability |
|---|---|---|
| 1 | Die lines | Acceptable if depth is < 0.1 mm |
| 2 | Twist | Gap at ends must not exceed 1 mm per meter |
| 3 | Bow | Deviation must be < 0.5 mm per meter |
| 4 | Surface scratches or gouges | Rejectable if deeper than 0.2 mm |
| 5 | Dimensional variation | Reject if outside ±0.3 mm for critical features |
| 6 | Anodizing defects | Pitting, uneven color, or bare spots are rejectable |
| 7 | End cut squareness | Deviation > 0.5 mm across the face is rejectable |
| 8 | Burrs on cut ends | Must be removed before assembly |
| 9 | Corrosion | White powder or pitting indicates improper storage |
| 10 | Slot obstruction | Debris or flash inside T-slot preventing nut insertion |
Storage, Handling & Racking Guidelines
- Store T-slot extrusions horizontally on dedicated racking with padded supports (wood or rubber) spaced every 4-5 ft to prevent sagging.
- Do not stack more than 5 layers high to avoid crushing lower profiles.
- Keep in a dry, indoor environment (RH < 60%) to prevent oxidation.
- If stored outdoors, cover with a breathable tarp and elevate off the ground.
- For anodized profiles, avoid contact with bare steel or concrete to prevent staining.
- Use lifting slings or padded clamps for long lengths; never drag profiles across each other.
- Implement FIFO inventory rotation and label each bundle with alloy, temper, size, length, and date received.
- For cut-to-length stock, store vertically in a dedicated bin rack with protective end caps and inspect monthly for corrosion or damage.