Rectangular Tube 6063-T5

Compare Wall Thickness, Opening and Weight

Start with the same 60 × 40 mm outside section and compare three available walls. A thicker wall increases material mass while reducing the space available to an internal fitting; it does not by itself establish the suitability of a complete assembly.

The ideal area is AB − (A − 2t)(B − 2t); nominal mass is area × 0.0027 kg/m for dimensions in mm. The unrounded masses are 1.0368, 1.2825 and 1.5228 kg/m. Percentage changes use those unrounded values; displayed masses are rounded to three decimals using decimal half-up rounding. Actual corner radii, tolerances and coating affect opening and mass. Compare wall thickness with the joint, span and installed orientation rather than treating the percentage as a load-capacity gain.

Why Rectangular Tube Orientation Matters

For a 40 × 20 × 2 mm Rectangular Tube 6063-T5 section, rotating the long side changes the cross-section geometry relative to the bending axis. Both views below use the same downward force direction F and a horizontal centroidal x-axis. This compares section geometry, not a rated load.

For the uniform-wall, sharp-corner model, Iₓ = [b h³ − (b − 2t)(h − 2t)³] / 12 about the horizontal centroidal x-axis. The ratio uses unrounded values. It is not a 3.09× strength or safe-load claim: span, support conditions, load type, connections and acceptable deformation must also be defined. Actual corner geometry changes section properties. Reference [5] shows rectangular-tube data with both sectional axes; its tolerances and machining services are not APW specifications.

Check Inserts, End Caps and Corner Clearance

A 40 × 20 × 2 mm section has a nominal 36 × 16 mm opening before corner, tolerance and surface-treatment effects. An insert that clears both straight walls can still interfere at the internal corners. Check the complete mating contour rather than comparing only two nominal dimensions.

Straight-wall clearance, corner interference

Corner relief with a clearance check

• Tube wall
• Mating insert outline
• Area requiring a fit check

• Check the long and short inside dimensions independently. For a uniform-wall model, the tightest straight-wall opening comes from the smallest allowed outside dimensions combined with the largest allowed wall thickness.
• Compare actual internal corner geometry with the full insert or end-cap outline, including its corner relief; the drawing symbol R does not specify a supplied radius.
• Identify whether fit dimensions apply before or after finishing. Anodizing can change dimensions, and total oxide thickness is not simply the outward growth on each surface. Agree the actual process and final dimensions. [6]
• State the required clearance, mating-part tolerances and any masked surfaces in the RFQ. Supply both mating drawings when a dimensional fit is critical.

These drawings explain contour relationships without assigning production radii, tolerances or coating thickness. A nominal 36 × 16 mm opening does not establish the largest insert that will fit; agree the finished geometry and acceptance method.

Estimate rectangular tube weight from your cut list

Use a geometry calculation for preliminary material planning. It is an estimate of the tube itself, not a shipping weight, measured piece weight or structural assessment.

1. Calculate the hollow section area

   For outside dimensions A and B and a uniform wall t, area = AB − (A − 2t)(B − 2t). A 40 × 20 × 2 mm section has a nominal opening of 36 × 16 mm and an ideal area of 224 mm².

2. Convert area to mass per metre

   Using nominal aluminum density 2,700 kg/m³, mass = 224 × 0.0027 = 0.6048 kg/m. This Rectangular Tube 6063-T5 estimate excludes the effect of actual corner radii, coating and manufacturing variation.

3. Multiply by total finished length

   For 20 pieces at 1,000 mm each, finished length = 20 m. Ideal theoretical mass = 0.6048 × 20 = 12.096 kg, or about 12.10 kg. The stock-length example above accounts separately for kerf, end losses and offcuts.

Compare theoretical mass on a consistent geometry and density basis. A supplier's published or measured mass may use different corner geometry; do not substitute it silently into this calculation.

Identify outside dimensions, bore and material

Use a section drawing to remove ambiguity from a Rectangular Tube 6063-T5 enquiry. A tube described only as '40 × 20' leaves wall thickness, length and fit unresolved.

1. 01

   Outside sizes and wall thickness

   State both outside dimensions and the nominal wall, with mm or inches. For example, 40 × 20 × 2 mm is one specific section; the 2 mm wall must not be inferred from another tube with the same outside sizes.

2. 02

   Internal opening and corners

   Record both nominal inside dimensions and the mating contour on the drawing. Use the fit illustrations above to identify corner interference, then specify the finished-part tolerances and clearance required by your assembly.

3. 03

   T5 is distinct from T6 and T52

   Request Rectangular Tube 6063-T5 by its complete designation. T6 uses solution heat treatment and artificial aging; T52 is a separate temper designation. Do not accept a substitution based only on shared outside dimensions or appearance. [4]

4. 04

   Cut length and drawing orientation

   List the length and quantity of each finished part. Include end squareness, hole positions, datum faces and any miter angles on the current drawing rather than relying on the A/B order in the size chart.

Agree connection and finish details

Rectangular Tube 6063-T5 has plain closed walls, not accessory slots. Define the connection and finishing sequence around the actual assembly.

1. 01

   Fasteners, inserts and end caps

   Provide connector dimensions, hole sizes and locations, engagement requirements and access needs. Attach the insert or end-cap drawing so that both sides and the corner contour can be checked together.

2. 02

   Mill, anodized or powder-coated finish

   All three finishes are available for Rectangular Tube 6063-T5. Specify color, texture, exposed faces and required coating thickness or finish standard; agree masking where a fit or contact surface needs protection.

3. 03

   Fabrication and surface sequence

   State whether drilling, cutting or joining is required before or after finishing. Agree the condition of cut edges and repaired surfaces rather than assuming they will match the coated outer faces.

4. 04

   Material and weld requirements

   6063 can be welded, but a general alloy description does not qualify a joint. Include any joint preparation, finished condition and verification requirements in the drawing and quotation review. [4]

Check the agreed requirements on receipt

Compare Rectangular Tube 6063-T5 against the accepted quotation and drawing. Define inspection criteria before ordering, so the material, dimensions and appearance have a shared reference.

1. 01

   Material identity and documents

   Match the alloy and temper designation, order identification and any agreed inspection documents. Appearance alone cannot distinguish 6063-T5 from another alloy or temper.

2. 02

   Section and finished length

   Check both outside dimensions, wall thickness, straightness, cut length and end condition against the agreed tolerances and measurement method. Verify fit with the specified mating component where required.

3. 03

   Surface and packing condition

   Compare exposed faces with the agreed finish sample and coating requirements. Check for transport damage and whether the agreed packing protects contact faces and open ends.