Executive Summary: The Core Decision

6061-T6 Aluminum: The versatile, cost-effective "workhorse." It is your default choice for most applications due to its excellent corrosion resistance, good strength, and weldability.

7075-T6 Aluminum: The high-strength "aerospace powerhouse." Choose this only when maximum strength-to-weight ratio is a critical design requirement and you can accommodate a higher budget and mandatory protective finishing.

Data-Driven Comparison: Material Properties

Key Performance Differences:

• Tensile Strength: 7075 is ~85% stronger (572 MPa vs 310 MPa)
• Yield Strength: 7075 is ~82% stronger (503 MPa vs 276 MPa)
• Hardness: 7075 is significantly harder (150 HB vs 95 HB)
• Weldability: 6061 is excellent, 7075 is poor
• Corrosion Resistance: 6061 is excellent, 7075 requires protective coating
• Cost: 7075 raw material is 50-80% more expensive

Decision Framework

Choose 6061-T6 when you need:
• Good all-around performance and cost-effectiveness
• Welding capability
• Corrosion resistance without coating
• Structural components, electronic enclosures, marine applications

Choose 7075-T6 when you need:
• Maximum strength-to-weight ratio
• Aerospace-grade performance
• High-stress applications
• Budget allows for mandatory protective finishing

Final Recommendation: Start every design with 6061-T6. Perform stress analysis (FEA). Only upgrade to 7075-T6 if analysis shows unacceptable deflection or failure and weight cannot be added.