Aluminum Flat Bars — The Most Versatile Bar Stock for Brackets, Bus Bars, Reinforcement and CNC Machining
Aluminum flat bars are solid rectangular-section bar stock and the single most versatile aluminum semi-finished product in industrial use. From electrical bus bars and structural reinforcement strips to CNC-machined brackets and machine guards, aluminum flat bar serves more applications than any other bar profile. ULAMEX supplies aluminum flat bars in three alloy families: PA38 (EN AW-6060 T6) for general-purpose and decorative applications, PA4 for specific forming requirements, and PA6 (EN AW-6082 T6) for high-strength structural use. Available widths range from 20 to 120 mm with thicknesses from 2 to 30 mm, all in a standard length of 6,000 mm. As an aluminum bar stock supplier, ULAMEX delivers cut-to-size flat bars across Europe with full material certification.
Material Properties and Technical Data
Our flat bar range covers two primary alloy grades in the T6 temper — solution heat-treated and artificially aged for optimal performance.
EN AW-6060 T6 (PA38, material no. 3.3206, AlMgSi):
- Tensile strength (Rm): 190-220 MPa
- Yield strength (Rp0.2): ≥150 MPa
- Elongation (A50): ≥8%
- Brinell hardness: ~75 HB
- Excellent surface finish, superior anodizing response, good formability
EN AW-6082 T6 (PA6, material no. 3.2315, AlSi1MgMn):
- Tensile strength (Rm): 295-340 MPa
- Yield strength (Rp0.2): ≥250 MPa
- Elongation (A50): ≥6%
- Brinell hardness: ~95 HB
- Highest strength in the 6000 series, preferred for load-bearing flat bar applications
Both alloys share a density of 2.70 g/cm³, inherent corrosion resistance, good thermal conductivity (150-210 W/m·K) and electrical conductivity. Aluminum flat bar is manufactured to EN 755-1/2 (extruded bar) and EN 573-3 (chemical composition).
Dimensions and Available Sizes
Width range: 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 90, 100, 110 and 120 mm.
Thickness range: 2, 3, 4, 5, 6, 8, 10, 12, 15, 20, 25 and 30 mm.
Not all width-thickness combinations are stocked in every alloy. Popular sizes include 30×5, 40×5, 40×10, 50×5, 50×10, 60×5, 60×10, 80×10 and 100×10 mm. PA38 (EN AW-6060) covers the lighter dimensions (thicknesses 2-10 mm), while PA6 (EN AW-6082) is typically available in thicknesses from 5 to 30 mm for structural use. Standard length: 6,000 mm for all alloys. Custom cutting to your specified length is available. Tolerances per EN 755-2. For non-standard combinations, contact us with your requirements.
Applications by Industry
Electrical Engineering and Bus Bars: Aluminum flat bars are the standard conductor profile for electrical bus bars, distribution bars, grounding strips and switchgear connections. The rectangular cross-section provides maximum surface area for heat dissipation, while the high electrical conductivity of EN AW-6060 (56% IACS) makes it a cost-effective and lightweight alternative to copper bus bar. Typical bus bar dimensions range from 30×5 to 100×10 mm. Flat bar connections are bolted or welded, with contact surfaces requiring clean, oxide-free preparation for optimal conductivity.
CNC Machining and Fabrication: Flat bar is the most frequently ordered starting material for CNC-milled brackets, mounting plates, gusset plates, adapters and custom hardware. The pre-defined width and thickness eliminate one machining operation compared to cutting from plate, reducing both cycle time and material cost. Both 6060 and 6082 offer excellent machinability with clean chip formation at high spindle speeds.
Construction and Structural Reinforcement: Aluminum flat bars serve as reinforcement strips, stiffener ribs, connection straps, splice plates and bearing pads in curtain wall systems, facade frames, glazing systems and modular building components. PA6 (6082) flat bars in 60×10 mm and above provide the load-carrying capacity required for structural connections designed to EN 1999 (Eurocode 9).
Mechanical Engineering: Flat bars function as wear strips, guide rails, slide plates, clamping bars, spacer shims and machine guards. The combination of lightweight, corrosion resistance and easy machinability makes aluminum flat bar the standard material for conveyor guide rails, packaging machine components and automation equipment.
Automotive and Transport: Lightweight aluminum flat bars replace steel in body reinforcements, mounting brackets, trim strips and structural stiffeners. The 65% weight saving is critical in commercial vehicle and trailer applications where payload efficiency directly affects operating economics.
Furniture, Signage and Architecture: EN AW-6060 flat bars in thinner dimensions (2-5 mm) serve as edge banding, trim strips, shelf supports, sign mounting rails and decorative framing elements. The alloy’s superior anodizing properties enable color-matched architectural finishes in natural, bronze, black and custom RAL colors.
Material Comparison: EN AW-6060 vs EN AW-6082 Flat Bars
Selecting between 6060 and 6082 aluminum flat bar (PA38 vs PA6) follows the same logic as all 6000-series products. EN AW-6060 T6 is your default choice for electrical bus bars, decorative applications, general-purpose brackets and any application where surface quality, anodizing response or formability matter most. EN AW-6082 T6 is the engineering choice when structural load-bearing capacity, fatigue resistance or yield strength above 250 MPa is required — choose it for structural connections, heavy-duty mounting brackets and high-stress fabrications.
Compared to steel flat bar, aluminum flat bar offers 65% lower weight (2.70 vs 7.85 g/cm³), inherent corrosion resistance, superior electrical and thermal conductivity, and 3-4x faster machining speeds. For applications requiring maximum strength or hardness, see our steel bar and stainless steel bar ranges.
Machining and Processing Guide
Aluminum flat bars are among the easiest metals to process. Cutting: band saw, circular saw or guillotine shear (for thicknesses up to 6 mm). CNC milling speeds of 200-500 m/min with feed per tooth of 0.05-0.20 mm deliver clean finishes. Bending: flat bars in 6060 can be cold-bent to 90° with inside radius ≥2x thickness; 6082 requires larger radii (≥3x thickness) to avoid surface cracking. Both alloys are TIG and MIG weldable using AlSi5 (4043) or AlMg5 (5356) filler wire. For bus bar applications, bolted connections with Belleville washers are preferred over welding to maintain full conductivity.
Quality and Certification
All ULAMEX aluminum flat bars are supplied with mill test certificate 3.1 per EN 10204, documenting chemical composition, mechanical properties and dimensional measurements. Our supply chain operates under ISO 3834-2 quality management. For structural applications, documentation per EN 1090 is available. Electrical-grade flat bars can be supplied with conductivity test results on request.
Frequently Asked Questions
What is the difference between EN AW-6060 and EN AW-6082 aluminum flat bars?
EN AW-6060 (PA38) is a medium-strength alloy with excellent surface finish, formability and anodizing properties — ideal for electrical bus bars, decorative trim and general brackets. EN AW-6082 (PA6) delivers approximately 50% higher tensile strength (295-340 MPa vs 190-220 MPa) and is chosen for structural, load-bearing connections and high-stress fabrications.
Can aluminum flat bars be used as bus bars?
Yes. Aluminum flat bar is the standard profile for electrical bus bar applications. EN AW-6060 offers 56% IACS electrical conductivity at roughly one-third the weight and one-fifth the cost of copper. For high-current applications, consult the IEC 61439 standard for bus bar sizing calculations based on your amperage requirements.
What is the weight of aluminum flat bar per meter?
Weight per meter = width (mm) × thickness (mm) × 0.0027 kg/mm²/m. Examples: 40×5 mm = 0.54 kg/m, 50×10 mm = 1.35 kg/m, 80×10 mm = 2.16 kg/m, 100×10 mm = 2.70 kg/m. This is approximately 34% of the equivalent steel flat bar weight.
Can aluminum flat bars be bent?
Yes. EN AW-6060 flat bars can be cold-bent to 90° with an inside radius of at least 2x the bar thickness. EN AW-6082 requires a minimum inside radius of 3x thickness. Thinner flat bars (2-5 mm) bend more easily than thicker sections. For tight radii on 6082, hot bending or T4 temper with subsequent aging may be required.
What widths and thicknesses are available?
ULAMEX stocks aluminum flat bars in widths from 20 to 120 mm and thicknesses from 2 to 30 mm, covering the full range of industrial requirements. Popular sizes such as 40×5, 50×10, 60×10 and 80×10 mm are available for immediate dispatch.
Compatible Products and Related Bar Stock
Complete your project with ULAMEX aluminum bar products: round bars for turned components and dowel pins, square bars for jig and fixture bases, aluminum pipes for structural framing, and T-bars for profile connections. See our full aluminum pipes and rods category. For flat bar in alternative materials, see steel flat bars and stainless steel flat bars.