Uploaded January 2026 | Updated September 2026, 2 weeks ago

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6061-T6 aluminum offers great conductivity and strength—but if you’ve ever tried bending it tight, you know the pain: cracks and failures.

In this episode of Ask an Engineer, Iain breaks down why 6061-T6 aluminum bus bars crack, what’s happening metallurgically, and how you can fix it.

🔩 Learn how to bend 6061 safely 
⚙️ See when to switch to 5052 aluminum or Copper C110 

💡 Bonus: Design tips for hole spacing and bend radius

Get your free Bus Bar Design Guide 👉🏻- protocase.com/products/bus-bars.php

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