If you’re sourcing forged wheels for your business—whether for high‑end performance cars, off‑road trucks, or specialty builds—you’ve likely come across two key material choices: AZ80 forged magnesium and 6061‑T6 forged aluminum. Each offers distinct advantages and trade‑offs. This article breaks down how they compare — weight, strength, cost, and durability — so you can make smarter sourcing decisions for your customers.

1. What Are AZ80 Magnesium and 6061‑T6 Aluminum?

• AZ80 Magnesium is a high‑performance alloy used increasingly in motorsports and premium aftermarket applications. It offers excellent strength‑to‑weight ratio, high fatigue resistance, and is one of the strongest commercial magnesium alloys available.
• 6061‑T6 Aluminum is the most commonly used alloy in forged wheel manufacturing. It offers excellent strength, corrosion resistance, and machinability, making it a reliable choice across most use cases.

Bottom line: AZ80 is lighter and higher-performing, while 6061‑T6 is more stable and accessible.

2. Weight Savings

One of magnesium’s biggest advantages is weight. On average, magnesium is about 33% lighter than aluminum. For wheels, this means significant reductions in unsprung and rotational mass — translating into:

• Faster acceleration
• Better suspension response
• Improved braking performance

Take‑away: For motorsports and performance applications, AZ80 magnesium offers a real edge in reducing weight without compromising strength.

3. Strength and Fatigue Performance

AZ80 magnesium and 6061‑T6 aluminum both offer high strength, but their mechanical properties differ:

• AZ80 Magnesium: High tensile strength and fatigue resistance when properly forged and heat-treated. Performs well under repeated stress and high-speed conditions.
• 6061‑T6 Aluminum: Balanced strength and durability. It’s widely trusted and extensively tested across street and performance use cases.

Take‑away: AZ80 excels in extreme environments but requires precise manufacturing. 6061‑T6 is proven and stable for a wider range of vehicles.

4. Corrosion Resistance

Historically, magnesium has struggled with corrosion, especially in humid or salty environments. While modern AZ80 with protective coatings can resist corrosion well, it still requires more attention during use and maintenance.

Aluminum, especially 6061‑T6, offers better inherent corrosion resistance, especially when anodized or powder-coated — making it more suitable for:

• Daily driven vehicles
• Off-road trucks
• Harsh weather conditions

Take‑away: For clients in coastal regions or with year-round use in wet climates, aluminum offers lower maintenance and longer service life.

5. Manufacturing Complexity and Cost

• AZ80 Magnesium Wheels:
  • Higher raw material cost
  • More complex forging and CNC machining process
  • Requires specialized coating and sealing
  • Limited supply sources
• 6061‑T6 Aluminum Wheels:
  • More cost-effective
  • Easier to machine and finish
  • More supplier options and faster lead times

Take‑away: Magnesium is for high-budget, high-performance builds. Aluminum is ideal for mainstream tuning shops and performance businesses.

6. Best Applications by Material

Final Thoughts

There’s no one-size-fits-all material. The right choice depends on your market, your client’s expectations, and your ability to support the product long-term.

• Choose AZ80 magnesium when your client demands every performance advantage and is ready for a higher budget and maintenance discipline.
• Choose 6061‑T6 aluminum when you want reliable performance, better value, and fewer supply chain challenges.

At FLEXIFORGED, we offer both materials — forged in precision and finished to global standards — so you can choose what fits your build best. If you’re not sure which is better for your market, reach out — we’re happy to offer practical advice, not just specs.