Two bars of 6061-T6 from the same nominal spec. One makes bright chips. The other smears, loads the tool, and the surface looks torn at the same feeds. Both are marked T6. Hardness on a handheld tester is close.
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T6 on the label is not a chip test. Ask the supplier for the mill cert and look at chemistry and actual temper. A bar that machines gummy at a feed that works next door is often a different lot or a bar that was not fully heat treated, even when a quick hardness check looks similar.
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Raise the chip load and use a sharp aluminum edge on the gummy bar before you slow down. Slowing down makes the smear worse.
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Keep the two lots apart in the rack. Mixing them in one setup is how a proved program starts failing halfway through the cart.
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Questions and answers were written on this account when they were published.
