This article describes the effect of extrusion ratio in direct extrusion process on mechanical behaviours of alloy AA-6101. The alloy is used mainly as feedstock in manufacturing of AAAC type aluminium alloy conductors and extrusions for compression joints and connectors in electrical industry. Extrusion ratio effect was examined by extruding the billets at different billet temperatures. The billet structures have been prepared as homogenised-rapid quenched (HRQ) and unhomogenised-slow cooled (UHSC). Keeping up constant the forward speed of the main ram and the exit temperature of the extrusions, AA-6101 billets were extruded directly by using three different dies with diameters 10, 30 and 50 mm. Mechanical measurements of the specimens were made after T-1 and T-6 treatments. Extrusion ratio effect on tensile strength, elongation and hardness of extrusions from the AA-6101 billets was appreciated on the graphics. (c) 2004 Elsevier B.V. All rights reserved.