Aluminum alloy AA6061 was SPD (Severe Plastic Deformation) processed by Equal Channel Angular Pressing (ECAP) to study the effect of accumulated strain on the hot workability and heat-treatment response of the alloy. In this study, O and W tempered AA 6061 samples were subjected to severe plastic deformation at room temperature by ECAP (Route BC), producing 50 mm and 100 mm square billets. Hot workability of O tempered material was determined by forging industrial parts at various temperatures. Heat treatment studies were carried out on as pressed W tempered material. Results show that both the forging temperature of the billets and the starting billet size can be substantially decreased compared to conventional forging practice. Peak hardness was obtained at shorter heat treatment times compared to that of the conventional material. Forging at lower temperatures, decreased material usage, and heat treatment at shorter times indicate that significant energy savings are possible.