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2025 Aluminum vs. SAE-AISI 1090 Steel

2025 aluminum belongs to the aluminum alloys classification, while SAE-AISI 1090 steel belongs to the iron alloys. There are 31 material properties with values for both materials. Properties with values for just one material (1, in this case) are not shown. Please note that the two materials have significantly dissimilar densities. This means that additional care is required when interpreting the data, because some material properties are based on units of mass, while others are based on units of area or volume.

For each property being compared, the top bar is 2025 aluminum and the bottom bar is SAE-AISI 1090 steel.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 110
220 to 280
Elastic (Young's, Tensile) Modulus, GPa 72
190
Elongation at Break, % 15
11
Fatigue Strength, MPa 130
320 to 380
Poisson's Ratio 0.33
0.29
Shear Modulus, GPa 27
72
Shear Strength, MPa 240
470 to 570
Tensile Strength: Ultimate (UTS), MPa 400
790 to 950
Tensile Strength: Yield (Proof), MPa 260
520 to 610

Thermal Properties

Latent Heat of Fusion, J/g 400
240
Maximum Temperature: Mechanical, °C 190
400
Melting Completion (Liquidus), °C 640
1450
Melting Onset (Solidus), °C 520
1410
Specific Heat Capacity, J/kg-K 870
470
Thermal Conductivity, W/m-K 150
50
Thermal Expansion, µm/m-K 23
12

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 40
7.1
Electrical Conductivity: Equal Weight (Specific), % IACS 120
8.2

Otherwise Unclassified Properties

Base Metal Price, % relative 10
1.8
Density, g/cm3 3.0
7.8
Embodied Carbon, kg CO2/kg material 7.9
1.4
Embodied Energy, MJ/kg 150
19
Embodied Water, L/kg 1130
46

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 55
82 to 91
Resilience: Unit (Modulus of Resilience), kJ/m3 450
730 to 1000
Stiffness to Weight: Axial, points 13
13
Stiffness to Weight: Bending, points 46
24
Strength to Weight: Axial, points 37
28 to 34
Strength to Weight: Bending, points 40
24 to 27
Thermal Diffusivity, mm2/s 58
13
Thermal Shock Resistance, points 18
25 to 31

Alloy Composition

Aluminum (Al), % 90.9 to 95.2
0
Carbon (C), % 0
0.85 to 1.0
Chromium (Cr), % 0 to 0.1
0
Copper (Cu), % 3.9 to 5.0
0
Iron (Fe), % 0 to 1.0
98 to 98.6
Magnesium (Mg), % 0 to 0.050
0
Manganese (Mn), % 0.4 to 1.2
0.6 to 0.9
Phosphorus (P), % 0
0 to 0.040
Silicon (Si), % 0.5 to 1.2
0
Sulfur (S), % 0
0 to 0.050
Titanium (Ti), % 0 to 0.15
0
Zinc (Zn), % 0 to 0.25
0
Residuals, % 0 to 0.15
0