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5040 Aluminum vs. SAE-AISI 1025 Steel

5040 aluminum belongs to the aluminum alloys classification, while SAE-AISI 1025 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 5040 aluminum and the bottom bar is SAE-AISI 1025 steel.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 66 to 74
130 to 140
Elastic (Young's, Tensile) Modulus, GPa 70
190
Elongation at Break, % 5.7 to 6.8
17 to 28
Fatigue Strength, MPa 100 to 130
190 to 280
Poisson's Ratio 0.33
0.29
Shear Modulus, GPa 26
73
Shear Strength, MPa 140 to 150
290 to 310
Tensile Strength: Ultimate (UTS), MPa 240 to 260
450 to 500
Tensile Strength: Yield (Proof), MPa 190 to 230
250 to 420

Thermal Properties

Latent Heat of Fusion, J/g 400
250
Maximum Temperature: Mechanical, °C 190
400
Melting Completion (Liquidus), °C 650
1460
Melting Onset (Solidus), °C 600
1420
Specific Heat Capacity, J/kg-K 900
470
Thermal Conductivity, W/m-K 160
52
Thermal Expansion, µm/m-K 23
12

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 41
6.9
Electrical Conductivity: Equal Weight (Specific), % IACS 130
8.0

Otherwise Unclassified Properties

Base Metal Price, % relative 9.5
1.8
Density, g/cm3 2.8
7.9
Embodied Carbon, kg CO2/kg material 8.3
1.4
Embodied Energy, MJ/kg 150
18
Embodied Water, L/kg 1180
45

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 14 to 15
80 to 110
Resilience: Unit (Modulus of Resilience), kJ/m3 260 to 380
170 to 470
Stiffness to Weight: Axial, points 14
13
Stiffness to Weight: Bending, points 50
24
Strength to Weight: Axial, points 24 to 26
16 to 18
Strength to Weight: Bending, points 31 to 32
17 to 18
Thermal Diffusivity, mm2/s 64
14
Thermal Shock Resistance, points 10 to 11
14 to 16

Alloy Composition

Aluminum (Al), % 95.2 to 98
0
Carbon (C), % 0
0.22 to 0.28
Chromium (Cr), % 0.1 to 0.3
0
Copper (Cu), % 0 to 0.25
0
Iron (Fe), % 0 to 0.7
99.03 to 99.48
Magnesium (Mg), % 1.0 to 1.5
0
Manganese (Mn), % 0.9 to 1.4
0.3 to 0.6
Phosphorus (P), % 0
0 to 0.040
Silicon (Si), % 0 to 0.3
0
Sulfur (S), % 0
0 to 0.050
Zinc (Zn), % 0 to 0.25
0
Residuals, % 0 to 0.15
0