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5040 Aluminum vs. SAE-AISI 1035 Steel

5040 aluminum belongs to the aluminum alloys classification, while SAE-AISI 1035 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 1035 steel.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 66 to 74
160 to 180
Elastic (Young's, Tensile) Modulus, GPa 70
190
Elongation at Break, % 5.7 to 6.8
13 to 21
Fatigue Strength, MPa 100 to 130
210 to 340
Poisson's Ratio 0.33
0.29
Shear Modulus, GPa 26
73
Shear Strength, MPa 140 to 150
360 to 370
Tensile Strength: Ultimate (UTS), MPa 240 to 260
570 to 620
Tensile Strength: Yield (Proof), MPa 190 to 230
300 to 530

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
51
Thermal Expansion, µm/m-K 23
12

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 41
7.0
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
7.8
Embodied Carbon, kg CO2/kg material 8.3
1.4
Embodied Energy, MJ/kg 150
18
Embodied Water, L/kg 1180
46

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 14 to 15
79 to 99
Resilience: Unit (Modulus of Resilience), kJ/m3 260 to 380
250 to 740
Stiffness to Weight: Axial, points 14
13
Stiffness to Weight: Bending, points 50
24
Strength to Weight: Axial, points 24 to 26
20 to 22
Strength to Weight: Bending, points 31 to 32
19 to 21
Thermal Diffusivity, mm2/s 64
14
Thermal Shock Resistance, points 10 to 11
18 to 20

Alloy Composition

Aluminum (Al), % 95.2 to 98
0
Carbon (C), % 0
0.32 to 0.38
Chromium (Cr), % 0.1 to 0.3
0
Copper (Cu), % 0 to 0.25
0
Iron (Fe), % 0 to 0.7
98.6 to 99.08
Magnesium (Mg), % 1.0 to 1.5
0
Manganese (Mn), % 0.9 to 1.4
0.6 to 0.9
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