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5042 Aluminum vs. AISI 202 Stainless Steel

5042 aluminum belongs to the aluminum alloys classification, while AISI 202 stainless steel belongs to the iron alloys. There are 30 material properties with values for both materials. Properties with values for just one material (3, 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 5042 aluminum and the bottom bar is AISI 202 stainless steel.

Metric UnitsUS Customary Units

Mechanical Properties

Elastic (Young's, Tensile) Modulus, GPa 68
200
Elongation at Break, % 1.1 to 3.4
14 to 45
Fatigue Strength, MPa 97 to 120
290 to 330
Poisson's Ratio 0.33
0.28
Shear Modulus, GPa 26
77
Shear Strength, MPa 200
490 to 590
Tensile Strength: Ultimate (UTS), MPa 340 to 360
700 to 980
Tensile Strength: Yield (Proof), MPa 270 to 310
310 to 580

Thermal Properties

Latent Heat of Fusion, J/g 400
290
Maximum Temperature: Mechanical, °C 180
910
Melting Completion (Liquidus), °C 640
1400
Melting Onset (Solidus), °C 570
1360
Specific Heat Capacity, J/kg-K 900
480
Thermal Conductivity, W/m-K 130
15
Thermal Expansion, µm/m-K 24
17

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 33
2.4
Electrical Conductivity: Equal Weight (Specific), % IACS 110
2.9

Otherwise Unclassified Properties

Base Metal Price, % relative 9.5
13
Density, g/cm3 2.7
7.7
Embodied Carbon, kg CO2/kg material 8.8
2.8
Embodied Energy, MJ/kg 150
40
Embodied Water, L/kg 1180
150

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 3.6 to 12
120 to 260
Resilience: Unit (Modulus of Resilience), kJ/m3 550 to 720
250 to 840
Stiffness to Weight: Axial, points 14
14
Stiffness to Weight: Bending, points 50
25
Strength to Weight: Axial, points 35 to 37
25 to 35
Strength to Weight: Bending, points 40 to 42
23 to 29
Thermal Diffusivity, mm2/s 53
4.0
Thermal Shock Resistance, points 15 to 16
15 to 21

Alloy Composition

Aluminum (Al), % 94.2 to 96.8
0
Carbon (C), % 0
0 to 0.15
Chromium (Cr), % 0 to 0.1
17 to 19
Copper (Cu), % 0 to 0.15
0
Iron (Fe), % 0 to 0.35
63.5 to 71.5
Magnesium (Mg), % 3.0 to 4.0
0
Manganese (Mn), % 0.2 to 0.5
7.5 to 10
Nickel (Ni), % 0
4.0 to 6.0
Nitrogen (N), % 0
0 to 0.25
Phosphorus (P), % 0
0 to 0.060
Silicon (Si), % 0 to 0.2
0 to 1.0
Sulfur (S), % 0
0 to 0.030
Titanium (Ti), % 0 to 0.1
0
Zinc (Zn), % 0 to 0.25
0
Residuals, % 0 to 0.15
0