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5154A Aluminum vs. SAE-AISI 9255 Steel

5154A aluminum belongs to the aluminum alloys classification, while SAE-AISI 9255 steel belongs to the iron alloys. 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 5154A aluminum and the bottom bar is SAE-AISI 9255 steel.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 58 to 100
200
Elastic (Young's, Tensile) Modulus, GPa 68
190
Elongation at Break, % 1.1 to 19
21
Fatigue Strength, MPa 83 to 160
270
Poisson's Ratio 0.33
0.29
Shear Modulus, GPa 26
72
Shear Strength, MPa 140 to 210
430
Tensile Strength: Ultimate (UTS), MPa 230 to 370
680
Tensile Strength: Yield (Proof), MPa 96 to 320
390

Thermal Properties

Latent Heat of Fusion, J/g 400
280
Maximum Temperature: Mechanical, °C 190
400
Melting Completion (Liquidus), °C 650
1430
Melting Onset (Solidus), °C 600
1390
Specific Heat Capacity, J/kg-K 900
480
Thermal Conductivity, W/m-K 130
46
Thermal Expansion, µm/m-K 24
13

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 32
7.4
Electrical Conductivity: Equal Weight (Specific), % IACS 110
8.6

Otherwise Unclassified Properties

Base Metal Price, % relative 9.5
2.0
Density, g/cm3 2.7
7.7
Embodied Carbon, kg CO2/kg material 8.8
1.5
Embodied Energy, MJ/kg 150
20
Embodied Water, L/kg 1180
46

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 4.0 to 36
120
Resilience: Unit (Modulus of Resilience), kJ/m3 68 to 760
400
Stiffness to Weight: Axial, points 14
13
Stiffness to Weight: Bending, points 51
25
Strength to Weight: Axial, points 24 to 38
24
Strength to Weight: Bending, points 31 to 43
22
Thermal Diffusivity, mm2/s 53
13
Thermal Shock Resistance, points 10 to 16
21

Alloy Composition

Aluminum (Al), % 93.7 to 96.9
0
Carbon (C), % 0
0.51 to 0.59
Chromium (Cr), % 0 to 0.25
0
Copper (Cu), % 0 to 0.1
0
Iron (Fe), % 0 to 0.5
96.2 to 97
Magnesium (Mg), % 3.1 to 3.9
0
Manganese (Mn), % 0 to 0.5
0.7 to 1.0
Phosphorus (P), % 0
0 to 0.035
Silicon (Si), % 0 to 0.5
1.8 to 2.2
Sulfur (S), % 0
0 to 0.040
Titanium (Ti), % 0 to 0.2
0
Zinc (Zn), % 0 to 0.2
0
Residuals, % 0 to 0.15
0