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5454 Aluminum vs. SAE-AISI 9260 Steel

5454 aluminum belongs to the aluminum alloys classification, while SAE-AISI 9260 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 5454 aluminum and the bottom bar is SAE-AISI 9260 steel.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 61 to 93
200
Elastic (Young's, Tensile) Modulus, GPa 69
190
Elongation at Break, % 2.3 to 18
21
Fatigue Strength, MPa 83 to 160
260
Poisson's Ratio 0.33
0.29
Shear Modulus, GPa 26
72
Shear Strength, MPa 140 to 200
420
Tensile Strength: Ultimate (UTS), MPa 230 to 350
660
Tensile Strength: Yield (Proof), MPa 97 to 290
380

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
45
Thermal Expansion, µm/m-K 24
13

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 34
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 8.6
1.5
Embodied Energy, MJ/kg 150
20
Embodied Water, L/kg 1180
46

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 6.3 to 34
120
Resilience: Unit (Modulus of Resilience), kJ/m3 68 to 590
380
Stiffness to Weight: Axial, points 14
13
Stiffness to Weight: Bending, points 50
25
Strength to Weight: Axial, points 23 to 36
24
Strength to Weight: Bending, points 30 to 41
22
Thermal Diffusivity, mm2/s 55
12
Thermal Shock Resistance, points 10 to 16
20

Alloy Composition

Aluminum (Al), % 94.5 to 97.1
0
Carbon (C), % 0
0.56 to 0.64
Chromium (Cr), % 0.050 to 0.2
0
Copper (Cu), % 0 to 0.1
0
Iron (Fe), % 0 to 0.4
96.1 to 96.9
Magnesium (Mg), % 2.4 to 3.0
0
Manganese (Mn), % 0.5 to 1.0
0.75 to 1.0
Phosphorus (P), % 0
0 to 0.035
Silicon (Si), % 0 to 0.25
1.8 to 2.2
Sulfur (S), % 0
0 to 0.040
Titanium (Ti), % 0 to 0.2
0
Zinc (Zn), % 0 to 0.25
0
Residuals, % 0 to 0.15
0