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AISI 309S Stainless Steel vs. 5040 Aluminum

AISI 309S stainless steel belongs to the iron alloys classification, while 5040 aluminum belongs to the aluminum alloys. There are 31 material properties with values for both materials. Properties with values for just one material (4, 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 AISI 309S stainless steel and the bottom bar is 5040 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 190
66 to 74
Elastic (Young's, Tensile) Modulus, GPa 200
70
Elongation at Break, % 42
5.7 to 6.8
Fatigue Strength, MPa 210
100 to 130
Poisson's Ratio 0.27
0.33
Shear Modulus, GPa 78
26
Shear Strength, MPa 400
140 to 150
Tensile Strength: Ultimate (UTS), MPa 580
240 to 260
Tensile Strength: Yield (Proof), MPa 230
190 to 230

Thermal Properties

Latent Heat of Fusion, J/g 290
400
Maximum Temperature: Mechanical, °C 1080
190
Melting Completion (Liquidus), °C 1420
650
Melting Onset (Solidus), °C 1370
600
Specific Heat Capacity, J/kg-K 480
900
Thermal Conductivity, W/m-K 15
160
Thermal Expansion, µm/m-K 16
23

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 2.2
41
Electrical Conductivity: Equal Weight (Specific), % IACS 2.5
130

Otherwise Unclassified Properties

Base Metal Price, % relative 19
9.5
Density, g/cm3 7.8
2.8
Embodied Carbon, kg CO2/kg material 3.6
8.3
Embodied Energy, MJ/kg 51
150
Embodied Water, L/kg 170
1180

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 190
14 to 15
Resilience: Unit (Modulus of Resilience), kJ/m3 140
260 to 380
Stiffness to Weight: Axial, points 14
14
Stiffness to Weight: Bending, points 25
50
Strength to Weight: Axial, points 21
24 to 26
Strength to Weight: Bending, points 20
31 to 32
Thermal Diffusivity, mm2/s 4.0
64
Thermal Shock Resistance, points 13
10 to 11

Alloy Composition

Aluminum (Al), % 0
95.2 to 98
Carbon (C), % 0 to 0.080
0
Chromium (Cr), % 22 to 24
0.1 to 0.3
Copper (Cu), % 0
0 to 0.25
Iron (Fe), % 58.1 to 66
0 to 0.7
Magnesium (Mg), % 0
1.0 to 1.5
Manganese (Mn), % 0 to 2.0
0.9 to 1.4
Nickel (Ni), % 12 to 15
0
Phosphorus (P), % 0 to 0.045
0
Silicon (Si), % 0 to 0.75
0 to 0.3
Sulfur (S), % 0 to 0.030
0
Zinc (Zn), % 0
0 to 0.25
Residuals, % 0
0 to 0.15