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SAE-AISI 1040 Steel vs. 3203 Aluminum

SAE-AISI 1040 steel belongs to the iron alloys classification, while 3203 aluminum belongs to the aluminum alloys. There are 30 material properties with values for both materials. Properties with values for just one material (2, 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 SAE-AISI 1040 steel and the bottom bar is 3203 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Elastic (Young's, Tensile) Modulus, GPa 190
70
Elongation at Break, % 13 to 20
4.5 to 29
Fatigue Strength, MPa 220 to 340
46 to 92
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 73
26
Shear Strength, MPa 350 to 390
72 to 120
Tensile Strength: Ultimate (UTS), MPa 570 to 640
110 to 200
Tensile Strength: Yield (Proof), MPa 320 to 530
39 to 190

Thermal Properties

Latent Heat of Fusion, J/g 250
400
Maximum Temperature: Mechanical, °C 400
180
Melting Completion (Liquidus), °C 1460
650
Melting Onset (Solidus), °C 1420
620
Specific Heat Capacity, J/kg-K 470
900
Thermal Conductivity, W/m-K 51
170
Thermal Expansion, µm/m-K 12
23

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.0
43
Electrical Conductivity: Equal Weight (Specific), % IACS 8.0
140

Otherwise Unclassified Properties

Base Metal Price, % relative 1.8
9.0
Density, g/cm3 7.8
2.8
Embodied Carbon, kg CO2/kg material 1.4
8.1
Embodied Energy, MJ/kg 18
150
Embodied Water, L/kg 46
1180

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 79 to 96
8.0 to 25
Resilience: Unit (Modulus of Resilience), kJ/m3 270 to 760
11 to 250
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 24
50
Strength to Weight: Axial, points 20 to 23
11 to 20
Strength to Weight: Bending, points 19 to 21
19 to 28
Thermal Diffusivity, mm2/s 14
70
Thermal Shock Resistance, points 18 to 20
4.9 to 8.8

Alloy Composition

Aluminum (Al), % 0
96.9 to 99
Carbon (C), % 0.37 to 0.44
0
Copper (Cu), % 0
0 to 0.050
Iron (Fe), % 98.6 to 99.03
0 to 0.7
Manganese (Mn), % 0.6 to 0.9
1.0 to 1.5
Phosphorus (P), % 0 to 0.040
0
Silicon (Si), % 0
0 to 0.6
Sulfur (S), % 0 to 0.050
0
Zinc (Zn), % 0
0 to 0.1
Residuals, % 0
0 to 0.15