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SAE-AISI 1040 Steel vs. 4032 Aluminum

SAE-AISI 1040 steel belongs to the iron alloys classification, while 4032 aluminum belongs to the aluminum alloys. There are 31 material properties with values for both materials. Properties with values for just one material (1, 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 4032 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 160 to 180
120
Elastic (Young's, Tensile) Modulus, GPa 190
73
Elongation at Break, % 13 to 20
6.7
Fatigue Strength, MPa 220 to 340
110
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 73
28
Shear Strength, MPa 350 to 390
260
Tensile Strength: Ultimate (UTS), MPa 570 to 640
390
Tensile Strength: Yield (Proof), MPa 320 to 530
320

Thermal Properties

Latent Heat of Fusion, J/g 250
570
Maximum Temperature: Mechanical, °C 400
180
Melting Completion (Liquidus), °C 1460
570
Melting Onset (Solidus), °C 1420
530
Specific Heat Capacity, J/kg-K 470
900
Thermal Conductivity, W/m-K 51
140
Thermal Expansion, µm/m-K 12
19

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.0
34
Electrical Conductivity: Equal Weight (Specific), % IACS 8.0
120

Otherwise Unclassified Properties

Base Metal Price, % relative 1.8
10
Density, g/cm3 7.8
2.6
Embodied Carbon, kg CO2/kg material 1.4
7.8
Embodied Energy, MJ/kg 18
140
Embodied Water, L/kg 46
1030

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 79 to 96
25
Resilience: Unit (Modulus of Resilience), kJ/m3 270 to 760
700
Stiffness to Weight: Axial, points 13
15
Stiffness to Weight: Bending, points 24
53
Strength to Weight: Axial, points 20 to 23
41
Strength to Weight: Bending, points 19 to 21
45
Thermal Diffusivity, mm2/s 14
59
Thermal Shock Resistance, points 18 to 20
20

Alloy Composition

Aluminum (Al), % 0
81.1 to 87.2
Carbon (C), % 0.37 to 0.44
0
Chromium (Cr), % 0
0 to 0.1
Copper (Cu), % 0
0.5 to 1.3
Iron (Fe), % 98.6 to 99.03
0 to 1.0
Magnesium (Mg), % 0
0.8 to 1.3
Manganese (Mn), % 0.6 to 0.9
0
Nickel (Ni), % 0
0.5 to 1.3
Phosphorus (P), % 0 to 0.040
0
Silicon (Si), % 0
11 to 13.5
Sulfur (S), % 0 to 0.050
0
Zinc (Zn), % 0
0 to 0.25
Residuals, % 0
0 to 0.15