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SAE-AISI 1042 Steel vs. 5005 Aluminum

SAE-AISI 1042 steel belongs to the iron alloys classification, while 5005 aluminum belongs to the aluminum alloys. There are 31 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 1042 steel and the bottom bar is 5005 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 180 to 200
28 to 64
Elastic (Young's, Tensile) Modulus, GPa 190
68
Elongation at Break, % 14 to 18
1.1 to 23
Fatigue Strength, MPa 230 to 370
38 to 86
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 73
26
Shear Strength, MPa 380 to 420
70 to 130
Tensile Strength: Ultimate (UTS), MPa 620 to 700
110 to 230
Tensile Strength: Yield (Proof), MPa 340 to 580
41 to 210

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
630
Specific Heat Capacity, J/kg-K 470
900
Thermal Conductivity, W/m-K 52
200
Thermal Expansion, µm/m-K 12
24

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.0
52
Electrical Conductivity: Equal Weight (Specific), % IACS 8.1
170

Otherwise Unclassified Properties

Base Metal Price, % relative 1.8
9.5
Density, g/cm3 7.8
2.7
Embodied Carbon, kg CO2/kg material 1.4
8.3
Embodied Energy, MJ/kg 18
150
Embodied Water, L/kg 46
1190

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 87 to 94
2.3 to 22
Resilience: Unit (Modulus of Resilience), kJ/m3 320 to 900
12 to 320
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 24
50
Strength to Weight: Axial, points 22 to 25
11 to 23
Strength to Weight: Bending, points 21 to 22
19 to 31
Thermal Diffusivity, mm2/s 14
82
Thermal Shock Resistance, points 20 to 22
4.9 to 10

Alloy Composition

Aluminum (Al), % 0
97 to 99.5
Carbon (C), % 0.4 to 0.47
0
Chromium (Cr), % 0
0 to 0.1
Copper (Cu), % 0
0 to 0.2
Iron (Fe), % 98.5 to 99
0 to 0.7
Magnesium (Mg), % 0
0.5 to 1.1
Manganese (Mn), % 0.6 to 0.9
0 to 0.2
Phosphorus (P), % 0 to 0.040
0
Silicon (Si), % 0
0 to 0.3
Sulfur (S), % 0 to 0.050
0
Zinc (Zn), % 0
0 to 0.25
Residuals, % 0
0 to 0.15