SAE-AISI 1090 Steel vs. 5040 Aluminum
SAE-AISI 1090 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 (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 1090 steel and the bottom bar is 5040 aluminum.
Metric UnitsUS Customary Units
Mechanical Properties
| Brinell Hardness | 220 to 280 | |
| 66 to 74 |
| Elastic (Young's, Tensile) Modulus, GPa | 190 | |
| 70 |
| Elongation at Break, % | 11 | |
| 5.7 to 6.8 |
| Fatigue Strength, MPa | 320 to 380 | |
| 100 to 130 |
| Poisson's Ratio | 0.29 | |
| 0.33 |
| Shear Modulus, GPa | 72 | |
| 26 |
| Shear Strength, MPa | 470 to 570 | |
| 140 to 150 |
| Tensile Strength: Ultimate (UTS), MPa | 790 to 950 | |
| 240 to 260 |
| Tensile Strength: Yield (Proof), MPa | 520 to 610 | |
| 190 to 230 |
Thermal Properties
| Latent Heat of Fusion, J/g | 240 | |
| 400 |
| Maximum Temperature: Mechanical, °C | 400 | |
| 190 |
| Melting Completion (Liquidus), °C | 1450 | |
| 650 |
| Melting Onset (Solidus), °C | 1410 | |
| 600 |
| Specific Heat Capacity, J/kg-K | 470 | |
| 900 |
| Thermal Conductivity, W/m-K | 50 | |
| 160 |
| Thermal Expansion, µm/m-K | 12 | |
| 23 |
Electrical Properties
| Electrical Conductivity: Equal Volume, % IACS | 7.1 | |
| 41 |
| Electrical Conductivity: Equal Weight (Specific), % IACS | 8.2 | |
| 130 |
Otherwise Unclassified Properties
| Base Metal Price, % relative | 1.8 | |
| 9.5 |
| Density, g/cm3 | 7.8 | |
| 2.8 |
| Embodied Carbon, kg CO2/kg material | 1.4 | |
| 8.3 |
| Embodied Energy, MJ/kg | 19 | |
| 150 |
| Embodied Water, L/kg | 46 | |
| 1180 |
Common Calculations
| Resilience: Ultimate (Unit Rupture Work), MJ/m3 | 82 to 91 | |
| 14 to 15 |
| Resilience: Unit (Modulus of Resilience), kJ/m3 | 730 to 1000 | |
| 260 to 380 |
| Stiffness to Weight: Axial, points | 13 | |
| 14 |
| Stiffness to Weight: Bending, points | 24 | |
| 50 |
| Strength to Weight: Axial, points | 28 to 34 | |
| 24 to 26 |
| Strength to Weight: Bending, points | 24 to 27 | |
| 31 to 32 |
| Thermal Diffusivity, mm2/s | 13 | |
| 64 |
| Thermal Shock Resistance, points | 25 to 31 | |
| 10 to 11 |
Alloy Composition
| Aluminum (Al), % | 0 | |
| 95.2 to 98 |
| Carbon (C), % | 0.85 to 1.0 | |
| 0 |
| Chromium (Cr), % | 0 | |
| 0.1 to 0.3 |
| Copper (Cu), % | 0 | |
| 0 to 0.25 |
| Iron (Fe), % | 98 to 98.6 | |
| 0 to 0.7 |
| Magnesium (Mg), % | 0 | |
| 1.0 to 1.5 |
| Manganese (Mn), % | 0.6 to 0.9 | |
| 0.9 to 1.4 |
| 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 |