SAE-AISI 5135 Steel vs. 6463 Aluminum
SAE-AISI 5135 steel belongs to the iron alloys classification, while 6463 aluminum belongs to the aluminum alloys. 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 5135 steel and the bottom bar is 6463 aluminum.
Metric UnitsUS Customary Units
Mechanical Properties
| Brinell Hardness | 150 | |
| 42 to 74 |
| Elastic (Young's, Tensile) Modulus, GPa | 190 | |
| 68 |
| Elongation at Break, % | 22 | |
| 9.0 to 17 |
| Fatigue Strength, MPa | 240 | |
| 45 to 76 |
| Poisson's Ratio | 0.29 | |
| 0.33 |
| Shear Modulus, GPa | 73 | |
| 26 |
| Shear Strength, MPa | 320 | |
| 86 to 150 |
| Tensile Strength: Ultimate (UTS), MPa | 510 | |
| 140 to 230 |
| Tensile Strength: Yield (Proof), MPa | 340 | |
| 82 to 200 |
Thermal Properties
| Latent Heat of Fusion, J/g | 250 | |
| 400 |
| Maximum Temperature: Mechanical, °C | 420 | |
| 160 |
| Melting Completion (Liquidus), °C | 1460 | |
| 660 |
| Melting Onset (Solidus), °C | 1420 | |
| 620 |
| Specific Heat Capacity, J/kg-K | 470 | |
| 900 |
| Thermal Conductivity, W/m-K | 45 | |
| 190 to 210 |
| Thermal Expansion, µm/m-K | 12 | |
| 23 |
Electrical Properties
| Electrical Conductivity: Equal Volume, % IACS | 7.2 | |
| 50 to 55 |
| Electrical Conductivity: Equal Weight (Specific), % IACS | 8.3 | |
| 170 to 180 |
Otherwise Unclassified Properties
| Base Metal Price, % relative | 2.2 | |
| 9.5 |
| Density, g/cm3 | 7.8 | |
| 2.7 |
| Embodied Carbon, kg CO2/kg material | 1.4 | |
| 8.3 |
| Embodied Energy, MJ/kg | 19 | |
| 150 |
| Embodied Water, L/kg | 50 | |
| 1190 |
Common Calculations
| Resilience: Ultimate (Unit Rupture Work), MJ/m3 | 100 | |
| 17 to 25 |
| Resilience: Unit (Modulus of Resilience), kJ/m3 | 300 | |
| 50 to 300 |
| Stiffness to Weight: Axial, points | 13 | |
| 14 |
| Stiffness to Weight: Bending, points | 24 | |
| 50 |
| Strength to Weight: Axial, points | 18 | |
| 14 to 24 |
| Strength to Weight: Bending, points | 18 | |
| 22 to 31 |
| Thermal Diffusivity, mm2/s | 12 | |
| 79 to 86 |
| Thermal Shock Resistance, points | 16 | |
| 6.3 to 10 |
Alloy Composition
| Aluminum (Al), % | 0 | |
| 97.9 to 99.4 |
| Carbon (C), % | 0.33 to 0.38 | |
| 0 |
| Chromium (Cr), % | 0.8 to 1.1 | |
| 0 |
| Copper (Cu), % | 0 | |
| 0 to 0.2 |
| Iron (Fe), % | 97.3 to 98.1 | |
| 0 to 0.15 |
| Magnesium (Mg), % | 0 | |
| 0.45 to 0.9 |
| Manganese (Mn), % | 0.6 to 0.8 | |
| 0 to 0.050 |
| Phosphorus (P), % | 0 to 0.035 | |
| 0 |
| Silicon (Si), % | 0.15 to 0.35 | |
| 0.2 to 0.6 |
| Sulfur (S), % | 0 to 0.040 | |
| 0 |
| Zinc (Zn), % | 0 | |
| 0 to 0.050 |
| Residuals, % | 0 | |
| 0 to 0.15 |