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SAE-AISI 5155 Steel vs. 4032 Aluminum

SAE-AISI 5155 steel belongs to the iron alloys classification, while 4032 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 5155 steel and the bottom bar is 4032 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 190
120
Elastic (Young's, Tensile) Modulus, GPa 190
73
Elongation at Break, % 21
6.7
Fatigue Strength, MPa 260
110
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 73
28
Shear Strength, MPa 390
260
Tensile Strength: Ultimate (UTS), MPa 620
390
Tensile Strength: Yield (Proof), MPa 380
320

Thermal Properties

Latent Heat of Fusion, J/g 250
570
Maximum Temperature: Mechanical, °C 420
180
Melting Completion (Liquidus), °C 1450
570
Melting Onset (Solidus), °C 1410
530
Specific Heat Capacity, J/kg-K 470
900
Thermal Conductivity, W/m-K 49
140
Thermal Expansion, µm/m-K 12
19

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.2
34
Electrical Conductivity: Equal Weight (Specific), % IACS 8.3
120

Otherwise Unclassified Properties

Base Metal Price, % relative 2.1
10
Density, g/cm3 7.8
2.6
Embodied Carbon, kg CO2/kg material 1.4
7.8
Embodied Energy, MJ/kg 19
140
Embodied Water, L/kg 49
1030

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 110
25
Resilience: Unit (Modulus of Resilience), kJ/m3 380
700
Stiffness to Weight: Axial, points 13
15
Stiffness to Weight: Bending, points 24
53
Strength to Weight: Axial, points 22
41
Strength to Weight: Bending, points 21
45
Thermal Diffusivity, mm2/s 13
59
Thermal Shock Resistance, points 20
20

Alloy Composition

Aluminum (Al), % 0
81.1 to 87.2
Carbon (C), % 0.51 to 0.59
0
Chromium (Cr), % 0.7 to 0.9
0 to 0.1
Copper (Cu), % 0
0.5 to 1.3
Iron (Fe), % 97.2 to 97.9
0 to 1.0
Magnesium (Mg), % 0
0.8 to 1.3
Manganese (Mn), % 0.7 to 0.9
0
Nickel (Ni), % 0
0.5 to 1.3
Phosphorus (P), % 0 to 0.035
0
Silicon (Si), % 0.15 to 0.35
11 to 13.5
Sulfur (S), % 0 to 0.040
0
Zinc (Zn), % 0
0 to 0.25
Residuals, % 0
0 to 0.15