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SAE-AISI 8645 Steel vs. 6065 Aluminum

SAE-AISI 8645 steel belongs to the iron alloys classification, while 6065 aluminum belongs to the aluminum alloys. There are 30 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 8645 steel and the bottom bar is 6065 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Elastic (Young's, Tensile) Modulus, GPa 190
68
Elongation at Break, % 12 to 23
4.5 to 11
Fatigue Strength, MPa 280 to 350
96 to 110
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 73
26
Shear Strength, MPa 380 to 400
190 to 230
Tensile Strength: Ultimate (UTS), MPa 600 to 670
310 to 400
Tensile Strength: Yield (Proof), MPa 390 to 560
270 to 380

Thermal Properties

Latent Heat of Fusion, J/g 250
400
Maximum Temperature: Mechanical, °C 410
180
Melting Completion (Liquidus), °C 1460
640
Melting Onset (Solidus), °C 1420
590
Specific Heat Capacity, J/kg-K 470
890
Thermal Conductivity, W/m-K 39
170
Thermal Expansion, µm/m-K 13
23

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.3
43
Electrical Conductivity: Equal Weight (Specific), % IACS 8.4
140

Otherwise Unclassified Properties

Base Metal Price, % relative 2.6
11
Density, g/cm3 7.8
2.8
Embodied Carbon, kg CO2/kg material 1.5
8.4
Embodied Energy, MJ/kg 20
150
Embodied Water, L/kg 50
1200

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 77 to 120
17 to 34
Resilience: Unit (Modulus of Resilience), kJ/m3 420 to 840
540 to 1040
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 24
49
Strength to Weight: Axial, points 21 to 24
31 to 40
Strength to Weight: Bending, points 20 to 22
36 to 43
Thermal Diffusivity, mm2/s 10
67
Thermal Shock Resistance, points 18 to 20
14 to 18

Alloy Composition

Aluminum (Al), % 0
94.4 to 98.2
Bismuth (Bi), % 0
0.5 to 1.5
Carbon (C), % 0.43 to 0.48
0
Chromium (Cr), % 0.4 to 0.6
0 to 0.15
Copper (Cu), % 0
0.15 to 0.4
Iron (Fe), % 96.5 to 97.7
0 to 0.7
Lead (Pb), % 0
0 to 0.050
Magnesium (Mg), % 0
0.8 to 1.2
Manganese (Mn), % 0.75 to 1.0
0 to 0.15
Molybdenum (Mo), % 0.15 to 0.25
0
Nickel (Ni), % 0.4 to 0.7
0
Phosphorus (P), % 0 to 0.035
0
Silicon (Si), % 0.15 to 0.35
0.4 to 0.8
Sulfur (S), % 0 to 0.040
0
Titanium (Ti), % 0
0 to 0.1
Zinc (Zn), % 0
0 to 0.25
Zirconium (Zr), % 0
0 to 0.15
Residuals, % 0
0 to 0.15