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SAE-AISI 9254 Steel vs. 1200 Aluminum

SAE-AISI 9254 steel belongs to the iron alloys classification, while 1200 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 9254 steel and the bottom bar is 1200 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 200
23 to 48
Elastic (Young's, Tensile) Modulus, GPa 190
69
Elongation at Break, % 20
1.1 to 28
Fatigue Strength, MPa 280
25 to 69
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 72
26
Shear Strength, MPa 410
54 to 100
Tensile Strength: Ultimate (UTS), MPa 660
85 to 180
Tensile Strength: Yield (Proof), MPa 410
28 to 160

Thermal Properties

Latent Heat of Fusion, J/g 270
400
Maximum Temperature: Mechanical, °C 410
170
Melting Completion (Liquidus), °C 1440
660
Melting Onset (Solidus), °C 1400
650
Specific Heat Capacity, J/kg-K 480
900
Thermal Conductivity, W/m-K 46
230
Thermal Expansion, µm/m-K 13
23

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.4
58
Electrical Conductivity: Equal Weight (Specific), % IACS 8.6
190

Otherwise Unclassified Properties

Base Metal Price, % relative 2.2
9.0
Density, g/cm3 7.7
2.7
Embodied Carbon, kg CO2/kg material 1.5
8.2
Embodied Energy, MJ/kg 20
150
Embodied Water, L/kg 49
1190

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 110
2.0 to 19
Resilience: Unit (Modulus of Resilience), kJ/m3 450
5.7 to 180
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 25
50
Strength to Weight: Axial, points 24
8.7 to 19
Strength to Weight: Bending, points 22
16 to 26
Thermal Diffusivity, mm2/s 12
92
Thermal Shock Resistance, points 20
3.8 to 8.1

Alloy Composition

Aluminum (Al), % 0
99 to 100
Carbon (C), % 0.51 to 0.59
0
Chromium (Cr), % 0.6 to 0.8
0
Copper (Cu), % 0
0 to 0.050
Iron (Fe), % 96.1 to 97.1
0 to 1.0
Manganese (Mn), % 0.6 to 0.8
0 to 0.050
Phosphorus (P), % 0 to 0.035
0
Silicon (Si), % 1.2 to 1.6
0 to 1.0
Sulfur (S), % 0 to 0.040
0
Titanium (Ti), % 0
0 to 0.050
Zinc (Zn), % 0
0 to 0.1
Residuals, % 0
0 to 0.15