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SAE-AISI 9254 Steel vs. 4115 Aluminum

SAE-AISI 9254 steel belongs to the iron alloys classification, while 4115 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 4115 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 200
38 to 68
Elastic (Young's, Tensile) Modulus, GPa 190
70
Elongation at Break, % 20
1.1 to 11
Fatigue Strength, MPa 280
39 to 76
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 72
26
Shear Strength, MPa 410
71 to 130
Tensile Strength: Ultimate (UTS), MPa 660
120 to 220
Tensile Strength: Yield (Proof), MPa 410
39 to 190

Thermal Properties

Latent Heat of Fusion, J/g 270
420
Maximum Temperature: Mechanical, °C 410
160
Melting Completion (Liquidus), °C 1440
640
Melting Onset (Solidus), °C 1400
590
Specific Heat Capacity, J/kg-K 480
900
Thermal Conductivity, W/m-K 46
160
Thermal Expansion, µm/m-K 13
23

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.4
41
Electrical Conductivity: Equal Weight (Specific), % IACS 8.6
140

Otherwise Unclassified Properties

Base Metal Price, % relative 2.2
9.5
Density, g/cm3 7.7
2.7
Embodied Carbon, kg CO2/kg material 1.5
8.1
Embodied Energy, MJ/kg 20
150
Embodied Water, L/kg 49
1160

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 110
2.1 to 10
Resilience: Unit (Modulus of Resilience), kJ/m3 450
11 to 270
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 25
50
Strength to Weight: Axial, points 24
12 to 23
Strength to Weight: Bending, points 22
20 to 30
Thermal Diffusivity, mm2/s 12
66
Thermal Shock Resistance, points 20
5.2 to 9.9

Alloy Composition

Aluminum (Al), % 0
94.6 to 97.4
Carbon (C), % 0.51 to 0.59
0
Chromium (Cr), % 0.6 to 0.8
0
Copper (Cu), % 0
0.1 to 0.5
Iron (Fe), % 96.1 to 97.1
0 to 0.7
Magnesium (Mg), % 0
0.1 to 0.5
Manganese (Mn), % 0.6 to 0.8
0.6 to 1.2
Phosphorus (P), % 0 to 0.035
0
Silicon (Si), % 1.2 to 1.6
1.8 to 2.2
Sulfur (S), % 0 to 0.040
0
Zinc (Zn), % 0
0 to 0.2
Residuals, % 0
0 to 0.15