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SAE-AISI 9254 Steel vs. 4145 Aluminum

SAE-AISI 9254 steel belongs to the iron alloys classification, while 4145 aluminum belongs to the aluminum alloys. There are 30 material properties with values for both materials. Properties with values for just one material (2, 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 9254 steel and the bottom bar is 4145 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Elastic (Young's, Tensile) Modulus, GPa 190
73
Elongation at Break, % 20
2.2
Fatigue Strength, MPa 280
48
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 72
28
Shear Strength, MPa 410
69
Tensile Strength: Ultimate (UTS), MPa 660
120
Tensile Strength: Yield (Proof), MPa 410
68

Thermal Properties

Latent Heat of Fusion, J/g 270
540
Maximum Temperature: Mechanical, °C 410
160
Melting Completion (Liquidus), °C 1440
590
Melting Onset (Solidus), °C 1400
520
Specific Heat Capacity, J/kg-K 480
880
Thermal Conductivity, W/m-K 46
100
Thermal Expansion, µm/m-K 13
21

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.4
26
Electrical Conductivity: Equal Weight (Specific), % IACS 8.6
84

Otherwise Unclassified Properties

Base Metal Price, % relative 2.2
10
Density, g/cm3 7.7
2.8
Embodied Carbon, kg CO2/kg material 1.5
7.6
Embodied Energy, MJ/kg 20
140
Embodied Water, L/kg 49
1040

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 110
2.3
Resilience: Unit (Modulus of Resilience), kJ/m3 450
31
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 25
50
Strength to Weight: Axial, points 24
12
Strength to Weight: Bending, points 22
19
Thermal Diffusivity, mm2/s 12
42
Thermal Shock Resistance, points 20
5.5

Alloy Composition

Aluminum (Al), % 0
83 to 87.4
Carbon (C), % 0.51 to 0.59
0
Chromium (Cr), % 0.6 to 0.8
0 to 0.15
Copper (Cu), % 0
3.3 to 4.7
Iron (Fe), % 96.1 to 97.1
0 to 0.8
Magnesium (Mg), % 0
0 to 0.15
Manganese (Mn), % 0.6 to 0.8
0 to 0.15
Phosphorus (P), % 0 to 0.035
0
Silicon (Si), % 1.2 to 1.6
9.3 to 10.7
Sulfur (S), % 0 to 0.040
0
Zinc (Zn), % 0
0 to 0.2
Residuals, % 0
0 to 0.15