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SAE-AISI D2 Steel vs. 4045 Aluminum

SAE-AISI D2 steel belongs to the iron alloys classification, while 4045 aluminum belongs to the aluminum alloys. There are 29 material properties with values for both materials. Properties with values for just one material (3, 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 D2 steel and the bottom bar is 4045 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Elastic (Young's, Tensile) Modulus, GPa 190
71
Elongation at Break, % 5.0 to 16
2.3
Fatigue Strength, MPa 310 to 860
45
Poisson's Ratio 0.28
0.33
Shear Modulus, GPa 75
27
Shear Strength, MPa 460 to 1160
69
Tensile Strength: Ultimate (UTS), MPa 760 to 2000
120
Tensile Strength: Yield (Proof), MPa 470 to 1510
64

Thermal Properties

Latent Heat of Fusion, J/g 270
540
Melting Completion (Liquidus), °C 1440
600
Melting Onset (Solidus), °C 1390
580
Specific Heat Capacity, J/kg-K 480
900
Thermal Conductivity, W/m-K 31
170
Thermal Expansion, µm/m-K 11
21

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 4.3
45
Electrical Conductivity: Equal Weight (Specific), % IACS 5.1
160

Otherwise Unclassified Properties

Base Metal Price, % relative 8.0
9.5
Density, g/cm3 7.7
2.6
Embodied Carbon, kg CO2/kg material 3.4
7.8
Embodied Energy, MJ/kg 50
150
Embodied Water, L/kg 100
1070

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 92 to 100
2.4
Resilience: Unit (Modulus of Resilience), kJ/m3 570 to 5940
29
Stiffness to Weight: Axial, points 14
15
Stiffness to Weight: Bending, points 25
54
Strength to Weight: Axial, points 27 to 72
13
Strength to Weight: Bending, points 24 to 46
21
Thermal Diffusivity, mm2/s 8.3
74
Thermal Shock Resistance, points 25 to 67
5.7

Alloy Composition

Aluminum (Al), % 0
87.4 to 91
Carbon (C), % 1.4 to 1.6
0
Chromium (Cr), % 11 to 13
0
Copper (Cu), % 0 to 0.25
0 to 0.3
Iron (Fe), % 81.3 to 86.9
0 to 0.8
Magnesium (Mg), % 0
0 to 0.050
Manganese (Mn), % 0 to 0.6
0 to 0.050
Molybdenum (Mo), % 0.7 to 1.2
0
Nickel (Ni), % 0 to 0.3
0
Phosphorus (P), % 0 to 0.030
0
Silicon (Si), % 0 to 0.6
9.0 to 11
Sulfur (S), % 0 to 0.030
0
Titanium (Ti), % 0
0 to 0.2
Vanadium (V), % 0 to 1.1
0
Zinc (Zn), % 0
0 to 0.1
Residuals, % 0
0 to 0.15