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SAE-AISI D3 Steel vs. 5040 Aluminum

SAE-AISI D3 steel belongs to the iron alloys classification, while 5040 aluminum belongs to the aluminum alloys. There are 28 material properties with values for both materials. Properties with values for just one material (4, 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 D3 steel and the bottom bar is 5040 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Elastic (Young's, Tensile) Modulus, GPa 190
70
Elongation at Break, % 9.8 to 15
5.7 to 6.8
Fatigue Strength, MPa 310 to 940
100 to 130
Poisson's Ratio 0.28
0.33
Shear Modulus, GPa 74
26
Shear Strength, MPa 470 to 1220
140 to 150
Tensile Strength: Ultimate (UTS), MPa 770 to 2050
240 to 260
Tensile Strength: Yield (Proof), MPa 480 to 1550
190 to 230

Thermal Properties

Latent Heat of Fusion, J/g 270
400
Melting Completion (Liquidus), °C 1430
650
Melting Onset (Solidus), °C 1390
600
Specific Heat Capacity, J/kg-K 480
900
Thermal Conductivity, W/m-K 31
160
Thermal Expansion, µm/m-K 12
23

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 3.0
41
Electrical Conductivity: Equal Weight (Specific), % IACS 3.5
130

Otherwise Unclassified Properties

Base Metal Price, % relative 8.0
9.5
Density, g/cm3 7.7
2.8
Embodied Carbon, kg CO2/kg material 3.2
8.3
Embodied Energy, MJ/kg 48
150
Embodied Water, L/kg 100
1180

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 97 to 180
14 to 15
Stiffness to Weight: Axial, points 14
14
Stiffness to Weight: Bending, points 25
50
Strength to Weight: Axial, points 28 to 74
24 to 26
Strength to Weight: Bending, points 24 to 47
31 to 32
Thermal Diffusivity, mm2/s 8.3
64
Thermal Shock Resistance, points 23 to 63
10 to 11

Alloy Composition

Aluminum (Al), % 0
95.2 to 98
Carbon (C), % 2.0 to 2.4
0
Chromium (Cr), % 11 to 13.5
0.1 to 0.3
Copper (Cu), % 0 to 0.25
0 to 0.25
Iron (Fe), % 80.3 to 87
0 to 0.7
Magnesium (Mg), % 0
1.0 to 1.5
Manganese (Mn), % 0 to 0.6
0.9 to 1.4
Nickel (Ni), % 0 to 0.3
0
Phosphorus (P), % 0 to 0.030
0
Silicon (Si), % 0 to 0.6
0 to 0.3
Sulfur (S), % 0 to 0.030
0
Tungsten (W), % 0 to 1.0
0
Vanadium (V), % 0 to 1.0
0
Zinc (Zn), % 0
0 to 0.25
Residuals, % 0
0 to 0.15