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SAE-AISI 5140 Steel vs. B535.0 Aluminum

SAE-AISI 5140 steel belongs to the iron alloys classification, while B535.0 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 5140 steel and the bottom bar is B535.0 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 170 to 290
65
Elastic (Young's, Tensile) Modulus, GPa 190
66
Elongation at Break, % 12 to 29
10
Fatigue Strength, MPa 220 to 570
62
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 73
25
Shear Strength, MPa 360 to 600
210
Tensile Strength: Ultimate (UTS), MPa 560 to 970
260
Tensile Strength: Yield (Proof), MPa 290 to 840
130

Thermal Properties

Latent Heat of Fusion, J/g 250
390
Maximum Temperature: Mechanical, °C 420
170
Melting Completion (Liquidus), °C 1460
630
Melting Onset (Solidus), °C 1420
550
Specific Heat Capacity, J/kg-K 470
910
Thermal Conductivity, W/m-K 45
96
Thermal Expansion, µm/m-K 13
25

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.2
24
Electrical Conductivity: Equal Weight (Specific), % IACS 8.3
82

Otherwise Unclassified Properties

Base Metal Price, % relative 2.1
9.5
Density, g/cm3 7.8
2.6
Embodied Carbon, kg CO2/kg material 1.4
9.4
Embodied Energy, MJ/kg 19
160
Embodied Water, L/kg 49
1180

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 76 to 180
22
Resilience: Unit (Modulus of Resilience), kJ/m3 220 to 1880
130
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 24
51
Strength to Weight: Axial, points 20 to 34
28
Strength to Weight: Bending, points 19 to 28
35
Thermal Diffusivity, mm2/s 12
40
Thermal Shock Resistance, points 16 to 29
11

Alloy Composition

Aluminum (Al), % 0
91.7 to 93.4
Carbon (C), % 0.38 to 0.43
0
Chromium (Cr), % 0.7 to 0.9
0
Copper (Cu), % 0
0 to 0.1
Iron (Fe), % 97.3 to 98.1
0 to 0.15
Magnesium (Mg), % 0
6.5 to 7.5
Manganese (Mn), % 0.7 to 0.9
0 to 0.050
Phosphorus (P), % 0 to 0.035
0
Silicon (Si), % 0.15 to 0.35
0 to 0.15
Sulfur (S), % 0 to 0.040
0
Titanium (Ti), % 0
0.1 to 0.25
Residuals, % 0
0 to 0.15