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SAE-AISI 5155 Steel vs. 3004 Aluminum

SAE-AISI 5155 steel belongs to the iron alloys classification, while 3004 aluminum belongs to the aluminum alloys. There are 31 material properties with values for both materials. Properties with values for just one material (1, 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 5155 steel and the bottom bar is 3004 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 190
45 to 83
Elastic (Young's, Tensile) Modulus, GPa 190
70
Elongation at Break, % 21
1.1 to 19
Fatigue Strength, MPa 260
55 to 120
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 73
26
Shear Strength, MPa 390
100 to 180
Tensile Strength: Ultimate (UTS), MPa 620
170 to 310
Tensile Strength: Yield (Proof), MPa 380
68 to 270

Thermal Properties

Latent Heat of Fusion, J/g 250
400
Maximum Temperature: Mechanical, °C 420
180
Melting Completion (Liquidus), °C 1450
650
Melting Onset (Solidus), °C 1410
630
Specific Heat Capacity, J/kg-K 470
900
Thermal Conductivity, W/m-K 49
160
Thermal Expansion, µm/m-K 12
24

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.2
42
Electrical Conductivity: Equal Weight (Specific), % IACS 8.3
140

Otherwise Unclassified Properties

Base Metal Price, % relative 2.1
9.5
Density, g/cm3 7.8
2.8
Embodied Carbon, kg CO2/kg material 1.4
8.3
Embodied Energy, MJ/kg 19
150
Embodied Water, L/kg 49
1180

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 110
3.2 to 27
Resilience: Unit (Modulus of Resilience), kJ/m3 380
33 to 540
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 24
50
Strength to Weight: Axial, points 22
18 to 31
Strength to Weight: Bending, points 21
25 to 37
Thermal Diffusivity, mm2/s 13
65
Thermal Shock Resistance, points 20
7.6 to 13

Alloy Composition


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Aluminum (Al), % 0
95.6 to 98.2
Carbon (C), % 0.51 to 0.59
0
Chromium (Cr), % 0.7 to 0.9
0
Copper (Cu), % 0
0 to 0.25
Iron (Fe), % 97.2 to 97.9
0 to 0.7
Magnesium (Mg), % 0
0.8 to 1.3
Manganese (Mn), % 0.7 to 0.9
1.0 to 1.5
Phosphorus (P), % 0 to 0.035
0
Silicon (Si), % 0.15 to 0.35
0 to 0.3
Sulfur (S), % 0 to 0.040
0
Zinc (Zn), % 0
0 to 0.25
Residuals, % 0
0 to 0.15