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SAE-AISI 5155 Steel vs. 5454 Aluminum

SAE-AISI 5155 steel belongs to the iron alloys classification, while 5454 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 5155 steel and the bottom bar is 5454 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 190
61 to 93
Elastic (Young's, Tensile) Modulus, GPa 190
69
Elongation at Break, % 21
2.3 to 18
Fatigue Strength, MPa 260
83 to 160
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 73
26
Shear Strength, MPa 390
140 to 200
Tensile Strength: Ultimate (UTS), MPa 620
230 to 350
Tensile Strength: Yield (Proof), MPa 380
97 to 290

Thermal Properties

Latent Heat of Fusion, J/g 250
400
Maximum Temperature: Mechanical, °C 420
190
Melting Completion (Liquidus), °C 1450
650
Melting Onset (Solidus), °C 1410
600
Specific Heat Capacity, J/kg-K 470
900
Thermal Conductivity, W/m-K 49
130
Thermal Expansion, µm/m-K 12
24

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.2
34
Electrical Conductivity: Equal Weight (Specific), % IACS 8.3
110

Otherwise Unclassified Properties

Base Metal Price, % relative 2.1
9.5
Density, g/cm3 7.8
2.7
Embodied Carbon, kg CO2/kg material 1.4
8.6
Embodied Energy, MJ/kg 19
150
Embodied Water, L/kg 49
1180

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 110
6.3 to 34
Resilience: Unit (Modulus of Resilience), kJ/m3 380
68 to 590
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 24
50
Strength to Weight: Axial, points 22
23 to 36
Strength to Weight: Bending, points 21
30 to 41
Thermal Diffusivity, mm2/s 13
55
Thermal Shock Resistance, points 20
10 to 16

Alloy Composition


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Aluminum (Al), % 0
94.5 to 97.1
Carbon (C), % 0.51 to 0.59
0
Chromium (Cr), % 0.7 to 0.9
0.050 to 0.2
Copper (Cu), % 0
0 to 0.1
Iron (Fe), % 97.2 to 97.9
0 to 0.4
Magnesium (Mg), % 0
2.4 to 3.0
Manganese (Mn), % 0.7 to 0.9
0.5 to 1.0
Phosphorus (P), % 0 to 0.035
0
Silicon (Si), % 0.15 to 0.35
0 to 0.25
Sulfur (S), % 0 to 0.040
0
Titanium (Ti), % 0
0 to 0.2
Zinc (Zn), % 0
0 to 0.25
Residuals, % 0
0 to 0.15