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SAE-AISI D4 Steel vs. A535.0 Aluminum

SAE-AISI D4 steel belongs to the iron alloys classification, while A535.0 aluminum belongs to the aluminum alloys. There are 27 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 D4 steel and the bottom bar is A535.0 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Elastic (Young's, Tensile) Modulus, GPa 190
67
Elongation at Break, % 8.4 to 15
9.0
Fatigue Strength, MPa 310 to 920
95
Poisson's Ratio 0.28
0.33
Shear Modulus, GPa 74
25
Tensile Strength: Ultimate (UTS), MPa 760 to 2060
250
Tensile Strength: Yield (Proof), MPa 470 to 1540
120

Thermal Properties

Latent Heat of Fusion, J/g 270
390
Melting Completion (Liquidus), °C 1430
620
Melting Onset (Solidus), °C 1380
550
Specific Heat Capacity, J/kg-K 480
910
Thermal Conductivity, W/m-K 31
100
Thermal Expansion, µm/m-K 12
24

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 4.2
23
Electrical Conductivity: Equal Weight (Specific), % IACS 5.0
79

Otherwise Unclassified Properties

Base Metal Price, % relative 8.0
9.5
Density, g/cm3 7.7
2.6
Embodied Carbon, kg CO2/kg material 3.3
9.3
Embodied Energy, MJ/kg 49
160
Embodied Water, L/kg 100
1180

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 100 to 160
19
Stiffness to Weight: Axial, points 14
14
Stiffness to Weight: Bending, points 25
51
Strength to Weight: Axial, points 27 to 75
26
Strength to Weight: Bending, points 24 to 47
33
Thermal Diffusivity, mm2/s 8.3
42
Thermal Shock Resistance, points 23 to 63
11

Alloy Composition

Aluminum (Al), % 0
91.4 to 93.4
Carbon (C), % 2.1 to 2.4
0
Chromium (Cr), % 11 to 13
0
Copper (Cu), % 0 to 0.25
0 to 0.1
Iron (Fe), % 80.6 to 86.3
0 to 0.2
Magnesium (Mg), % 0
6.5 to 7.5
Manganese (Mn), % 0 to 0.6
0.1 to 0.25
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
0 to 0.2
Sulfur (S), % 0 to 0.030
0
Titanium (Ti), % 0
0 to 0.25
Vanadium (V), % 0 to 1.0
0
Residuals, % 0
0 to 0.15