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SAE-AISI D5 Steel vs. 1235 Aluminum

SAE-AISI D5 steel belongs to the iron alloys classification, while 1235 aluminum belongs to the aluminum alloys. There are 25 material properties with values for both materials. Properties with values for just one material (6, 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 D5 steel and the bottom bar is 1235 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Elastic (Young's, Tensile) Modulus, GPa 190
69
Elongation at Break, % 5.4 to 14
28 to 34
Poisson's Ratio 0.28
0.33
Shear Modulus, GPa 75
26
Shear Strength, MPa 470 to 1180
52 to 56
Tensile Strength: Ultimate (UTS), MPa 770 to 2030
80 to 84

Thermal Properties

Latent Heat of Fusion, J/g 270
400
Melting Completion (Liquidus), °C 1430
640
Melting Onset (Solidus), °C 1390
640
Specific Heat Capacity, J/kg-K 480
900
Thermal Conductivity, W/m-K 27
230
Thermal Expansion, µm/m-K 11
23

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 4.2
60
Electrical Conductivity: Equal Weight (Specific), % IACS 4.9
200

Otherwise Unclassified Properties

Base Metal Price, % relative 13
9.5
Density, g/cm3 7.7
2.7
Embodied Carbon, kg CO2/kg material 3.5
8.3
Embodied Energy, MJ/kg 51
160
Embodied Water, L/kg 120
1190

Common Calculations

Stiffness to Weight: Axial, points 14
14
Stiffness to Weight: Bending, points 25
50
Strength to Weight: Axial, points 28 to 73
8.2 to 8.6
Strength to Weight: Bending, points 24 to 46
15 to 16
Thermal Diffusivity, mm2/s 7.4
93
Thermal Shock Resistance, points 26 to 67
3.6 to 3.7

Alloy Composition

Aluminum (Al), % 0
99.35 to 100
Carbon (C), % 1.4 to 1.6
0
Chromium (Cr), % 11 to 13
0
Cobalt (Co), % 2.5 to 3.5
0
Copper (Cu), % 0 to 0.25
0 to 0.050
Iron (Fe), % 77.9 to 84.4
0 to 0.65
Magnesium (Mg), % 0
0 to 0.050
Manganese (Mn), % 0 to 0.6
0 to 0.050
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 0.65
Sulfur (S), % 0 to 0.030
0
Titanium (Ti), % 0
0 to 0.060
Vanadium (V), % 0 to 1.0
0 to 0.050
Zinc (Zn), % 0
0 to 0.1