5052 aluminum vs 6061 Aluminum: Complete Guide

Aluminum alloys are found everywhere whether it is aerospace industry, automotive or flooring panels. As name suggests, aluminum is the main metal in aluminum alloy with different alloying elements such as copper, magnesium, zinc, tin, nickel and lithium and further categorize into different series of aluminum alloys. Aluminum alloys are found in various applications in wrought as well as cast conditions. This article will cover two wrought alloys of aluminum from different series i.e., 5xxx and 6xxx. 5xxx series is non-heat treatable whereas 6xxx is heat treatable. Both alloys have magnesium among alloying elements. This article will help you to understand the differences and similarities of both alloys by reinforcing the importance of selection of right material for a particular application.

5052 Aluminum Alloy

Main alloying element of 5052 is magnesium (Mg) apart from base metal aluminum. It has good weldability and workability. As this alloy is not heat treatable, so mechanical strength is achieved by cold working. Well, non-heat treatable means that mechanical properties cannot be modified by utilizing heat treatments due to the absence of precipitate formation. In heat treatable alloys, precipitates form and aging results in the most optimized size of the precipitates which in turn provide improved mechanical properties. Here, in this case, cold working is used to form dislocations which is also a strengthening mechanism. So, strength of 5052 aluminum alloy is increased by cold working. After cold working, density of dislocation is increased as the resistance of dislocation motion increased. It has good corrosion resistance as well. It is also available in various tempering conditions such as annealed, H32, H34, H36 and H38 condition.

What is 5052 aluminum is used for

5052 aluminum alloy is used in multiple applications including flooring panels, wires, chemical drums, sheets, pressure vessels, containers [3], clocks, appliances, rivets, kitchen cabinets, buses and trucks manufacturing, automotive body parts, air crafts, marine applications, street lights and is also used in architectural applications.

6061 Aluminum Alloy

Main alloying elements in 6061 aluminums are magnesium (Mg) and silicon (Si) along with the base metal aluminum. As, it is already mentioned that this alloy heat treatable, which means that it forms precipitates of magnesium and silicon which in turn increases its mechanical properties. Number of heat treatment cycles are used such as T1, T2… T7. Here we will be discussing 6061 in T6 condition which is also known as artificial aging [5]. At 533 °C, 6061 is heat treated for sufficient period of time, and this step is carried out for homogenization. Then quenching of 6061 leads to the seizing of atom movements and later on ageing is done at 160 °C for 18 hours [6].  

What is 6061 Aluminum used for

It is used in structural and automotive applications such as flooring, rivets, truck frames [7], engine components, rail coaches, ships [7], helicopter skin, stairs, drive train components, frame components and suspension components.

Aluminum Sheet Grades Chart

Here is the chart of formability or workability of different grades of aluminum sheet.

 Aluminum alloys 1100, 5052, and 3003 are better option than 2011

Types of Aluminum Sheet Metal

A chart of different types of aluminum sheets is given below which are in market for their efficient working in concerned applications [12].

Aluminum Plates Grades

Following are the few grades of aluminum alloys used for plates.

Aluminum Plate Sizes

Plates are available in various thicknesses and generally considered as a plate if thickness is greater than 6mm. Different dimensions of sheets fabricated from aluminum alloys are given below;

60 X 120 Aluminum Sheet

60*120 means that 60 is the length and 120 is width in inches and its thickness can be varied as per requirement. These dimensions are usually used in industries and constructional applications.

1/4 5052 Aluminum Sheet

¼ means that the plate is ¼ inches thick (0.25 inch or 6.35 mm). Such plates are good combination of strength, corrosion, formability and workability. Standard size of the sheet is 4 feet * 8 feet but customized sizes are also being fabricated as per requirement. It is used in construction, storage tanks, and automotive parts.  

4x4 Aluminum Sheet

It is a square shape sheet and commonly used in many applications. 4*4 means that 4 feet length and 4 feet width of the plate. It is available in mill, brushed and anodized finished form.

1/16 Thick Aluminum Sheet

This dimension is used in light weight applications and consider among thin gauge plates.

What is the Difference Between 6061 and 5052 Aluminum?

Differences as well as similarities between 6061 and 5052 will be discussed in this section regarding mechanical properties, chemical compositions, physical properties and applications.

Chemical Compositions Of 5052 Vs 6061 Aluminum Alloys

Following table is giving the chemical composition of 5051 an d6063 aluminum alloys.

What is the Density of 5051 and 6061 Aluminum Alloys?

2.68 g/cm³ for 5052 aluminum alloy  and the density of 6061 is 2.70g/cm³. So, 6061 is relatively denser than 5052.

Young's modulus of aluminum 5052 vs 6061

Young’s modulus of 5052 is 70.3 GPa and young’s modulus of 6061 is 69 GPa [16].

5052 vs 6061 Strength

Ultimate tensile strength and yield strength of aluminum 6061 is 290 MPa and 241 MPa, respectively. On contrary, tensile strength and yield strength of aluminum 5052 is 228 MPa and 193 MPa, respectively.

5052 vs 6061 thermal conductivity

Thermal conductivity of aluminum 6061 at room is temperature is 152 W/m K and 138-150 W/m·K is the thermal conductivity of aluminum 5051 which is slightly lower than 6061 but still exhibit good thermal properties.

Weight

As, density of 6061 is slightly higher than 5051 alloy so 6061 will be heavier if same dimensions or volume of the products are taken which are manufactured from both alloys.

5052 vs 6061 price

Cost depends upon the material, heat treatment conditions, finishing conditions, dimensions, availability and demand. While taking about cost, all these factors need to be kept in mind. To give you an idea, cost of 6061 sheet in T6 condition for 18*12 is ~63.33 dollars [25] and cost of 5052 is 7.76 $ for 0.02 sheet in H32 condition.

Are 5052 aluminum sheets bendable

Yes, 5052 aluminum sheets are bendable aluminum. Numerous factors are involved in influencing the bendability of 5052alumnium which includes bending radius, lubrication, tempering, thickness of the sheet, spring back, operator experience as well as tooling and equipment. For 5052, usually larger radius is preferred for bending, Lubrication reduces friction which also participates in successful bending. Selection of appropriate die, equipment, punch and bending machine is essential for bending. 5052 in H32 tempering condition is good for bending. 5052 has ability to spring back after bending so appropriate thickness and degree of bending is important to overcome the spring back phenomena.

Are 6061 aluminums bendable

Yes, 6061 aluminums are bendable. It depends on the heat treatment condition. In annealing, elongation of 6061 is satisfactory. Its bendability decreases as moved towards T4 (natural aging) and T6 (artificial aging). It is recommended that 6061 should bend in T4 condition and then artificially aged (T6). Grain size plays an important role in bendability along with mechanical properties. Spring back phenomena is more likely to be experienced in case of T4. No such phenomena will be experienced in T6 condition due to its high yield strength as compared to T4.

6061 aluminum machinability

6061 has good machinability properties and certain parameters can influence the machinability of 6061. Those factors comprise of hardness of the material, selection of tool with appropriate geometry, cutting speed and lubrication. 6061 is softer material and easy to machine by preventing the tool wear and tear. In that case, shelf life of tool will also be increased. Chip formation of 6061 makes the process manageable and efficient by avoiding blockage. Moreover, heat dissipates in 6061 efficiently which prevent the over heating or burning of the component and also protects the tool from tearing.

5052 aluminum machinability

Machinability of 5052 is fair. Presence of magnesium as an alloying element might reduce the machinability of 5052. Relatively higher cutting speed is preferred for 5052 aluminums. 6061 exhibit better machinability than 5052. For 5052, proper evacuation of formed chips is required for good surface finish and smooth process. High-speed cutting tools or carbide tools are recommended for cutting. Lubrication and coolants are essential during cutting [33].

Finish

5052 and 6061 are available in various finished forms in different surface finished condition. While taking about the finish forms of 6061, it is available in structural components, extruded parts, aluminum alloy bars and machined components. 5052 is available in 5052 aluminum square tubing, sheet metals, machined parts, welded assembles and formed parts. In case of surface finish, 6061 and 5052 are obtainable in brushed, mill, anodized, painted or coated condition as per application requirement.

Make 5052 vs 6061

6061 offers comparatively high strength and rigidity. In structural components 6061 is preferred whereas 5052 provides good formability as compared to 6061 and used in making sheets. Both offers good corrosion resistance and weldability. Machineability of 5052 is lower than 6061. Different alloying elements are used in 6061 (Mg+Si+Al) and 5052 (Mg+Cr+Al). T6 in 6061 provide good set of properties and H32 temper condition is more famous for 5052.

Most common aluminum alloy for machining

Most commonly used aluminum alloy for machining is 6061. This material can be machined by using numerous processes such as milling, drilling, turning and tapping. Also, 6061 is easily accessible in the form of rods, sheets and plates for machining.

Cheapest aluminum alloy

1100 aluminum alloy is considered less expensive among aluminum alloys as it is approximately a pure form of aluminum. While comparing 5052 and 6061, 5052 is cheaper than 6061 due to alloying elements, manufacturing route and heat treatment process. Aluminum sheet steels are also available in market where steels are cladded with aluminum.

Best aluminum for bending

Among 6061 and 5052, aluminum H32 (5052) has superior bending properties than 6061. 6061 has better extrusion properties and can be shaped into tees, alloy bars, tubes and angles.

Heat sink aluminum alloy

While comparing the better heat sink between 5052 and 6061 possess better mechanical as well as thermal conductivity as compared to 5052. So, 6061 is considered as better heat sink aluminums alloy [38].

Aluminum for boat building

5052 are commonly used for boat building due to good strength, workability and formability along with high corrosion resistance. Usually, boat hulls and other boat parts are manufactured by utilizing 5052. 6061 is also used for this application due to high corrosion resistance and frames and superstructures are formed by 6061.

Why Choose Tuofa Custom Aluminum Parts

A comparison guide built in this article, which will enable the reader to get an understanding of 5052 and 6061 aluminums alloys. Both alloys, 6061 and 5052 have their own advantages and disadvantages. 6061 is stronger than 5051 with better extrusion properties. On the other hand, 5051 has better formability and metal sheet working capacity. While talking about the affordability 5051 is available in less expensive rates than 6061. Both alloys, possess good corrosion resistance and weldability. Various heat-treatments are used for the fabrication of 5052 and 6061 aluminums alloy for various applications. Those alloys are available in different surface finishes such as mill, anodized, coated and painted. Selection of correct heat treatment, fabrication route and machining process is as important as right material for specific applications.

Toufa has become a well-known company which offers best engineering solutions to your industrial problems. We offer you cost effective solutions to your industrial problems without compromising quality and also committed to deliver high quality aluminums products with cost effectiveness.

FAQs

Aluminum 3003 Vs 5052

Aluminum 3003 and 5052 have good formability, workability and weldability. 5052 has better corrosion resistance and higher strength than 3003. 3003 is softer than 5052.

Welding 5052 To 6061

5052 can be welded with 6061, by using TIG or MIG welding by utilizing appropriate filler. Avoid the presence of electrolyte, otherwise, it will form a cell and lead to galvanic corrosion.