When comparing aluminum 5052 vs 6061, the main considerations are corrosion resistance and strength.
Aluminum 5052 excels in corrosion resistance, making it useful for marine equipment. On the other hand, 6061 is used for structural components, automotive parts, and aerospace due to its higher strength.
In this guide, you are going to learn a few of the properties, costs, applications and processing mechanisms of both aluminum 5052 and 6061.
Property：5052 vs 6061 Aluminum Comparison
The aluminum alloys have different properties due to their alloying elements and their ratio with which they are mixed. Few of them and stronger, and some have great corrosion-resistant properties.
Aluminum 5052 is a combination of mainly aluminum and magnesium (2.2-2.8%).
The aluminum 6061 has aluminum and a small amount of silicon alongside magnesium. The magnesium is (0.8% – 1.2%), and silicon is (0.4% – 0.8%).
Here is an overview of the properties of the aluminum 5052 and 6061.
Mechanical Properties
Mechanical properties like Yield Strength, Elongation, Tensile Strength, and Hardness are different from one alloy to the other. You can see its comparison between 5052 and 6061 from this chart.
Note: compare 5052-H32 and 6061-T6 on mechanical properties
- Tensile Strength: Aluminum 5052 has 31000-38000 psi (214-262Mpa) Tensile Strength, whereas 6061 has almost 45000 psi (310Mpa). So, in terms of strength, 6061 is stronger, making it a perfect choice for large structures.
- Elongation: Aluminum 5052 has an elongation of about 12-20% whereas 6061 has 8-17% elongation. Aluminum 5052 is more stretchable as compared to 6061.
- Yield Strength: Aluminum 5052 has a 28000 psi (193Mpa) yield strength, and 6061 is about 40000 psi (276Mpa), making it stronger. The large and load-bearing structures are made with the help of 6061. For small structures and corrosion-sensitive areas, you can use 5052.
- Hardness: Aluminum 5052 is softer compared to 6061. Aluminum 6061 is useful for making large structures that need more strength.
Is 5052 strong enough for structural parts?
5052 is not valuable for heavy loads or high-tension structures. Although you can use it for lightweight structures having zero to low load on it. For marine lightly loaded structural parts, it could be the perfect choice.
Physical Properties
The physical properties of both alloys are more or less the same, with a little difference. Here is an overview of the physical properties when compare 6061 vs 5052 aluminum.
- Density: Aluminum 5052 has a density of about 2.68 g/cm³and 6061 has adensity of about 2.70 g/cm³. The density of both alloys is approximately the same, making them a perfect choice for making lightweight materials.
- Melting Point: The melting range of aluminum 5052 is approximately 605–650°C, while that of 6061 is 582–652°C.
. The higher melting points of these alloys make them stronger. - Thermal Conductivity:The thermal conductivity of the aluminum 5052 is approcimately138 W/m·K. The thermal conductivity for aluminum 6061 is slightly higher,e., 167 W/m·K, making it a perfect choice for making heated materials and electrical components.
- Electrical Conductivity: The electrical conductivity of the Aluminum 5052 is about 35% IACS and 43% IACS for aluminum 6061. The electrical conductivity of these materials is almost the same, making them fit for use in most of the electrical machinery.
Corrosion Resistance
The corrosion resistance for 5052 is excellent as compared to aluminum 6061, making it a perfect choice to use in salt water. That’s why it could be a better choice to use in marine equipment.
Why is aluminum 5052 more corrosion-resistant than 6061?
Copper is the key factor responsible for the performance differences between these two alloys.
There is a chemical phenomenon known as Galvanic Corrosion. This phenomenon effectively explains why the 6061 alloy, which contains copper (0.15–0.40%), experiences accelerated corrosion when exposed to saltwater.
In contrast, the copper content (≤0.10%) in 5052 alloy effectively avoids galvanic corrosion, resulting in better corrosion resistance compared to aluminum 6061.
Whereas, the corrosion resistance for 6061 is good but less than that of 5052. While not the first choice for untreated marine applications, it can be used if protected by correct surface treatments.
In a controlled environment or indoor use, you can make structures from 6061 and keep them safe from corrosion.
Can 6061 replace 5052 in marine applications?
Marine applications require stronger corrosion resistance. However, 6061 is a good choice, but it is not as valuable when it comes to marine applications as compared to aluminum 5052. So, it is better to use 5052 in marine applications.
READ MORE: How to prevent aluminum corrosion?
Processing Comparison
The aluminum alloys 6061 and 5052 are different from each other in terms of strength and properties. While using them for different applications, they must have some basic properties and their effective of weldability, machinability and formability.
Machinability
Aluminum 5052 is quite soft, which can cause clogging in tools. So, its machinability is generally considered worse compared to 6061.
Aluminum 6061 is a harder aluminum alloy, making it a perfect choice for CNC machining due to its strength. It is a common choice for CNC machining where dimensional accuracy and a decent surface finish are required.
Which alloy is better for CNC machining? Aluminum 5052 or 6061?
6061 is a better alloy for CNC machining due to its hardness, machinability, and surface finish. 5052 would be rough and gummy, making it not a perfect choice for CNC machining.
Formability (Bending)
Aluminum 5052 has excellent formability. It is easier to bend, especially at H32 temper. It is the best option for rolling, deep drawing, and bending, making it a perfect choice for enclosed trucks, roofing, siding, marine sheets, and signage.
Aluminum 6061 has poor formability. It can crack while bending, especially at T6 temper. So, you need to avoid using it for tight bends.
READ MORE: Which Aluminum Is Best for Bending? Is 5052 easier to bend than 6061?
Weldability
Aluminum 5052 has excellent weldability, especially when using MIG and TIG welding. The welding joints are corrosion-resistant and long-lasting.
Aluminum 6061 has good weldability, but you need to heat the welding joints after welding; otherwise, the joints start loosening up. It is prone to making cracks at the welded joints, and corrosion resistance is observed less at the joint zones.
Cost Factors
The costs for both aluminum alloys 5052 and 6061 are different depending on the raw material, machining, forming, welding, and availability. Alloy 5052 is generally more cost-effective than 6061.
Applications：When to Use 5052 or 6061 Aluminum
Aluminum 5052 and 6061 are the alloys used for different applications according to their properties and different strengths.
When to Choose 5052?
Aluminum 5052 is quite useful in areas where corrosion resistance is required, especially in salt waters. It offers excellent resistance against corrosion in watery areas.
- The storage tanks, low-stressbrackets, and vessel flooring panels might use aluminum 5052 for the best performance.
- Whenever welding is needed, you can use aluminum 5052 due to its excellent weldability.
- If you need to cut off the cost prices, you can also use aluminum 5052.
When to Choose 6061?
Aluminum 6061 is a stronger alloy used for heavy and load-bearing structures. It would be used to make electrical components due to its thermal conduction properties.
- Aluminum 6061 could be used for aerospace frames, automotive suspension, bridges,etc, due to its higher strength over other alloys.
- Whenever high-strengthstructures are needed, you need to choose 6061.
- You can use 6061 if moderate to good corrosion is.
READ MORE:
6061 aluminum is the most widely used alloy in industrial products. This article The Applications of 6061 will help you learn more details.
Final Words：Choosing Between Aluminum 5052 vs 6061
Aluminum 5052 and 6061 are the aluminum alloys used for different purposes, as they have different mechanical, physical, and corrosive properties.
- 6061 is used for strong structures due to its load-bearing capabilities.
- Aluminum 5052 is also used for applications that require strong corrosion resistance, like marine applications.
This guide has shown a complete comparison between the two alloys.
About Author
- Xue Song
- Quality Engineer at FONNOV Aluminium Fabrication Plant
Xue Song has been a senior quality engineer at FONNOV Aluminium since 2018. He has more than ten years of experience in aluminum fabrication. Through his articles, Xue hopes to share his practical experiences and thoughts, which may help customers make the most informed decisions on aluminum extrusion and fabrication products.
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