Aluminum 5052: Composition, Properties, Temper Guide & Applications

Comprehensive Overview

5052 is an aluminum alloy in the 5xxx series (Al-Mg class) characterized by magnesium as the principal alloying element. It belongs to the non-heat-treatable, strain-hardenable family of wrought aluminum alloys, where strength is achieved primarily through cold work (work hardening) rather than precipitation hardening.

Major alloying elements are magnesium (typically ~2.2–2.8%) and small additions of chromium (≈0.15–0.35%) with trace amounts of silicon, iron, copper and others. The Al-Mg solid solution provides moderate to high strength, excellent corrosion resistance—particularly in marine and chloride environments—good weldability, and reasonable formability depending on temper.

Key traits include higher strength than commercially pure aluminum and many 3xxx series alloys, very good resistance to seawater pitting and general atmospheric corrosion, and good combination of ductility and fatigue performance in the annealed and lightly-hardened conditions. These properties make 5052 widely used in marine hardware, fuel lines, pressure vessels, sheet metal work, and components where corrosion resistance and moderate strength are required.

Engineers select 5052 where a balance of formability, corrosion resistance and weldability is needed but the higher peak strengths of heat-treatable alloys (6xxx or 7xxx series) are not required. It is often chosen over 1100 and 3003 when improved strength and marine performance are necessary, and over 6061 when superior corrosion behavior and better forming are more important than maximum achievable yield strength.

Temper Variants

Temper	Strength Level	Elongation	Formability	Weldability	Notes
O	Low	High	Excellent	Excellent	Fully annealed, maximum ductility for forming
H111	Low-Moderate	High	Excellent	Excellent	Slight work hardening from process control
H32	Moderate	Moderate	Good	Excellent	Strain-hardened and partially stabilized; common for sheet
H34	Moderate-High	Moderate-Lower	Fair	Excellent	Heavier strain hardening than H32 for higher strength
H36	High	Low	Fair-Poor	Excellent	Maximum commercially available cold work for sheet
H112	Moderate	Moderate	Good	Excellent	As-fabricated temper controlled by mill

Temper affects tensile, yield and ductility by controlling the degree of cold work and dislocation density in the alloy. Annealed (O) condition provides the best formability and elongation for drawing and severe forming operations, while H3x tempers trade ductility for higher yield and tensile strengths through strain hardening.

Work-hardened tempers (H32/H34/H36) are commonly used for structural and welded components where additional strength from cold work is desired without losing corrosion performance. Selected temper should match intended forming operations and service loads since subsequent forming or welding can alter local temper and properties.

Chemical Composition

Element	% Range	Notes
Si	≤ 0.25	Impurity; reduces fluidity in casting, minimal effect on wrought properties
Fe	≤ 0.40	Impurity; intermetallic particles form, minor effect on ductility
Mn	≤ 0.10	Small effect; improves strength marginally
Mg	2.2 – 2.8	Primary strengthening element; improves corrosion resistance and work hardening
Cu	≤ 0.10	Limited addition; increases strength but can reduce corrosion resistance
Zn	≤ 0.10	Minor impurity; negligible strengthening
Cr	0.15 – 0.35	Controls grain structure, limits brittleness and improves corrosion resistance
Ti	≤ 0.15	Grain refiner trace when present
Others (each)	≤ 0.05	Residuals and trace elements; balance Al

Magnesium is the dominant alloying element and sets the alloy’s mechanical and corrosion performance by forming a strong Al-Mg solid solution and enabling effective strain hardening. Chromium is deliberately added in small amounts to control grain structure and prevent grain boundary precipitates that would promote intergranular corrosion and reduce toughness.

Minor elements and residuals influence castability, surface finish and the formation of intermetallics that affect fatigue crack initiation, machinability and surface treatment behavior. Overall, composition limits are tightly controlled to ensure consistent weldability, anodizing response and corrosion resistance.

Mechanical Properties

5052 exhibits distinct tensile behavior depending on temper: annealed (O) material shows low yield and moderate ultimate tensile strength with high elongation, while H3x tempers show considerably higher yield and tensile values with reduced ductility. Yield strength increases significantly with cold work due to increased dislocation density; typical yield-to-ultimate ratios vary with temper and gauge thickness.

Elongation and hardness are strongly thickness- and temper-dependent. Thin-gauge sheet in H32 may show lower elongation and higher apparent hardness than thicker plate in the same nominal temper. Fatigue resistance of 5052 is generally good for aluminum, benefiting from its corrosion resistance and relatively ductile fracture behavior; surface finish, residual stresses and cold work degree strongly influence fatigue life.

Temperature and thickness affect mechanical metrics: thinner gauges usually show higher strength from processing (rolling) and may show less ductility, while elevated temperatures reduce strength due to thermally activated recovery. For design, engineers must specify both temper and thickness to obtain reliable strength and elongation values in service.

Property	O/Annealed	Key Temper (e.g., H32)	Notes
Tensile Strength	110 – 145 MPa	215 – 250 MPa	UTS varies with thickness and work hardening; H32 commonly ~215–235 MPa
Yield Strength	35 – 70 MPa	120 – 160 MPa	Substantial increase from cold working; conservative design should use tested values
Elongation	15 – 30%	6 – 12%	Annealed has high ductility; H32 is formable but less ductile
Hardness (Brinell/HB)	~25 – 40 HB	~60 – 85 HB	Hardness rises with temper and correlates with yield strength

Physical Properties

Property	Value	Notes
Density	2.68 g/cm³	Typical for Al-Mg alloys; gives favorable strength-to-weight
Melting Range	~605 – 650 °C	Solidus/liquidus depend on minor constituents; alloy melts below pure Al peak
Thermal Conductivity	~130 – 150 W/m·K	Lower than pure Al but still high; conductive for heat spreading applications
Electrical Conductivity	~36 – 40 % IACS	Reduced compared to pure Al due to Mg; adequate for certain electrical applications
Specific Heat	~0.90 kJ/kg·K	Typical room-temperature value; varies slightly with alloying
Thermal Expansion	~23.5 – 24.0 µm/m·K	Similar to other Al alloys; important for thermal cycling and joining design

5052’s density and thermal conductivity make it useful for components where light weight and heat spreading are advantages, such as heat sinks and enclosures. Electrical conductivity is reduced from pure aluminum by alloying but remains suitable for many conductive parts where mechanical strength is important.

The thermal expansion coefficient is similar to other aluminum alloys and must be considered in multi-material assemblies to avoid stresses during thermal cycles. The relatively low melting range compared with steel requires care in welding and high-temperature processing.

Product Forms

Form	Typical Thickness/Size	Strength Behavior	Common Tempers	Notes
Sheet	0.2 – 6.0 mm	Thin sheet often exhibits higher apparent strength due to rolling	O, H32, H34	Widely available; used for panels, tanks and housings
Plate	6 – 100 mm	Thicker plate has lower work hardening from rolling; strength depends on mill processing	O, H112	Used for structural parts, brackets and pressure vessels
Extrusion	Variable cross-sections	Strength depends on extrusion and subsequent cold work	H32, H111	Profiles for frames, rails, and marine fittings
Tube	OD and wall varied	Welded or seamless; mechanical properties depend on manufacturing	O, H32	Fuel and hydraulic lines, marine tubing
Bar/Rod	Diameters up to ~100 mm	Bars have lower strength than cold-rolled sheet unless strain-hardened	H112, O	Machined components and fasteners where corrosion resistance is needed

Processing route strongly affects final mechanical behavior: rolled sheet undergoes high strain and can be supplied in H3x tempers with predictable strength increases, while plate and extrusion may be supplied in O or H112 and subsequently cold worked for higher properties. Selecting the appropriate product form and temper ensures manufacturability and consistent in-service performance.

Sheet and extrusions dominate applications that exploit 5052’s formability and corrosion resistance, while plate is chosen where thickness and stiffness are required. Welded fabrications often use sheet or extruded forms to simplify joining and reduce post-weld distortion.

Equivalent Grades

Standard	Grade	Region	Notes
AA	5052	USA	Primary designation in the Aluminum Association standard
EN AW	5052	Europe	EN AW-5052 corresponds closely to AA5052 with harmonized limits
JIS	A5052	Japan	JIS A5052 matches composition and properties for domestic supply
GB/T	5052	China	Chinese standard grade aligns with international 5052 specifications

Equivalent standards carry very similar chemical limits and mechanical property expectations but may differ slightly in manufacturing tolerances, surface finish, and permitted impurity limits. Users should verify the specific standard revision and supplier certification to ensure compliance with design requirements and any regulatory constraints.

Subtle differences can affect formability and welding acceptance criteria, so engineers should request mill certificates and qualify material batches for critical applications, especially in pressure-containing or marine structures.

Corrosion Resistance

5052 exhibits excellent resistance to atmospheric corrosion and outstanding behavior in chloride-containing environments, which is why it is a common marine and coastal alloy. The high magnesium content enhances pitting resistance and the alloy forms a stable, adherent oxide that protects the substrate under normal exposure conditions.

In seawater and salt-spray environments, 5052 tends to resist general corrosion and localized attack better than many other wrought aluminum alloys, though prolonged immersion and galvanic coupling with cathodic metals (e.g., copper, stainless steel) require design attention. Proper isolation materials and fastener selection reduce galvanic potentials and minimize localized corrosion around joints.

Stress corrosion cracking (SCC) susceptibility for 5052 is low compared with high-strength heat-treatable Al alloys; however, heavily cold-worked tempers and exposure to tensile stresses in aggressive environments can elevate risk. Compared with 6061 and 7075 families, 5052 accepts a more aggressive chloride environment with far less SCC and pitting, making it preferable for marine hulls, fuel tanks and outdoor enclosures.

Fabrication Properties

Weldability

5052 is readily welded using common fusion methods such as TIG (GTAW), MIG (GMAW), and spot welding. Filler alloys like 5356 (Al-Mg) are typically recommended to maintain corrosion resistance and strength in the weld zone, and to avoid hydrogen-induced porosity and excessive dilution of Mg content.

Hot-cracking risk is low compared to Al-Si or Al-Cu alloys, but weld heat input creates localized softening in work-hardened tempers because the HAZ undergoes partial recovery and recrystallization. Pre- and post-weld controls are generally not required for non-critical components, yet for heavily cold-worked parts a stress-relief or re-hardening sequence may be necessary to restore uniform properties.

Machinability

5052 is considered more difficult to machine than free-cutting aluminum alloys and considerably less machinable than many steels in terms of ease and chip control. Tooling with positive rake carbide inserts, sharp geometry and high coolant flow reduces built-up edge and improves surface finish; moderate cutting speeds and heavy feed rates are often preferable to minimize heat concentration and tool rubbing.

Drilling and tapping perform acceptably with standard carbide drills but require careful control of spindle speed and pecking cycles to evacuate chips. Overall machinability indexes place 5052 below 6xxx alloys; designers should minimize heavy machining when possible and select near-net shapes or extrusions for complex geometries.

Formability

Formability is excellent in annealed O condition and good in moderately strain-hardened tempers such as H32; deep drawing, spinning and bending are feasible with properly selected tooling and lubrication. Minimum bend radii depend on temper and thickness—annealed material can approach 1–1.5× thickness for inside radii, while H32 often requires 2–3× thickness to avoid cracking.

Cold working increases strength through strain hardening but reduces ductility; incremental forming strategies, multi-step bends, or intermediate anneals allow more aggressive shapes in production environments. For complex forming, specify O temper or allow for post-forming strain-hardening to target final mechanical properties.

Heat Treatment Behavior

5052 is a non-heat-treatable alloy; it does not gain significant strength from solution treatment and precipitation aging. Attempts to apply conventional T6-style heat treatments are ineffective and can degrade corrosion resistance and dimensional stability without meaningful strengthening.

Strength control is achieved through cold working and controlled annealing cycles. Full anneal (O) is achieved by heating to temperatures sufficient to recrystallize the microstructure—typical industrial practice uses recovery/anneal cycles in the 300–415 °C range followed by controlled cooling to restore ductility and reduce residual stresses.

Temper transitions occur primarily via mechanical operations: H1x tempers indicate strain hardening without subsequent stabilization, while H3x indicates strain hardening followed by stabilization to partially arrest changes during forming. Any thermal exposure above typical service temperatures can reduce cold-worked strength due to recovery processes.

High-Temperature Performance

5052 experiences gradual strength loss with increasing temperature; above approximately 100–150 °C the yield and tensile strengths decline noticeably, limiting continuous elevated-temperature service. For short-term or intermittent exposures up to ~200 °C the alloy retains some load-bearing capability but creep resistance is limited compared with heat-resistant alloys.

Oxidation at elevated temperatures is generally mild for aluminum, but prolonged high-temperature exposure can promote surface scale formation and diffusion of solute elements that alter local corrosion behavior. HAZ effects from welding are limited to softening due to recovery; there is no age-hardening reversal since the alloy is not heat-treatable.

Designers should specify temperature limits based on loss of mechanical margin and consider alternative alloys for structural applications requiring maintained strength above ~100 °C for extended periods.

Applications

Industry	Example Component	Why 5052 Is Used
Automotive	Fuel tanks and inner body panels	Corrosion resistance and formability for stamped components
Marine	Hull components, deck fittings	Excellent seawater corrosion resistance and weldability
Aerospace	Interior fittings and non-critical fittings	Good strength-to-weight and corrosion performance
Electronics	Chassis, heat spreaders	Thermal conductivity combined with corrosion resistance
Oil & Gas	Pressure and storage tanks	Good weldability and fatigue resistance in corrosive environments

5052’s balance of corrosion resistance, weldability and reasonable strength makes it a go-to alloy for many industries where long-term environmental exposure is a key driver. Its availability in multiple product forms and tempers simplifies procurement and reduces the need for exotic joining or coating strategies.

Selection Insights

5052 is preferred when corrosion resistance, especially in chloride environments, and good weldability must accompany moderate strength and formability. Choose 5052 over commercially pure aluminum like 1100 when additional strength and improved fatigue life are required, noting that electrical and thermal conductivity will be reduced relative to pure Al.

Compared with 3003 (another work-hardenable Al-Mn alloy), 5052 offers higher strength and better pitting resistance due to its higher magnesium content; however, 3003 may be chosen for slightly better cold workability and lower cost. Compared with heat-treatable alloys such as 6061, 5052 will be selected when superior corrosion resistance and forming are more critical than peak strength and stiffness.

Practical selection logic: specify O temper for complex forming, H32 for structural sheet where higher yield is needed, and prefer fillers like 5356 for welds. Consider galvanic isolation when mating with dissimilar metals and validate thickness-dependent properties for fatigue-critical parts.

Closing Summary

5052 remains a versatile aluminum alloy offering a robust combination of corrosion resistance, weldability and moderate strength achieved by work hardening, making it highly valuable across marine, automotive and general fabrication sectors. Its predictable behavior in common tempers and widespread availability in sheets, plates, extrusions and tubes ensure it continues to be a practical choice where durability in corrosive environments and manufacturability are paramount.