Aluminum 5152: Composition, Properties, Temper Guide & Applications

Comprehensive Overview

Alloy 5152 is a member of the 5xxx series of aluminum alloys, characterized by magnesium as the principal alloying element. It is a non-heat-treatable, strain-hardenable alloy whose primary strengthening mechanism is solid-solution strengthening combined with work hardening; it does not respond to conventional solution/precipitation heat treatment.

5152 offers a balance of moderate-to-high strength, excellent corrosion resistance in many environments (notably marine atmospheres), good weldability, and reasonable formability in annealed and light-hardened tempers. Typical industries using 5152 include marine construction, transportation (including automotive and rail), pressure vessels, and architectural applications where corrosion performance and formability are required.

Engineers choose 5152 where a combination of resistance to seawater or de-icing salts, good fatigue behavior, and the ability to be formed and welded economically is needed, often preferring it to softer commercial-purity alloys for added strength and to heat-treatable alloys when the fabrication route involves extensive cold working. 5152 is also selected where dimensional stability after moderate strain hardening and resistance to stress-corrosion cracking are important.

Temper Variants

Temper	Strength Level	Elongation	Formability	Weldability	Notes
O	Low	High (20–30%)	Excellent	Excellent	Fully annealed, best for deep drawing and severe forming
H14	Moderate	Moderate (12–18%)	Good	Excellent	Quarter-hard, improved strength with retained ductility
H16	Moderate-High	Moderate (8–15%)	Good	Excellent	Half-hard, common for formed sheet parts
H18	High	Lower (5–12%)	Fair	Excellent	Three-quarter hard, used for structural stiffness
H22	Moderate	Moderate (10–18%)	Good	Excellent	Stress-relieved after partial anneal
H32	High (stabilized)	Lower (6–12%)	Fair-Good	Excellent	Strain-hardened and stabilized for controlled properties

Temper profoundly influences the trade-off between strength and ductility in 5152, with annealed O condition providing the best formability for deep drawing and severe bending operations. Work-hardening (H-series) increases yield and tensile strength at the expense of elongation, improving stiffness and dent resistance for fabricated components.

Chemical Composition

Element	% Range	Notes
Si	≤ 0.25	Impurity from melting; low Si preserves formability
Fe	≤ 0.40	Typical impurity; higher Fe can reduce ductility
Mn	≤ 0.15	Minor; aids grain structure control
Mg	2.2–2.8	Principal alloying element providing strength and corrosion resistance
Cu	≤ 0.10	Low to control susceptibility to SCC and maintain corrosion resistance
Zn	≤ 0.10	Kept low to avoid hot cracking and galvanic concerns
Cr	≤ 0.15	Can improve grain structure and corrosion performance slightly
Ti	≤ 0.15	Grain refiner in castings/ingots; low content in wrought stock
Others	≤ 0.05 each, 0.15 total	Trace elements and residuals; balance Al

Magnesium is the dominant alloying addition and sets the alloy’s mechanical and corrosion-response baseline; higher Mg increases strength via solid solution hardening but can influence formability and joining characteristics. Trace elements such as Fe, Si and Cu are controlled to limit brittle intermetallics and to maintain weldability and resistance to localized corrosion.

Mechanical Properties

Tensile behavior in 5152 is strongly temper-dependent: annealed material shows relatively low yield and modest tensile strength with high uniform elongation, while H-tempered material demonstrates significantly higher yield and ultimate strength but reduced elongation. The alloy generally displays a smooth stress–strain response with appreciable strain hardening, providing good energy absorption and predictable forming springback for structural parts.

Fatigue performance benefits from the alloy's good resistance to corrosion fatigue and the absence of coarse precipitates; fatigue life is improved in well-finished surfaces and when avoiding sharp stress concentrators. Thickness substantially affects mechanical metrics and formability — thinner gauges are easier to cold-form and have higher allowable bend radii relative to thicker plate where bending-induced strain gradients can localize.

Property	O/Annealed	Key Temper (e.g., H32/H16)	Notes
Tensile Strength	170–240 MPa	240–330 MPa	Values vary with temper and thickness; H-tempers show significant uplift
Yield Strength	60–120 MPa	150–275 MPa	Yield increases rapidly with work hardening; design for lowest expected temper
Elongation	20–30%	6–15%	Ductility diminishes with increasing temper; gauge affects elongation values
Hardness	30–45 HB	60–95 HB	Correlates with temper level; hardness correlates with yield/tensile behavior

Physical Properties

Property	Value	Notes
Density	2.68 g/cm³	Typical for wrought aluminum alloys; useful for mass calculations
Melting Range	570–650 °C	Solidus/liquidus vary with impurities; not heat-treatable for strengthening
Thermal Conductivity	~130–150 W/m·K	Lower than pure Al but still high for heat dissipation applications
Electrical Conductivity	~30–40 % IACS	Alloying reduces conductivity compared with pure aluminum
Specific Heat	~900 J/kg·K	Typical room-temperature value used in thermal modeling
Thermal Expansion	23–24 µm/m·K	Similar to other Al-Mg alloys; important for joined dissimilar assemblies

5152’s thermal and electrical properties make it suitable for components needing good heat dissipation and moderate electrical conduction while still offering corrosion resistance. The combination of low density and good thermal conductivity is advantageous in marine and transport applications where weight and heat management are concerns.

Product Forms

Form	Typical Thickness/Size	Strength Behavior	Common Tempers	Notes
Sheet	0.2–6.0 mm	Uniform across width; temper-dependent	O, H14, H16, H18, H32	Widely produced; used for formed panels and tanks
Plate	6–25 mm	Lower formability, higher stiffness	H18, H32	Used for structural panels and pressure vessel components
Extrusion	Profiles up to large sections	Strength depends on temper and section size	H22, H32	Limited use compared with 5000-series extrusions optimized for 5xxx alloys
Tube	0.5–10 mm wall	Behavior similar to sheet; welding and drawing important	O, H16, H32	Used for fluid handling and structural applications
Bar/Rod	Up to 100 mm diameter	Generally produced in strain-hardened conditions	H14–H32	Used where machined components require corrosion resistance and moderate strength

Sheet and coil are the most common commercial forms for 5152, produced with close control of surface finish for decorative and exposed applications. Plate and extrusions require adjusted processing parameters and often different tempers to balance mechanical performance with manufacturability for thicker or more complex sections.

Equivalent Grades

Standard	Grade	Region	Notes
AA	5152	USA	Primary designation in Aluminum Association standards
EN AW	5152	Europe	Generally equivalent but EN standards may include distinct suffixes for temper and impurity limits
JIS	A5152 (designation)	Japan	Local standards may reflect slight compositional or mechanical tolerances
GB/T	5152	China	Often mapped directly to AA 5152 but minor spec differences can exist

Equivalent designations mostly map across major standards because 5xxx-series alloys are globally standardized, but subtle differences in impurity limits, temper designations, and certification practices can affect interchangeability. Always check the specific standard and mill test certificates for critical applications that require strict compositional or mechanical conformity.

Corrosion Resistance

5152 exhibits robust atmospheric corrosion resistance, particularly in marine environments and where exposure to sea spray or de-icing salts occurs. The magnesium content confers improved resistance to general and pitting corrosion relative to many 3xxx-series alloys, and the alloy forms a protective oxide film that is stable in alkaline and many near-neutral environments.

Stress-corrosion cracking (SCC) susceptibility is low compared with higher-copper alloys, but localized corrosion can arise in crevices or when galvanically coupled to more noble metals without isolation. In galvanic pairings, 5152 is anodic to stainless steel and copper alloys, so designers should use insulating barriers or sacrificial cathodic protection strategies in mixed-metal assemblies.

Compared with 1xxx and 3xxx series alloys, 5152 offers superior corrosion resistance and higher strength; compared with 6xxx series alloys it is generally more resistant to marine corrosion but does not offer the same peak strength of heat-treatable materials.

Fabrication Properties

Weldability

5152 welds readily with common fusion processes including MIG (GMAW) and TIG (GTAW); its low copper and controlled magnesium limit hot cracking tendencies when good practice is followed. Recommended filler alloys include 5356 (Al-Mg) for strength retention and corrosion resistance, with 4043 used for improved flow and reduced discoloration on decorative surfaces. Heat-affected zone softening is minimal because the alloy is non-heat-treatable, but distortion and burn-through control are important when welding thin gauges.

Machinability

Machinability of 5152 is moderate to fair; it machines more readily than some higher-strength Al-Mg alloys but is not as free-cutting as certain Al-Si alloys. Carbide tooling, positive rake geometries, and higher feed rates with adequate coolant deliver the best surface finish and tool life; built-up edge can be an issue on interrupted cuts or sticky alloy conditions. Avoid excessive cutting speeds that induce work hardening near the surface, and ensure chip control for thin-wall sections.

Formability

Formability in the annealed O temper is excellent, enabling deep drawing, spinning, and complex bending with relatively low springback. For H-tempers, bending radii must be increased and forming operations staged to avoid cracking; intermediate anneals or stretch forming can be used to achieve tighter radii. Designers should reference minimum bend radii expressed in gauge-diameter multiples and account for work hardening in final springback predictions.

Heat Treatment Behavior

These alloys are non-heat-treatable; mechanical strengthening is achieved through cold working (strain hardening) and stabilizing heat treatments rather than solution and precipitation steps. Typical processing uses annealing to restore ductility followed by controlled cold working to reach required strength levels, sometimes with a stabilization (low-temperature bake) to reduce future property changes.

Standard annealing for 5xxx alloys is performed at temperatures that restore a recrystallized structure without creating undesirable intermetallics; the O temper is achieved by full anneal and controlled cooling. Attempts to apply T-type solution/aging cycles do not produce significant age-hardening in 5152 and are therefore not used for strength enhancement.

High-Temperature Performance

5152 loses strength progressively with increasing temperature; usable structural strength diminishes beyond approximately 100–150 °C and thermal exposure above about 200 °C accelerates annealing and property relaxation. Oxidation of aluminum itself is minimal under service conditions unless temperatures are high and aggressive atmospheres are present, but elevated temperatures can change microstructure and reduce fatigue life.

Weld heat-affected zones can experience localized softening when subsequently exposed to elevated service temperatures combined with mechanical stress, so design for reduced temperature exposure in critical welded joints. For continuous high-temperature operation, a different alloy family (e.g., certain Al-Si or Al-Zn-Mg alloys) should be considered.

Applications

Industry	Example Component	Why 5152 Is Used
Automotive	Fuel tanks and body panels	Corrosion resistance and formability for complex shapes
Marine	Hull plating, deck components	Excellent resistance to seawater and de-icing salts
Aerospace	Interior fittings and fairings	Good strength-to-weight and ease of fabrication
Electronics	Chassis and panels	Thermal conductivity and corrosion resistance
Pressure Vessel	LPG tanks and cylinders	Ductility, weldability, and fatigue resistance

5152 is commonly chosen where a combination of seawater corrosion resistance and the ability to be formed and welded in-shop or on-line is more important than obtaining the highest possible strength. The alloy’s balance of properties supports a wide set of design solutions across transport, marine, and industrial hardware.

Selection Insights

When selecting 5152, prioritize applications needing resistance to marine environments, moderate structural strength, and good formability. Use 5152 over softer commercial-purity alloys when increased yield and tensile properties are required without sacrificing corrosion performance.

Compared with commercially pure aluminum (e.g., 1100), 5152 trades some electrical conductivity and ultimate formability for significantly higher strength and improved corrosion resistance. Compared with common work-hardened alloys such as 3003 or 5052, 5152 typically delivers equal or slightly higher strength and superior corrosion resistance in chloride-containing environments. Compared with heat-treatable alloys like 6061/6063, 5152 will not reach the same peak strengths, but it is often preferred where welding, formability, and marine corrosion resistance are more critical than maximum strength.

Closing Summary

Aluminum 5152 remains a practical, well-rounded alloy for modern engineering where corrosion resistance, good weldability, and the ability to be formed economically are needed. Its work-hardening response and stable performance in marine and atmospheric environments keep it relevant for transportation, marine, and structural applications where long-term durability and maintainability are priorities.