Aluminum 5652: Composition, Properties, Temper Guide & Applications

Comprehensive Overview

5652 is an aluminum alloy that falls within the 5xxx series of Al–Mg alloys, characterized by magnesium as the principal alloying element. It is a non-heat-treatable, strain-hardened alloy that gains strength primarily through cold working rather than precipitation hardening.

Major alloying constituents in 5652 are magnesium with controlled additions of manganese and chromium for grain structure control and corrosion resistance. The alloy delivers a combination of elevated strength (relative to pure aluminum), very good corrosion resistance in atmospheric and marine environments, and reasonable formability and weldability when used in appropriate tempers.

Typical industries that specify 5652 include marine construction, transportation (including trailer and lightweight structural components), pressure vessels and piping where a balance of strength and corrosion resistance is required, and select architectural or industrial applications. Engineers select 5652 over other alloys when they need a stronger alternative to near-pure Al or 3xxx series materials while retaining superior marine corrosion performance compared with many heat-treatable 6xxx and 7xxx alloys.

The alloy is chosen over higher-strength heat-treatable alloys when deep formability, resistance to intergranular corrosion and simpler thermal processing are priorities. Its non-heat-treatable nature simplifies production and reduces susceptibility to heat-related property changes, which can be an advantage in welded and formed assemblies.

Temper Variants

Temper	Strength Level	Elongation	Formability	Weldability	Notes
O	Low	High (20–30%)	Excellent	Excellent	Fully annealed condition for maximum formability
H12	Low–Medium	Medium (12–18%)	Very Good	Excellent	Lightly strain hardened, retains good forming capability
H14	Medium	Medium (10–15%)	Good	Very Good	Moderate strain hardening for increased strength
H32	Medium–High	Lower (8–12%)	Fair	Very Good	Strain hardened and stabilized, common commercial temper
H34	High	Low (6–9%)	Limited	Good	Heavily cold worked to maximize strength at expense of formability
H112	Varies	Moderate (15–25%)	Good	Excellent	As-fabricated temper with properties dependent on production history

Tempers strongly influence the trade-off between strength and ductility in 5652. Annealed (O) material offers the best formability and elongation for deep drawing and complex shaping, while H‑tempers progressively increase strength by cold work at the expense of stretchability.

Weldability remains favorable across most tempers because 5652 is non-heat-treatable; however, localized softening in heavily worked tempers can happen adjacent to weld HAZs. Designers should therefore pick the lowest temper consistent with required strength to maximize both formability and post-weld properties.

Chemical Composition

Element	% Range	Notes
Si	≤ 0.25	Impurity control; excessive Si can reduce ductility
Fe	≤ 0.50	Iron forms intermetallics that can reduce ductility and corrosion performance
Mn	0.2–0.6	Grain structure control and improves strength and corrosion resistance
Mg	2.7–3.6	Primary strengthening element; controls solid solution strengthening and work hardenability
Cu	≤ 0.10	Kept low to maintain corrosion resistance and anodic behavior
Zn	≤ 0.25	Low levels to avoid galvanic susceptibility and maintain ductility
Cr	0.05–0.25	Microalloying for grain control and resistance to recrystallization and stress corrosion
Ti	≤ 0.15	Grain refiner for cast or wrought processing when controlled
Others	≤ 0.15 (each)	Trace elements and residuals; collectively limited to preserve properties

The composition is optimized to deliver solid solution strengthening from magnesium while maintaining corrosion resistance via low copper and controlled iron. Chromium and manganese are deliberately added at low levels to control grain size, inhibit recrystallization during thermo‑mechanical processing, and stabilize strength after cold work.

Minor elements and residuals are tightly limited to prevent deleterious intermetallics and to maintain good weldability and surface finishing characteristics. The Mg content range is the principal lever for tailoring mechanical properties and work-hardening response.

Mechanical Properties

5652 exhibits ductile tensile behavior in annealed conditions and progressively higher strength with decreasing elongation as cold work increases. Yield behavior is typically gradual with a well-defined elastic limit and a pronounced strain-hardening region; heavily worked tempers show higher proof stresses but reduced uniform elongation. Fatigue performance is generally favorable for welded or unwelded structures when design accounts for stress concentrations and surface finish, but welds and sharp geometries significantly reduce fatigue life.

Hardness follows the same trend as tensile properties, increasing from relatively low Brinell numbers in the O temper to much higher values in H‑tempers, reflecting the accumulation of dislocation structures. Thickness effects are notable: thinner gauge sheet can be cold worked to higher strength levels and is more easily strain hardened; thicker plate retains lower work-hardening rates and may require different processing to reach comparable strengths.

Property	O/Annealed	Key Temper (H34)	Notes
Tensile Strength	120–160 MPa	280–320 MPa	Values depend on thickness and precise Mg content
Yield Strength	35–70 MPa	220–260 MPa	0.2% offset yield for design use
Elongation	20–30%	6–9%	Significant reduction with heavy cold work
Hardness	30–40 HB	80–100 HB	Hardness correlates with cold work and strain history

Values in the table are representative ranges for commonly produced plate and sheet products; exact values must be verified from mill certificates for critical designs. Designers should also account for anisotropy in properties caused by rolling direction and for the influence of forming operations on local strength and ductility.

Physical Properties

Property	Value	Notes
Density	2.66–2.70 g/cm³	Slightly less dense than steel, enabling weight savings
Melting Range	~570–640 °C	Solidus and liquidus vary with alloying; typical for Al–Mg alloys
Thermal Conductivity	~110–140 W/m·K (room temp)	Lower than pure aluminum but still good for heat transfer applications
Electrical Conductivity	~22–28 % IACS	Reduced by alloying relative to pure aluminum
Specific Heat	~0.90 J/g·K	Useful for transient heat capacity calculations
Thermal Expansion	23–24 x10^-6 /K	Typical coefficient for wrought aluminum alloys

The thermal and electrical properties make 5652 suitable for applications requiring reasonable heat dissipation and electrical conduction, while the density provides a significant strength-to-weight benefit versus ferrous materials. Thermal expansion should be considered when combining 5652 with dissimilar materials to avoid joint stresses over temperature cycles.

Because thermal conductivity remains relatively high, 5652 is acceptable for heat-spreading components where moderate mechanical strength is also required, but for high‑temperature structural applications its mechanical properties degrade substantially above approximately 100–150 °C.

Product Forms

Form	Typical Thickness/Size	Strength Behavior	Common Tempers	Notes
Sheet	0.3–6.0 mm	Readily strain hardened; thin gauges achieve higher work-hardening	O, H12, H14, H32	Used for formed panels and shallow drawn parts
Plate	6–50+ mm	Lower work-hardening rate; heavy sections less ductile	O, H112, H32	Structural components and thicker panels
Extrusion	Section-specific	Strength influenced by post‑extrusion strain and aging history	As‑extruded, H112	Complex profiles for frames and structural members
Tube	Diameters to 600 mm	Cold drawn or welded; mechanical properties depend on processing	O, H32	Pressure tubing and structural hollow sections
Bar/Rod	Ø3–100 mm	Machinable and cold worked to achieve higher strength	O, H14, H34	Fasteners, pins, and machined components

Sheets and thin-gauge products are commonly used where forming and surface finish matter, while plate and extrusions are selected for structural load-bearing applications. Processing differences such as hot rolling, cold rolling, and controlled annealing define final microstructure and therefore mechanical response in each product form.

Welded tubing and extrusions often require post‑weld mechanical treatment or stress-relief operations when they are produced in stronger H‑tempers to mitigate distortion and localized softening. Specification of temper, thickness, and forming sequence is critical to ensure that the delivered condition matches design expectations.

Equivalent Grades

Standard	Grade	Region	Notes
AA	5652	USA	Primary designation used in North American mill specs
EN AW	5652	Europe	European naming convention; chemistry and tempers may vary by mill
JIS	A5652 (informal)	Japan	Not widely standardized; local suppliers may use similar chemistries
GB/T	5652	China	Regional literature may list comparable compositions under this identifier

Standard designations across regions attempt to represent the same nominal chemistry, but differences in allowable ranges, processing practices and temper definitions can lead to meaningful property variations. Materials sourced from different regions should be evaluated using mill test reports and mechanical test data rather than relying solely on grade name.

Subtle differences often arise from maximum impurity limits (Fe, Si), trace elements, and the producer’s thermo‑mechanical processing; these influence fatigue, corrosion behavior, and formability in service.

Corrosion Resistance

5652 exhibits robust atmospheric corrosion resistance typical of Al–Mg alloys, forming a stable oxide layer that protects the substrate under normal environmental exposure. The high magnesium level enhances resistance to pitting and general corrosion in many marine and coastal environments, making the alloy suitable for hulls, deck structures and exposed outdoor assemblies.

In aggressive chloride environments, localized corrosion can occur, especially at stressed or scratched areas and around galvanic couples. Careful design to avoid dissimilar metal contact and the use of compatible fasteners or isolating coatings is necessary to limit galvanic corrosion; sacrificial protection or coatings are commonly specified for prolonged seawater immersion.

Stress corrosion cracking susceptibility in 5xxx alloys increases with both higher magnesium content and tensile pre-stress; alloys with Mg > 3.5% can be more sensitive in specific conditions such as elevated temperature and sustained tensile stress. Compared with 2xxx or 7xxx alloys, 5652 is significantly less susceptible to SCC in marine environments but remains more vulnerable than pure aluminum in certain weld‑stressed configurations.

Fabrication Properties

Weldability

5652 welds readily by common processes such as TIG (GTAW) and MIG (GMAW), with good fusion and limited hot-cracking risk when appropriate filler alloys are selected. Recommended filler alloys are typically 5356 or 5183 (Al–Mg fillers) to match corrosion performance and mechanical properties; avoid high-copper fillers to prevent localized corrosion.

The heat-affected zone will experience some softening relative to heavily strain-hardened parent metal due to annealing of cold work; designers must account for a decrease in strength adjacent to welds and consider post‑weld mechanical processing if strength is critical. Proper joint fit-up and control of weld heat input reduce porosity and maintain fatigue life.

Machinability

Machining 5652 is moderate in machinability compared with free‑machining aluminum alloys; it responds well to sharp carbide tools, positive rake angles and moderate feeds. Chip formation tends to be continuous with a tendency to adhere at low speeds unless cutting fluid or air blast cooling is used; coated carbide or high-speed steel with TiAlN coatings give good tool life.

Because 5652 work-hardens, interrupted cuts or re-cutting of hardened surfaces can increase tool wear; light depth-of-cut with higher cutting speeds and continuous chip evacuation improves surface finish and dimensional stability.

Formability

Formability in O and light H tempers is excellent with predictable bend radii and stretch characteristics; typical minimum internal bend radii for sheet are on the order of 1–3× material thickness depending on temper and bend method. Cold forming increases dislocation density and thus work-hardens the material, which can be used to tailor local strength but may necessitate intermediate anneals for severe deformation.

Best practice is to stamp or form in the softest temper that still meets dimensional tolerances, and to avoid sharp radii or severe reverse bends in high-H‑tempers. Springback should be accounted for in die design due to aluminum’s high yield-to-tensile ratio.

Heat Treatment Behavior

5652 is a non-heat-treatable alloy and will not respond to solution treatment and artificial aging in the way 6xxx or 7xxx series alloys do. Strength modifications are achieved primarily through cold work and tempering operations that control dislocation structures and recovery.

Annealing (full or partial) is used to soften the alloy prior to forming; typical annealing cycles for wrought Al–Mg alloys are in the range of 300–415 °C with soak times and cooling rates selected to avoid excessive grain growth. For production control, stabilization heat treatments (e.g., H112) and controlled quenching after hot working are used to set an initial temper and reduce variability in mechanical behavior.

High-Temperature Performance

At elevated temperatures, 5652 loses strength progressively due to recovery and the reduction of dislocation density; significant strength reduction is typically observed above 100–150 °C. Long‑term exposure at elevated temperatures can also accelerate grain growth and reduce fatigue resistance and creep limits compared with room-temperature behavior.

Oxidation is limited because aluminum forms a protective oxide film, but scaling and surface changes can occur at high temperatures that affect surface finish and coating adhesion. Welding introduces localized thermal cycles that can cause softening in cold-worked tempers; designers should consider post-weld mechanical processing or select tempers that tolerate HAZ effects.

Applications

Industry	Example Component	Why 5652 Is Used
Marine	Deck fittings, small hull structures	Excellent corrosion resistance in seawater, good strength-to-weight
Automotive / Transport	Trailer panels, cargo floors	Good formability for panels with higher strength than pure Al
Aerospace (secondary)	Fittings, brackets	Favorable strength/ductility balance and corrosion resistance for non-primary structures
Pressure & Storage	Tanks, pressure vessel shells	Ductility and toughness with weldability and corrosion resistance
Industrial / Electronics	Heat spreaders, housings	Thermal conductivity with adequate structural strength

5652 is commonly specified where a balance of manufacturability, corrosion resistance and higher-than-pure-aluminum strength are required, especially in marine and transportation applications. Its combination of properties enables designers to reduce weight while maintaining durability and service life in outdoor and corrosive environments.

Selection Insights

Choose 5652 when you need a marine‑grade aluminum with higher strength than commercially pure grades while retaining excellent corrosion resistance and weldability. It is a practical alternative to low-strength alloys when forming and joining are required without the complexity of heat‑treatable processing.

Compared with commercially pure aluminum (1100), 5652 trades some electrical conductivity and ultimate formability for significantly higher strength and improved chloride resistance. Against work-hardened alloys like 3003 or 5052, 5652 generally provides higher strength and comparable or better marine corrosion resistance, but formability is lower than 3003.

Compared with heat-treatable alloys such as 6061, 5652 offers better corrosion resistance in marine environments and simpler processing (no solution-aging cycle), making it preferable when performance under chloride exposure and weld reliability outweighs the need for peak age-hardening strength.

Closing Summary

5652 remains a relevant choice for modern engineering where a combination of elevated strength, excellent corrosion resistance and straightforward fabrication are required. Its non-heat-treatable nature simplifies manufacturing and makes it particularly attractive for marine, transport and structural applications where weldability and long-term durability are prioritized.