Aluminum 5754: Composition, Properties, Temper Guide & Applications

Comprehensive Overview

5754 is a member of the 5xxx series of aluminum alloys, an Al‑Mg family typified by magnesium as the principal alloying addition. It is commonly supplied in wrought product forms and classified under EN AW‑5754 and AA‑5754 designations; its Mg content (~2.6–3.6 wt%) places it among the higher‑strength, non-heat‑treatable commercial magnesium alloys.

Strengthening in 5754 is achieved primarily through solid‑solution strengthening and strain hardening rather than precipitation heat treatment. As a non‑heat‑treatable alloy, properties are tuned by cold work and thermomechanical processing rather than solution/aging cycles.

Key traits of 5754 include elevated strength relative to commercially pure aluminum and many 3xxx and 1xxx series alloys, good to very good corrosion resistance in atmospheric and marine environments, good weldability using Al‑Mg filler metals, and favorable formability especially in the annealed condition. Typical industries using 5754 are automotive body and structural components, marine and offshore fabrications, pressure vessels, and general sheet/plate applications where strength, fatigue resistance and corrosion performance are required.

Engineers choose 5754 over other alloys when a balance of moderate to high strength, reliable corrosion resistance, and good cold‑formability is needed without the cost or process constraints of heat‑treatable alloys. It is often selected where welding is frequent and the elevated magnesium content provides improved strength without compromising seakeeping longevity.

Temper Variants

Temper	Strength Level	Elongation	Formability	Weldability	Notes
O	Low	High (20–30%)	Excellent	Excellent	Fully annealed, maximum ductility for complex forming
H111	Medium	Moderate (12–20%)	Good	Very good	Slightly strain‑hardened, commonly supplied for general use
H22	Medium-High	Lower (8–15%)	Fair-Good	Very good	Quarter‑hard condition, balanced strength and formability
H24	High	Low-Moderate (6–12%)	Fair	Good	Strain‑hardened and partially stabilized for increased strength
H34	High	Low (4–10%)	Limited	Good	Heavier strain hardening for applications needing higher yield

Temper modifies 5754 primarily by introducing dislocation density through cold deformation (H tempers) or by removing work hardening in O. Annealed O gives the best drawability and stretch formability for deep shapes and complex bends.

As strain hardening increases, yield and tensile strength rise while elongation and bendability fall; weldability remains generally good across tempers but joint design must consider reduced ductility in harder tempers.

Chemical Composition

Element	% Range	Notes
Si	0.40 max	Impurity; low silicon helps retain ductility
Fe	0.40 max	Typical impurity; can form intermetallics affecting formability
Mn	0.50 max	Controls grain structure and improves strength and resistance to recrystallization
Mg	2.6–3.6	Principal strengthening element, improves corrosion resistance and strain hardenability
Cu	0.10 max	Low content to avoid reducing corrosion resistance
Zn	0.20 max	Minor impurity; higher Zn can reduce ductility
Cr	0.30 max	Microalloying to control grain structure and limit grain growth
Ti	0.15 max	Grain refiner during casting/melt practice
Others (each)	0.05 max	Limits on other trace elements to maintain consistent performance

Magnesium is the dominant performance lever in 5754; its concentration governs baseline strength, work‑hardening response and resistance to pitting in chloride environments. Manganese and chromium are present at low levels to refine grain size and stabilize the alloy during thermo‑mechanical processing.

Low limits on copper and iron preserve the alloy's corrosion resistance and ductility, while controlled silicon and titanium contents support consistent rolling and extrusion behavior.

Mechanical Properties

In tensile behavior 5754 exhibits a ductile fracture mode with good uniform elongation in annealed tempers and progressively lower elongation as strain hardening increases. Yield and ultimate tensile strengths scale with temper: the O condition emphasizes elongation and formability while H‑tempers provide substantial increases in yield for structural applications. Hardness correlates with the dislocation density created by cold work; Brinell hardness increases notably from O to H34 while fatigue strength benefits from higher baseline strength but can be sensitive to surface condition and thickness.

Fatigue performance of 5754 is favorable for Al‑Mg alloys when compared to lower‑strength commercial purities, because moderate solid solution strengthening improves crack initiation thresholds. Thickness effects are significant: thinner gauge sheet generally exhibits higher apparent strength due to cold rolling, and bending/forming limits change with thickness and temper. Surface finish and residual stresses from forming or welding also materially affect fatigue life.

Property	O/Annealed	Key Temper (H111/H22)	Notes
Tensile Strength (UTS)	115–155 MPa	220–265 MPa	UTS increases significantly with strain hardening; values vary with gauge and supplier specifications
Yield Strength (0.2% offset)	35–65 MPa	125–170 MPa	Yield rises sharply in H tempers; design must use certified temper data for safety factors
Elongation (A50mm)	20–30%	8–18%	Ductility reduces with tempering; minimum elongation depends on thickness and processing
Hardness (HB)	25–35 HB	60–85 HB	Brinell hardness tracks strength and work hardening

Physical Properties

Property	Value	Notes
Density	2.66 g/cm³	Typical for Al‑Mg wrought alloys; relevant for mass and stiffness calculations
Melting Range	~605–650 °C (solidus to liquidus)	Alloyed melt range; casting/solidification behavior controlled by minor elements
Thermal Conductivity	~120–160 W/m·K	Lower than pure Al but still high, useful for thermal management applications
Electrical Conductivity	~28–36 % IACS	Reduced from pure Al due to Mg; affects conductor design and EMI considerations
Specific Heat	~900 J/kg·K	Roughly similar to other Al alloys; useful for thermal transient analysis
Thermal Expansion	~23.5 ×10⁻⁶ /K	Typical linear expansion coefficient for structural design in temperature cycles

5754 preserves many of aluminum's desirable thermal and electrical traits while trading off some conductivity and conductivity stability due to alloying. Density and thermal expansion figures are critical for joining dissimilar materials and for precision assemblies where differential thermal movement can induce stress.

The melting/solidus range guides fabrication processes such as brazing and melting practices; careful thermal control is needed to avoid incipient melting of secondary phases and to ensure suitable microstructure for wrought processing.

Product Forms

Form	Typical Thickness/Size	Strength Behavior	Common Tempers	Notes
Sheet	0.3–6.0 mm	Strength varies with temper and rolling reduction	O, H111, H22, H24	Widely used in automotive panels and marine decks
Plate	6–30 mm	Lower ductility, can be supplied in strengthened H tempers	H24, H34	Structural plate for pressure vessels and frames
Extrusion	Various cross-sections	Strength depends on tempering after extrusion; strain hardening used	O, H111	Profiles for railings, conveyors, and structural sections
Tube	0.5–10 mm wall	Similar to sheet in behavior; wall thickness critical for pressure loads	H111, H22	Heat exchanger tubes and fluid lines where corrosion resistance is needed
Bar/Rod	Ø5–100 mm	Can be rolled/cold drawn for higher strength	H111, H34	Machined components, fittings and fasteners in corrosion‑sensitive environments

Sheet and thin gauges are the most common product forms and are optimized for deep drawing, hemming and hydroforming in O and light H tempers. Plate and extrusions are used where stronger sections are necessary; extruded profiles can be supplied in the O condition for forming or in strain‑hardened tempers for final use.

Processing differences (rolling vs extrusion vs drawing) influence grain directionality and anisotropy; designers must consider directional properties for bending, stretching and fatigue critical orientations.

Equivalent Grades

Standard	Grade	Region	Notes
AA	5754	USA	American Aluminum Association designation for wrought alloy
EN AW	5754	Europe	EN designation; often referenced as AlMg3.5 in European material standards
JIS	A5754	Japan	Japanese Industrial Standard uses A5754 nomenclature for similar composition
GB/T	AlMg3.5	China	Chinese standard often lists the alloy by nominal Mg content as AlMg3.5

Equivalency across standards is functional but not absolute; nominal composition ranges and permitted impurities can differ slightly between supplier certificates and regional norms. These small differences can influence formability limits, surface finish for anodizing, and certified mechanical properties, so specification calls and material certificates should be reviewed for critical components.

When sourcing globally, engineers should request detailed chemical and mechanical test reports and be attentive to temper definitions (e.g., H111 geometric and strain limits may be interpreted differently by mills in different regions).

Corrosion Resistance

5754 has very good atmospheric corrosion resistance and performs well in marine and chloride‑bearing environments compared with many aluminum families. The relatively high Mg content increases susceptibility to localized pitting if the surface is mechanical damaged or if aggressive anions are present without protective coatings; however, when protected by coatings or anodic films 5754 exhibits long service life in seawater exposures.

Stress corrosion cracking (SCC) is generally low for 5754 compared to some high‑strength aluminum alloys, but SCC sensitivity increases with higher magnesium levels and with tensile residual stresses from forming or welding. Designers should mitigate SCC risk by controlling stress concentration, post‑weld treatments and by using appropriate tempers.

Galvanic considerations are important: 5754 is cathodic to steels and more noble metals and anodic to pure aluminum in some conditions; appropriate isolation, sacrificial anodes or coatings are required in multi‑material assemblies. Compared to 6xxx series (Al‑Mg‑Si), 5754 offers superior localized corrosion resistance but lower paint adhesion after anodizing; compared to 3xxx series (Al‑Mn) it offers higher strength and similar or slightly improved chloride resistance.

Fabrication Properties

Weldability

5754 is readily welded by TIG, MIG/GMAW and resistance welding using appropriate consumables and parameters. Recommended filler alloys for common joints are 5356 or 5183 (Al‑Mg fillers) to match base metal strength and to minimize galvanic and corrosion issues; avoid high‑silicon fillers unless required for specific welding processes. Hot‑cracking risk is relatively low for this alloy family, but welds can show reduced ductility and local softening in the heat‑affected zone; post‑weld mechanical finishing and stress relief may be required for fatigue‑critical parts.

Machinability

Machinability of 5754 is moderate to difficult relative to 6xxx series because of higher ductility and work hardening tendencies. Carbide tooling with positive rake, high shear angles and good chip breakers are recommended; cutting speeds should be adjusted to avoid built‑up edge and to control tool temperatures. Surface finish and burr formation can be controlled through sharp tooling, sufficient coolant, and minimal feed per tooth; extruded bars and heavy plates may require pre‑stress relief for best dimensional stability.

Formability

Formability is excellent in the fully annealed O condition, allowing tight bend radii and deep draw operations with minimal springback. Typical minimum inside bend radii for sheet in O can be 1–2× material thickness for simple bends, while H‑tempers typically require 3–6× thickness to avoid cracking. Cold working increases strength but reduces elongation; for complex stamping operations plan forming sequence to exploit O for major draws and use light strain hardening for final shaping.

Heat Treatment Behavior

As a non‑heat‑treatable alloy, 5754 does not respond to solution and precipitation heat treatments to increase strength; instead mechanical properties are controlled by cold work and annealing. Annealing (full softening) is achieved by heating into the range where recrystallization occurs, typically around 300–415 °C depending on time and prior cold work, followed by slow cooling; this restores ductility but reduces strength.

Work hardening through cold rolling, drawing or bending increases yield and tensile strength by increasing dislocation density; the degree of attainable strengthening correlates with the amount of plastic deformation. Stabilization or partial anneal tempers (e.g., H24) are achieved by controlled thermal processes that relax some residual stresses without fully softening the material.

High-Temperature Performance

Elevated temperatures accelerate recovery and recrystallization processes in 5754, resulting in a measurable loss of yield and tensile strength at relatively modest temperatures. Continuous service at temperatures above ~100 °C will progressively reduce yield strength, and exposures above ~150–200 °C will produce significant softening and microstructural changes that impair mechanical performance.

Oxidation at typical atmospheric temperatures is minimal due to the protective aluminum oxide, but prolonged high‑temperature exposure increases scaling and can alter surface chemistry important for coatings and adhesions. In welded or heat‑affected regions, thermal cycles can cause localized softening and grain growth; design should limit sustained high‑temperature exposure or apply post‑weld heat stabilization where feasible.

Applications

Industry	Example Component	Why 5754 Is Used
Automotive	Body panels, inner structures	Balance of formability, strength and corrosion resistance for visible and structural parts
Marine	Decking, hull fittings, structural plates	Superior chloride corrosion resistance and weldability for saltwater service
Aerospace	Secondary fittings, interior panels	Good strength‑to‑weight and fatigue resistance for non‑primary structures
Electronics	Heat spreaders, enclosures	Thermal conductivity and corrosion resistance combined with formability
Pressure Vessels	Low‑pressure tanks and piping	Corrosion resistance and ease of fabrication for lightweight vessels

5754 is often specified where a combination of isotropic sheet strength, robust corrosion resistance and cost‑effective fabrication is required. Its ability to be welded using common Al‑Mg fillers and to tolerate marine environments makes it a preferred choice for a wide variety of structural and clad components.

Selection Insights

5754 is a practical choice when designers require higher strength than commercially pure aluminum (1100) while retaining much of the formability and corrosion resistance. Compared with 1100, 5754 sacrifices some electrical and thermal conductivity but gains significant yield and tensile strength for structural uses.

Against common work‑hardened alloys such as 3003 and 5052, 5754 generally sits higher in strength and offers equal or superior chloride corrosion resistance; it is chosen when a stronger sheet is needed without moving to heat‑treatable systems. Compared to heat‑treatable alloys like 6061, 5754 will not attain the same peak strengths but is often preferred for extensive welding and for applications where sustained corrosion resistance or better ductility is needed; it avoids the distortion and thermal sensitivity associated with solution and aging treatments.

Select 5754 when the design requires a middle ground of strength, formability and marine durability, and when welding and cold forming are frequent operations; verify temper and thickness effects against component fatigue and forming requirements.

Closing Summary

5754 remains a widely used Al‑Mg alloy because it combines solid solution strength, dependable corrosion resistance and excellent fabrication characteristics in a cost‑effective wrought form. Its non‑heat‑treatable nature simplifies manufacturing and makes it particularly well suited for welded, cold‑formed and marine applications where long‑term durability and predictable mechanical performance are required.