Aluminum EN AW-5454: Composition, Properties, Temper Guide & Applications

Comprehensive Overview

EN AW-5454 is a member of the 5xxx series aluminum alloys, defined by magnesium as the principal alloying element. The 5xxx family is characterized by its non-heat-treatable, strain-hardenable microstructures and is typically designated for Al–Mg compositions intended to balance strength and corrosion resistance for structural use.

Major alloying elements in EN AW-5454 are magnesium (primary), with controlled levels of silicon, iron, manganese, chromium, and trace elements such as titanium and zinc. Strength in this alloy is developed predominantly through solid-solution strengthening from Mg and by strain hardening (work-hardening) in its H-tempers; it is not strengthened by precipitation heat treatment like 6xxx or 7xxx series alloys.

Key traits of EN AW-5454 include elevated specific strength relative to commercially pure aluminum, very good corrosion resistance in atmospheric and marine environments, good weldability with appropriate filler metals, and fair-to-good cold formability depending on temper and thickness. Typical industries using 5454 are marine and shipbuilding, truck and trailer bodywork, pressure vessels, and general structural applications where corrosion resistance and moderate strength are required.

Engineers select EN AW-5454 over other alloys when a balance of higher strength than 1xxx and 3xxx alloys is needed while retaining superior corrosion resistance compared with many heat-treatable alloys. It is chosen over some higher-magnesium 5xxx alloys when a compromise between corrosion performance and work-hardening capacity is required, and over 6xxx alloys when weldability and avoidance of precipitation hardening are priorities.

Temper Variants

Temper	Strength Level	Elongation	Formability	Weldability	Notes
O	Low	High	Excellent	Excellent	Fully annealed condition, best for deep drawing and complex forming
H111	Low–Moderate	High–Moderate	Very Good	Excellent	Slightly strain-hardened in one direction; common for sheet goods
H11 / H12	Moderate	Moderate	Good	Excellent	Light strain hardening, improved yield for moderate-gauge parts
H14	Moderate–High	Low–Moderate	Fair–Good	Excellent	Typical commercial half-hard tempers for sheet/thin plate
H16	High	Low	Limited	Excellent	Strain-hardened to higher strength for stiff structural panels
H24 / H32	Variable	Variable	Variable	Excellent	Combinations of strain hardening and partial anneal to tailor properties

Temper has a strong influence on the balance of strength and ductility. Annealed (O) material offers maximum formability and elongation for deep drawing operations, while H-number tempers progressively increase yield and tensile strength at the expense of ductility and bendability.

For fabrication planning, choose softer tempers for forming and those with higher H‑numbers for final structural stiffness; temper selection also controls springback, drawing limits, and fatigue initiation sensitivity in cyclic-loaded parts.

Chemical Composition

Element	% Range	Notes
Si	≤ 0.40	Controlled to limit low-melting interdendritic phases and maintain ductility
Fe	≤ 0.40	Typical impurity that influences intermetallic particle formation and toughness
Mn	≤ 0.50	Small additions help control grain structure and inhibit recrystallization
Mg	2.6 – 3.6	Primary strengthening element via solid-solution; controls corrosion behavior and work-hardening
Cu	≤ 0.10	Kept low to preserve corrosion resistance and minimize susceptibility to SCC
Zn	≤ 0.25	Low level to avoid galvanic effects and elevated strength that could reduce corrosion resistance
Cr	≤ 0.20	Microalloying to control grain growth and improve strain hardenability and stress-corrosion performance
Ti	≤ 0.15	Grain refiner in cast and wrought products; small amounts improve toughness
Others (each)	≤ 0.05	Residuals and tramp elements; total others limited to specified maximums

The composition is designed to maximize solid-solution strengthening from Mg while limiting elements that would form deleterious intermetallic phases or reduce corrosion resistance. Magnesium level drives yield and tensile strength in the working tempers, and chromium/manganese additions refine grains and improve resistance to recrystallization and localized corrosion.

Trace impurities such as iron and silicon are controlled to reduce the size and distribution of intermetallic particles that can act as initiation sites for pitting and fatigue cracks. The compositional envelope keeps copper and zinc low to preserve marine corrosion performance and minimize SCC risk.

Mechanical Properties

Tensile behavior of EN AW-5454 is strongly temper- and thickness-dependent; annealed material shows relatively low yield and high elongation, while H-tempered material attains substantially higher yield and tensile strengths through cold working. Yield strength increases markedly with H-number, and common production tempers allow designers to select a compromise between strength and ductility for forming or structural use.

Elongation in the O temper typically exceeds values required for deep drawing and complex stamping; in mid-to-high H tempers, elongation drops and bend radii must be increased. Hardness follows the same trend as tensile strength, rising with strain hardening. Fatigue performance is generally good for 5xxx alloys due to the absence of hard, brittle precipitates, but surface quality, thickness, and temper influence fatigue crack initiation.

Thickness effects are important: thinner gauges can be cold-worked to higher strength levels via strain-hardening than thick plate, and residual stress distributions in multi-pass forming or welding will affect local yield and fatigue life. Designers should consider temper, thickness, and surface condition when specifying fatigue-critical components.

Property	O/Annealed	Key Temper (e.g., H14/H16)	Notes
Tensile Strength	approx. 110–150 MPa	approx. 200–280 MPa	Values vary with temper and thickness; work-hardened tempers show substantial gains
Yield Strength	approx. 40–70 MPa	approx. 130–240 MPa	Yield increases strongly with H-number; consider springback for forming
Elongation	approx. 18–30%	approx. 6–15%	Annealed delivers high ductility, H-tempers reduce elongation and increase stiffness
Hardness	approx. 25–45 HV	approx. 60–95 HV	Hardness correlates with tensile properties; used as quick QC check for cold work

Physical Properties

Property	Value	Notes
Density	2.67 g/cm³	Typical for wrought Al–Mg alloys; useful for mass and inertia calculations
Melting Range	approx. 570–650 °C	Alloy solidus/liquidus range depends on minor constituents; avoid high-temper exposures
Thermal Conductivity	~120–150 W/m·K	Lower than pure Al due to alloying; still excellent for heat dissipation applications
Electrical Conductivity	~30–40 %IACS	Reduced relative to pure Al; trade-off for improved mechanical strength and corrosion resistance
Specific Heat	~0.90 J/g·K (900 J/kg·K)	Typical aluminum alloy value for thermal storage and transient response modeling
Thermal Expansion	~23–24 µm/m·K	Typical isotropic expansion for wrought Al; important for thermal stress calculations

EN AW-5454 retains many of aluminum’s favorable physical properties such as low density and good thermal conductivity, making it attractive where lightweight and heat dissipation are needed. Thermal conductivity and electrical conductivity are reduced versus pure aluminum because of Mg and other solutes; designers should account for this when specifying for thermal or electrical functions.

The melting/solidus range and thermal expansion data influence processing limits: welding and brazing procedures must be controlled to avoid overheating, and thermal expansion must be considered in assemblies with dissimilar materials to avoid distortion or stress concentrations.

Product Forms

Form	Typical Thickness/Size	Strength Behavior	Common Tempers	Notes
Sheet	0.3 – 6 mm	Responds well to cold rolling; available in many H-tempers	O, H111, H14, H16	Most common form for body panels and marine plating
Plate	6 – 200+ mm	Lower work-hardening rate in thicker sections; thicker plate typically supplied softer	O, H32, H111	Used in hull construction and structural components
Extrusion	Cross-section dependent	Extrusion strain and subsequent work-hardening tailor final properties	O, H111	Profiles for structural framing and stiffeners
Tube	Variable	Cold drawn or welded tubes exhibit similar temper-dependent strength	O, H14	Used in piping, chassis, and lightweight structures
Bar/Rod	Ø few mm – 100+ mm	Limited commercial sizes, behaves predictably under cold work	O, H11	Used for machined components and fittings

Processing differences between forms arise from thermomechanical history. Sheet and thin gauge products are readily cold formed and can achieve higher strain-hardened strengths. Plate and heavy sections are more difficult to cold work and often supplied in softer tempers or require post-forming treatments to meet mechanical property targets.

Extrusion and tube production impart aligned grain structures and directional anisotropy, which engineers must consider for fatigue loading and directional forming. Surface finish and mill processing also affect corrosion initiation and fatigue performance in final applications.

Equivalent Grades

Standard	Grade	Region	Notes
AA	5454	USA	Common shorthand equivalent in ASTM/AMS listings for Al–Mg alloys
EN AW	5454	Europe	Industry-standard designation under EN numeric system
JIS	A5049 / A5052 family	Japan	Closest JIS equivalents are from the Al–Mg wrought series; direct matches require cross-reference
GB/T	5A05 / 5454	China	Local standards use similar Al–Mg designations; chemical/tempering tolerances may differ

Standards across regions use different designation systems and tolerances; EN AW-5454 is the European designation and is often cross-referenced to AA 5454 in international specifications. JIS and GB/T systems have related Al–Mg grades, but precise substitution requires review of permitted composition limits, mechanical property tables, and temper designations specific to each standard.

When sourcing material globally, specify the exact standard and temper, and request mill certificates and mechanical test reports to verify conformity, particularly for critical marine or pressure-vessel applications.

Corrosion Resistance

EN AW-5454 exhibits very good atmospheric corrosion resistance, especially in marine and industrial environments, due to its moderate Mg content and low copper/zinc levels. The alloy forms a protective oxide layer and is comparatively resistant to pitting and general corrosion when properly finished and maintained.

In marine service, 5454 behaves well for hulls, superstructures, and exposed fittings, but susceptibility to stress-corrosion cracking (SCC) increases with rising Mg content and in elevated temperature chloride-rich environments. Alloys with Mg > 3.5–4% show higher SCC sensitivity; 5454’s Mg range places it in a moderate SCC-risk category under severe service conditions.

Galvanic interactions are typical for aluminum alloys: 5454 placed against more noble metals (e.g., copper, stainless steel) requires isolation or protective measures to prevent galvanic attack. Compared to 6xxx series alloys, 5454 generally offers better corrosion resistance in chloride environments but does not attain the higher strength of heat-treatable families.

Fabrication Properties

Weldability

EN AW-5454 welds well by common fusion methods (MIG/GMAW, TIG/GTAW, and resistance welding) with low risk of hot cracking when good practices are used. Recommended filler metals for matching corrosion performance and ductility in 5xxx series joints include Al‑Mg fillers such as 5356 or 5183, chosen to match base-metal magnesium content and ensure compatible mechanical/ electrochemical behavior.

Weld heat-affected zones may experience some softening relative to strain-hardened parent metal due to local annealing; designers should account for reduced yield strength in HAZs for structural calculations. Pre- and post-weld cleaning, control of heat input, and appropriate joint design reduce porosity and maintain corrosion performance.

Machinability

Machinability of EN AW-5454 is moderate—better than many high-strength aluminum alloys but poorer than pure aluminum. The alloy tends to produce continuous chips and can be mildly gummy; carbide tooling with positive rake angles is recommended for stable cutting. Typical practice uses higher spindle speeds and moderate feeds to optimize surface finish and tool life, and lubrication/coolant is advised when producing longchips or deep cuts.

CNC milling and turning operations are straightforward for O and low-H tempers, while heavily strain-hardened tempers require higher forces and may increase tool wear. Machining allowances should be planned considering potential work-hardening in the outer surface layers.

Formability

Formability is excellent in O temper and remains good in the H111/H11 tempers for standard stamping and bending operations. Minimum bend radii depend on temper and thickness; as a rule of thumb, O temper can be formed to tighter radii (e.g., 1–2× thickness for many geometries) whereas H14/H16 may require 2.5–4× thickness to avoid cracking.

Cold-work response is predictable: the material work-hardens steadily, enabling designers to use intermediate forming + stress-relief strategies to reach final geometries without fracture. For complex or severe forming, anneal to O temper and re‑work to control springback and limit fracture initiation.

Heat Treatment Behavior

EN AW-5454 is a non-heat-treatable alloy and therefore does not respond to solution treatment and artificial precipitation aging to increase strength. Attempting conventional T‑type heat treatments used for 6xxx series will not produce significant precipitation hardening in this alloy.

Strength adjustments are made by mechanical deformation (cold work) and by annealing. Full anneal (O) is achieved by heating to the prescribed anneal temperature to restore ductility, while intermediate tempers (H‑numbers) are obtained by controlled cold working and, where needed, partial anneals to set the desired combination of strength and ductility.

Thermal exposure during welding can locally anneal strain-hardened regions, so designers must consider the impact of HAZ softening on load-bearing members and may require post‑weld mechanical processing or design allowances to maintain structural performance.

High-Temperature Performance

EN AW-5454 experiences progressive strength loss with increasing temperature and is not suitable for sustained high‑temperature structural service above roughly 100–150 °C. The alloy maintains reasonable mechanical properties at moderate elevated temperatures, but creep and strength degradation accelerate with time and stress at higher service temperatures.

Oxidation of aluminum alloys is minimal due to a stable oxide scale, but at elevated temperatures the protective layer may grow and spall under thermal cycling. Welded joints exposed to high temperatures will see expanded HAZ regions and further reductions in local yield strength, necessitating conservative design for elevated-temperature applications.

For short-term or intermittent exposures up to several hundred degrees Celsius during forming or brazing, control of heat input and cooling rates prevents excessive grain growth and loss of mechanical integrity.

Applications

Industry	Example Component	Why EN AW-5454 Is Used
Automotive / Transportation	Trailer bodies, tankers, structural panels	Good strength-to-weight, corrosion resistance, and formability for stamped components
Marine / Shipbuilding	Hull panels, superstructure plating	Superior seawater corrosion resistance and weldability for hull assemblies
Aerospace (secondary structures)	Fittings, fairings, interior panels	Favorable strength-to-weight and fatigue resistance for non-primary structures
Energy / Pressure vessels	Fuel tanks, storage vessels	Corrosion resistance and good weldability for fluid containment
Electronics / Heat transfer	Heat spreaders, housings	Low density and good thermal conductivity for moderate thermal management needs

EN AW-5454 is favored where a combination of corrosion resistance, weldability, and moderate strength is required in a lightweight form. Its range of product forms and tempers makes it versatile across industries that balance fabrication ease with long-term environmental durability.

Selection Insights

EN AW-5454 is the preferred choice when an engineer needs better mechanical strength than commercially pure aluminum (e.g., 1100) while retaining much of the ductility and formability required for sheet-forming operations. Compared with 1100, 5454 trades some electrical and thermal conductivity for substantially higher yield and tensile strength, making it a better structural material.

When compared with common work-hardened alloys such as 3003 and 5052, EN AW-5454 generally offers higher strength for similar or slightly reduced formability; it often provides equal or better corrosion resistance in marine environments than 5052, depending on exact Mg content and temper. Against heat-treatable alloys like 6061/6063, 5454 will not reach the same peak strengths but is preferred where superior weldability, reduced susceptibility to heat-treatment variability, and better corrosion performance are more important than maximum tensile values.

Select EN AW-5454 when the design priorities are weldability, marine-grade corrosion resistance, and a predictable, strain-hardened strength envelope. If peak heat-treatable strength is required and post-weld mechanical properties are less critical, consider 6xxx alloys; if maximum electrical conductivity or extreme formability is required, consider 1xxx or softer 3xxx alloys instead.

Closing Summary

EN AW-5454 remains a highly relevant wrought aluminum alloy for modern engineering because it provides a practical balance of solid-solution strength, excellent corrosion resistance—especially in marine atmospheres—good weldability, and useful formability across a range of product forms. Its predictable behavior under cold work and stable composition make it a reliable choice for structural, transport, and marine applications where long-term durability and fabrication flexibility are required.