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Should I use 5052 or 6061 aluminum?
Use 5052-H32 for sheet metal that gets bent. It forms to an inside radius of about 1× thickness in gauges up to 0.125 in (3.2 mm), where 6061-T6 needs 1.5–3×, and it resists salt water better. Use 6061-T6 for flat plate and machined parts: it is stronger, 45 ksi (310 MPa) versus 33 ksi (228 MPa) tensile, and machines far cleaner.
Aluminum 5052-H32
Aluminum 6061-T6
By the numbers
Priced on the same representative part: bracket, sheet metal, 100 pcs.
Tensile strengthMPa
5052-H32
228
6061-T6
310
Yield strengthMPa
5052-H32
193
6061-T6
276
Densityg/cm³
5052-H32
2.68
6061-T6
2.7
Max service temp°C
5052-H32
150
6061-T6
150
Elongation%
5052-H32
12
6061-T6
12
Raw material cost$/kg
5052-H32
6
6061-T6
7
Which should you pick?
Pick 5052-H32 when
- The part has bends, hems or flanges
- It sees salt water or marine air
- It is a welded tank, enclosure or chassis formed from sheet
- Vibration fatigue matters in a thin panel
Pick 6061-T6 when
- The part is machined from plate or bar
- It is flat or lightly formed and needs more strength
- Yield must exceed 28 ksi (193 MPa); 6061-T6 yields at 40 ksi (276 MPa)
- Matching bar, tube and extrusions in one alloy simplify the assembly
Key differences
| 5052-H32 | 6061-T6 | |
|---|---|---|
| Minimum inside bend radius | About 1× thickness in gauges to 0.125 in (3.2 mm) | 1.5–3× thickness in T6; tight bends crack |
| Heat treatable | No; strength comes from strain hardening (H32) | Yes; T6 by solution treatment and aging |
| Welding | Welds easily with 5356; loses less strength at the weld than heat-treated alloys | Welds well; the heat-affected zone drops to about 24 ksi (165 MPa) |
| Salt-water resistance | Marine grade | Good, but lower; coat for marine service |
| Machining | Gummy; a poor choice for machined bar parts | Machines fast with good chip control |
| Stock forms | Mostly sheet and plate | Bar, plate, sheet, tube and extrusions |
| Anodize | Type II clear and dyed; color differs slightly from 6061 | Type II and Type III, clear and dyed |
Questions
Can you bend 6061-T6 sheet?
Only with generous radii: plan an inside bend radius of 1.5–3× thickness, more in heavier gauges. For tight bends, specify 5052-H32, or form 6061 in the O or T4 temper and age it afterward.
Is 5052 stronger than 6061?
No. 5052-H32 runs about 33 ksi (228 MPa) tensile and 28 ksi (193 MPa) yield versus 45 ksi (310 MPa) and 40 ksi (276 MPa) for 6061-T6. 5052 wins on formability, strength retained at welds, and fatigue in sheet form.
Which aluminum is best for marine sheet metal?
5052-H32 for enclosures, brackets, tanks and boat hardware. For hulls and long-term immersion, 5083 and 5086 are the heavier-duty marine alloys.
Can 5052 be heat treated for more strength?
No. It is a non-heat-treatable alloy. Harder tempers such as H34 add strength through more strain hardening, at some cost in formability.
Try both on your part.
The builder prices the same geometry in every suitable process and material, with DFM for each.