Materials Comparison: Al 6061-T6, Al 5052-H38, and ASTM A36 Steel

This report provides a comparative analysis of three materials: Al 6061-T6, Al 5052-H38, and ASTM A36 carbon steel. The report examines their mechanical properties, including yield strength, tensile strength, and resistance to deformation, highlighting the superior shear, tensile, and tangent modulus of steel compared to aluminum alloys. It explores factors such as weight, cost, and resistance to corrosion, with aluminum exhibiting better corrosion resistance. The report also discusses malleability, with aluminum alloys being more adaptable for complex shapes. Additionally, the report references finite element analysis, indicating that Al 6061 can replace steel in certain applications like LPG cylinders. The analysis covers strength, malleability, and resistance to corrosion, providing a comprehensive overview of the materials' suitability for various applications. References are also included.

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Al 6061-T6 and Al 5052-H38 are members of the aluminium alloys groups while ASTM A36
carbon steel is a member of the iron alloys. Al 6061-T6 and Al 5052-H38, as well as most of the
low carbon merchant steels, would be of highly comparable yield alongside ultimate tensile
strength. Weight, as well as the cost, is among the other factors that may be taken into
consideration. Nevertheless, steel is about three times the shear, tensile and tangent modulus of
Al 6061 T6 and Al 5052-H38 aluminium. This insinuates that steel would be able to resist
deformation three times stronger in comparison with aluminium when the yield point is crossed
over as it stretches towards ultimate fail [1].
Still, steel has relatively greater shear stress capability in comparison with aluminium. This
translates to about five times as much as the carrying capacity in a specific threads engagement
in steel as for the case with aluminium. This forms the basis of the difference between a
hexagonal structure which is aluminium and a cubic crystal structure that is body-centered which
is LC steel. Unscaled merchant steel will bear nearly four times the resistance to penetration of
the surface hardness of 6061-T6 and Al 5052-H38 of non-anodized aluminium.
In as much as this is perceived as counter-intuitive, aluminium would wear out (unhardened)
steel when it comes to sliding wear [2]. Bare aluminium undergoes quite thorough oxidation.
Aluminium oxide tends to be one of the commonly used abrasive. In most cases, a sulfuric
anodize is often ideal as a hard anodize. The chromic anodize which is hard would flake off with
effects in which the sulfuric anodize would undergo deformation.
Weight is yet another factor that may be taken into consideration in the comparison. Al 6061-T6
and Al 5052-H38 are having a density of 0.098 lb/in3. On the other hand, most of the low carbon
steels are of density that is in the range between 0.282 and 0.285 ln/in3. Low carbon steel tends
to be harder than Al 6061-T6 despite the possibility of corruption. Most of the spinnable tempers

as well as alloys of aluminium scratch, ding or warp more easily in comparison with low carbon
steel. Low carbon steel tends to be stronger and least likely to bend, deform or warp when
subjected to heat, force or even weight [3]. However, the strength of low carbon steel’s trade-off
is such that low carbon steel tends to be heavier or has a higher density than aluminium. Low
carbon steel is ideally 2.5 times denser than Al 6061-T6.
Strength and malleability: Al 6061-T6 and Al 5052-H38 are some of the most often desired
metals owing to its excellent features with regard to malleability as well as elasticity in
comparison with low carbon steel. The two alloys of aluminium are able to get to places as well
as generate shapes that cannot be generated by low carbon steel mostly forming deeper as well as
more intricate spinning. Mostly for the components that have deep as well as straight walls, the
two alloys of aluminium may be selected as the material of choice. low carbon steel is quite a
tough as well as a resilient metal even though it may not be generally be forced to the very
extreme limits of dimension without experiencing ripping as well as cracking during the process
of spinning [4].
Resistance to corrosion: In as much as malleability is very significant for manufacturing, the
greatest attribute of aluminium is that it is resistant to corrosion in the absence of further
treatment upon it being spun [5]. Aluminium does not undergo rusting and instead does not have
a coating or paint that can scratch off or wear. Steel or even carbon in the world of metals often
need treatment or painting upon spinning for protecting it from corrosion and rust especially in
cases where steel would be used under moist, abrasive or damp conditions.
Finite element analysis has been conducted and the findings illustrate Al 6061 has very high
specific strength and hence can be used a replacement of steel in Liquid petroleum gas cylinder.
The analysis that includes low carbon steel, Glass-Epoxy composite as well as Al 6061 T6

established that each of the materials had various features and analyses done of all the
calculations based on the various features [6]. In as much as it was established of the experiment
that Glass Epoxy was the best of all the three materials owing to the extra advantages including
fuel level indicator using the transparency property of Glass as well as high specific impact
resistance, Al 6061 T6 was also usable as a replacement of low carbon steel.

References
[1] Boumerzoug Z, Helal Y. Friction stir welding of dissimilar materials aluminum AL6061-
T6 to ultra-low carbon steel. Metals. 2017 Feb 3;7(2):42
[2] Kumar R, Chattopadhyay S, Hloch S, Krolczyk G, Legutko S. Wear characteristics and
defects analysis of friction stir welded joint of aluminium alloy 6061-T6. Eksploatacja i
niezawodność. 2016;18(1)
[3] Lan S, Liu X, Ni J. Microstructural evolution during friction stir welding of dissimilar
aluminum alloy to advanced high-strength steel. The International Journal of Advanced
Manufacturing Technology. 2016 Feb 1;82(9-12):2183-93
[4] Ling Z, Li Y, Luo Z, Ao S, Yin Z, Gu Y, Chen Q. Microstructure and fatigue behavior of
resistance element welded dissimilar joints of DP780 dual-phase steel to 6061-T6
aluminum alloy. The International Journal of Advanced Manufacturing Technology.
2017 Sep 1;92(5-8):1923-31
[5] Shrivastava A, Krones M, Pfefferkorn FE. Comparison of energy consumption and
environmental impact of friction stir welding and gas metal arc welding for aluminum.
CIRP Journal of Manufacturing Science and Technology. 2015 May 1;9:159-68
[6] Warsi SS, Jaffery SH, Ahmad R, Khan M, Ali L, Agha MH, Akram S.
Development of energy consumption map for orthogonal machining of Al 6061-
T6 alloy. Proceedings of the Institution of Mechanical Engineers, Part B: Journal
of Engineering Manufacture. 2018 Dec;232(14):2510-22