5052 Aluminum Round Bar

1. Material Composition & Manufacturing Process

5052 aluminum round bar is a medium-strength non-heat-treatable aluminum-magnesium alloy that offers an exceptional balance of formability, weldability, and corrosion resistance, making it ideal for marine applications and general-purpose fabrication:

• Primary Alloying Elements:

• Magnesium (Mg): 2.2-2.8% (solid solution strengthening)
• Chromium (Cr): 0.15-0.35% (corrosion resistance enhancement)
  • Base Material:
• Aluminum (Al): ≥95.7% (balance)
  • Controlled Impurities:
• Iron (Fe): ≤0.40% max
• Silicon (Si): ≤0.25% max
• Copper (Cu): ≤0.10% max
• Manganese (Mn): ≤0.10% max
• Zinc (Zn): ≤0.10% max
• Other elements: ≤0.05% each, ≤0.15% total

Premium Manufacturing Process:

1. Melt Preparation:

• High-purity primary aluminum (99.7% minimum)
• Precise alloying element additions
• Melt filtration through ceramic foam filters (20-30 ppi)
• Advanced degassing treatment (hydrogen < 0.15 ml/100g)
• Grain refinement with Al-Ti-B master alloy
• Direct-chill (DC) semi-continuous casting
  2. Homogenization:
• 450-480°C for 6-12 hours
• Uniform temperature control: ±5°C
• Controlled cooling rate: 30-50°C/hour
  3. Hot Working:
• Initial breakdown: 380-420°C
• Intermediate rolling/forging: 350-380°C
• Final hot working: 320-350°C
• Careful temperature control to ensure uniform properties
  4. Cold Working:
• H32: Quarter-hard condition (strain hardened)
• H34: Half-hard condition (strain hardened)
• H38: Full-hard condition (strain hardened)
  5. Annealing (for O temper):
• 340-360°C for 1-3 hours
• Controlled cooling to achieve optimal grain structure
  6. Finishing:
• Surface conditioning
• Precision straightening
• Dimensional verification
• Surface quality inspection

Full manufacturing traceability with comprehensive documentation for all production steps.

2. Mechanical Properties of 5052 Aluminum Round Bar

Property	O (Annealed)	H32	H34	H38	Test Method
Ultimate Tensile Strength	170-215 MPa	230-265 MPa	255-290 MPa	290-320 MPa	ASTM E8
Yield Strength (0.2%)	65-95 MPa	160-190 MPa	180-210 MPa	220-250 MPa	ASTM E8
Elongation (2 inch)	18-30%	12-18%	8-14%	5-10%	ASTM E8
Hardness (Brinell)	45-55 HB	60-70 HB	68-78 HB	75-85 HB	ASTM E10
Fatigue Strength (5×10⁸)	90-110 MPa	120-140 MPa	130-150 MPa	140-160 MPa	ASTM E466
Shear Strength	110-130 MPa	140-160 MPa	150-170 MPa	165-185 MPa	ASTM B769
Modulus of Elasticity	70.3 GPa	70.3 GPa	70.3 GPa	70.3 GPa	ASTM E111

Property Distribution:

• Longitudinal to transverse property ratio: 1.00:0.95
• Variation across diameter: <3% for bars up to 50mm, <5% for bars >50mm
• Core to surface hardness variation: <5 HB
• Property retention after welding: Excellent compared to heat-treatable alloys

3. Microstructural Characteristics

Key Microstructural Features:

1. Grain Structure:

• Equiaxed grains in annealed condition
• Elongated grains in strain-hardened tempers
• ASTM grain size 5-8 (63-22μm)
• Uniform grain distribution across section
  2. Precipitate Distribution:
• Al₁₂Mg₂Cr dispersoids: 50-200nm, uniform distribution
• Al-Fe-Si intermetallics: Refined distribution
• Cr-rich dispersoids: Enhances corrosion resistance
  3. Texture Development:
• Near-random orientation in O condition
• Moderate deformation texture in H32/H34 tempers
• Strong deformation texture in H38 temper
  4. Special Features:
• Fine Mg₂Si precipitates at grain boundaries (minimal)
• Low dislocation density in O condition
• Higher dislocation density in strain-hardened tempers
• Excellent recrystallization control in intermediate tempers

4. Dimensional Specifications & Tolerances

Parameter	Standard Range	Precision Tolerance	Commercial Tolerance	Test Method
Diameter	6-200 mm	±0.20mm up to 30mm	±0.30mm up to 30mm	Micrometer
		±0.6% above 30mm	±1.0% above 30mm
Ovality	N/A	50% of diameter tolerance	75% of diameter tolerance	Micrometer
Length	2000-6000 mm	±3mm	±6mm	Tape measure
Straightness	N/A	0.5mm/m	1.0mm/m	Straightedge
Surface Roughness	N/A	3.2 μm Ra max	6.3 μm Ra max	Profilometer
Cut End Squareness	N/A	0.5° max	1.0° max	Protractor

Standard Available Forms:

• Round Bar: Diameters 6-200mm
• Cut-to-length service available
• Special tolerances available upon request
• Precision ground bars for critical applications
• Custom lengths and surface finishes available

5. Temper Designations & Work Hardening Options

Temper Code	Process Description	Optimal Applications	Key Characteristics
O	Fully annealed, softened	Applications requiring maximum formability	Maximum ductility, lowest strength
H32	Quarter-hard (strain hardened)	General purpose fabrication	Good balance of strength and formability
H34	Half-hard (strain hardened)	Moderate strength applications	Higher strength with moderate ductility
H36	Three-quarter hard	High-strength requirements	High strength with reduced formability
H38	Full-hard (strain hardened)	Maximum strength applications	Highest strength with minimum formability

Temper Selection Guidance:

• O: Maximum forming, bending, or drawing operations
• H32: General purpose fabrication with moderate forming
• H34: Applications requiring higher strength with some formability
• H36/H38: Applications requiring maximum strength with minimal forming

6. Machining & Fabrication Characteristics

Operation	Tool Material	Recommended Parameters	Comments
Turning	HSS, Carbide	Vc=180-400 m/min, f=0.1-0.4 mm/rev	Good surface finish with proper tooling
Drilling	HSS, Carbide	Vc=60-120 m/min, f=0.15-0.35 mm/rev	Good hole quality, minimal burring
Milling	HSS, Carbide	Vc=180-500 m/min, fz=0.1-0.2 mm	Use climb milling for best finish
Tapping	HSS, TiN coated	Vc=15-30 m/min	Good thread quality with proper lubrication
Reaming	HSS, Carbide	Vc=40-90 m/min, f=0.2-0.5 mm/rev	H8 tolerance achievable
Sawing	HSS, Carbide-tipped	Vc=1000-2000 m/min	Fine tooth pitch for best results

Fabrication Guidance:

• Machinability Rating: 70% (1100 aluminum = 100%)
• Surface Finish: Very Good (Ra 0.8-3.2μm readily achievable)
• Chip Formation: Medium-length chips; chip breakers beneficial
• Coolant: Water-soluble emulsion preferred (5-8% concentration)
• Tool Wear: Low with proper parameters
• Weldability: Excellent with TIG, MIG, and resistance welding
• Cold Working: Excellent formability in O condition
• Hot Working: 340-420°C recommended temperature range
• Cold Bending: Minimum radius 1× diameter (O temper), 1.5× diameter (H32), 2× diameter (H34/H38)

7. Corrosion Resistance & Protection Systems

Environment Type	Resistance Rating	Protection Method	Expected Performance
Industrial Atmosphere	Excellent	Clean surface	15-20+ years
Marine Atmosphere	Very Good	Clean surface	10-15+ years
Seawater Immersion	Good	Cathodic protection	5-10+ years with maintenance
High Humidity	Excellent	Standard cleaning	15-20+ years
Stress Corrosion	Excellent	Proper temper selection	Superior to 6xxx/7xxx series
Galvanic Corrosion	Good	Proper isolation	Careful design with dissimilar metals

Surface Protection Options:

• Anodizing:

• Type II (Sulfuric): 10-25μm thickness
• Type III (Hard): 25-50μm thickness
• Color anodizing: Excellent color retention
  • Mechanical Finishing:
• Polishing: Enhanced appearance and reduced corrosion initiation sites
• Brushed finish: Decorative and functional
• Bead blasting: Uniform matte appearance
  • Painting Systems:
• Chromate conversion coating pretreatment
• Epoxy primer + polyurethane topcoat
• Marine-grade systems available
  • Chemical Conversion:
• Alodine/Iridite chromate conversion
• RoHS-compliant alternatives

8. Physical Properties for Engineering Design

Property	Value	Design Consideration
Density	2.68 g/cm³	Weight calculation for components
Melting Range	607-649°C	Welding parameters
Thermal Conductivity	138 W/m·K	Thermal management design
Electrical Conductivity	35-37% IACS	Electrical applications design
Specific Heat	880 J/kg·K	Thermal mass calculations
Thermal Expansion (CTE)	23.8 ×10⁻⁶/K	Thermal stress analysis
Young's Modulus	70.3 GPa	Deflection and stiffness calculations
Poisson's Ratio	0.33	Structural analysis parameter
Damping Capacity	Moderate	Vibration-sensitive applications

Design Considerations:

• Operating Temperature Range: -80°C to +200°C
• Cryogenic Performance: Good (increased strength at low temperatures)
• Magnetic Properties: Non-magnetic
• Recyclability: 100% recyclable with high scrap value
• Environmental Impact: Low carbon footprint compared to steel alternatives

9. Quality Assurance & Testing

Standard Testing Procedures:

1. Chemical Composition:

• Optical emission spectroscopy
• Verification of all major elements and impurities
  2. Mechanical Testing:
• Tensile testing (longitudinal)
• Hardness testing (Brinell)
  3. Dimensional Inspection:
• Diameter measurements at multiple locations
• Straightness verification
• Ovality measurement
  4. Visual Inspection:
• Surface defects assessment
• Finish quality verification
  5. Specialized Testing (When Required):
• Ultrasonic inspection per ASTM E114
• Grain size determination (ASTM E112)
• Corrosion testing (ASTM B117 salt spray)
• Conductivity testing (eddy current)

Standard Certifications:

• Mill Test Report (EN 10204 3.1)
• Chemical analysis certification
• Mechanical properties certification
• Dimensional inspection report
• Material traceability documentation

10. Applications & Design Considerations

Primary Applications:

• Marine Components:

• Small boat hardware
• Fittings and fasteners
• Railings and ladders
• Non-structural marine components
  • Electrical & Electronics:
• Electronic chassis and enclosures
• Transformer components
• Terminal blocks and connectors
• Heat sinks for moderate thermal loads
  • Food & Beverage:
• Food processing equipment
• Commercial kitchen components
• Beverage dispensing equipment
• Storage tank components
  • Architectural:
• Interior decorative elements
• Signage components
• Furniture components
• Non-load bearing fixtures
  • General Fabrication:
• Sheet metal components
• Brackets and mounting hardware
• Covers and panels
• Machinery guards

Design Advantages:

• Excellent corrosion resistance in most environments
• Superior formability, especially in O temper
• Excellent weldability without post-weld heat treatment
• Good fatigue resistance
• Attractive appearance with various finishes
• Non-magnetic properties for electronic applications
• Non-sparking properties for safety applications
• Good machinability for complex components
• Lightweight alternative to stainless steel
• Moderate strength with excellent ductility

Design Limitations:

• Lower strength compared to 6xxx and 7xxx series alloys
• Not heat-treatable for strength enhancement
• Moderate wear resistance
• May experience stress relaxation under sustained loading
• Not recommended for high-temperature applications above 200°C
• Limited strength retention after welding in strain-hardened tempers

Economic Considerations:

• Cost-effective alternative to stainless steel
• Good balance of properties and cost
• Lower maintenance costs in corrosive environments
• Reduced finishing costs due to natural corrosion resistance
• Excellent recyclability and high scrap value
• Lower fabrication costs compared to harder materials

Sustainability Aspects:

• 100% recyclable with no loss of properties
• Energy-efficient alternative to steel
• Long service life reduces replacement frequency
• No harmful substances or RoHS-restricted elements
• Low environmental impact throughout lifecycle
• High percentage of recycled content available

Material Selection Guidance:

• Choose 5052 when corrosion resistance and formability are priorities
• Select harder tempers (H34/H38) for increased strength requirements
• Consider 6061-T6 when higher strength is required with moderate corrosion resistance
• Consider 5083 for higher strength marine applications
• Consider 3003 for less demanding applications with cost constraints

Processing Recommendations:

• Allow for springback in forming operations (increases with harder tempers)
• Use appropriate radius in bending operations based on temper
• Employ proper cleaning procedures before welding