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:
   1. High-purity primary aluminum (99.7% minimum)
   1. Precise alloying element additions
   1. Melt filtration through ceramic foam filters (20-30 ppi)
   1. Advanced degassing treatment (hydrogen < 0.15 ml/100g)
   1. Grain refinement with Al-Ti-B master alloy
   1. Direct-chill (DC) semi-continuous casting
2. Homogenization:
   1. 450-480°C for 6-12 hours
   1. Uniform temperature control: ±5°C
   1. Controlled cooling rate: 30-50°C/hour
3. Hot Working:
   1. Initial breakdown: 380-420°C
   1. Intermediate rolling/forging: 350-380°C
   1. Final hot working: 320-350°C
   1. Careful temperature control to ensure uniform properties
4. Cold Working:
   1. H32: Quarter-hard condition (strain hardened)
   1. H34: Half-hard condition (strain hardened)
   1. H38: Full-hard condition (strain hardened)
5. Annealing (for O temper):
   1. 340-360°C for 1-3 hours
   1. Controlled cooling to achieve optimal grain structure
6. Finishing:
   1. Surface conditioning
   1. Precision straightening
   1. Dimensional verification
   1. 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:
   1. Equiaxed grains in annealed condition
   1. Elongated grains in strain-hardened tempers
   1. ASTM grain size 5-8 (63-22μm)
   1. Uniform grain distribution across section
2. Precipitate Distribution:
   1. Al₁₂Mg₂Cr dispersoids: 50-200nm, uniform distribution
   1. Al-Fe-Si intermetallics: Refined distribution
   1. Cr-rich dispersoids: Enhances corrosion resistance
3. Texture Development:
   1. Near-random orientation in O condition
   1. Moderate deformation texture in H32/H34 tempers
   1. Strong deformation texture in H38 temper
4. Special Features:
   1. Fine Mg₂Si precipitates at grain boundaries (minimal)
   1. Low dislocation density in O condition
   1. Higher dislocation density in strain-hardened tempers
   1. 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:
   1. Optical emission spectroscopy
   1. Verification of all major elements and impurities
2. Mechanical Testing:
   1. Tensile testing (longitudinal)
   1. Hardness testing (Brinell)
3. Dimensional Inspection:
   1. Diameter measurements at multiple locations
   1. Straightness verification
   1. Ovality measurement
4. Visual Inspection:
   1. Surface defects assessment
   1. Finish quality verification
5. Specialized Testing (When Required):
   1. Ultrasonic inspection per ASTM E114
   1. Grain size determination (ASTM E112)
   1. Corrosion testing (ASTM B117 salt spray)
   1. 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