5052 Large Diameter Aluminum Bar

1. Material Composition & Manufacturing Process

5052 large diameter aluminum bar is a medium-strength, non-heat-treatable aluminum-magnesium alloy that offers exceptional corrosion resistance, good formability, and weldability across a wide range of diameters, making it ideal for marine, general fabrication, and structural applications:

• 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 to produce large ingots
  2. Homogenization:
• 450-480°C for 6-12 hours
• Uniform temperature control: ±5°C
• Controlled cooling rate: 30-50°C/hour
  3. Hot Working (Extrusion or Forging):
• Large extrusion presses: Capable of producing bars up to 300mm diameter
• Or Forging: Processing ingots into bars via radial forging or die forging
• Deformation temperature: 350-420°C
• Ensures adequate deformation and grain refinement for optimal internal quality
  4. Cold Working (for H Tempers):
• Stretching or straightening to achieve desired hardness
• Ensures uniform deformation across the large diameter
  5. Annealing (for O Temper):
• 340-360°C for 1-3 hours
• Controlled cooling to achieve optimal grain structure and ductility
  6. Finishing:
• Surface conditioning (e.g., peeled, ground, or precision turned)
• Precision straightening
• Dimensional verification
• Surface quality inspection

Full manufacturing traceability with comprehensive documentation for all production steps.

2. Mechanical Properties of 5052 Large Diameter Aluminum Bar

Property Distribution:

• Axial vs. Radial properties: <5% variation in strength properties
• Internal property variation across large diameter bars: typically less than 5%
• 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, especially ensured in large diameter bars through proper processing
  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:
• Minimal Mg₂Si precipitates at grain boundaries
• Low dislocation density in O condition
• Higher dislocation density in strain-hardened tempers
• Excellent recrystallization control in intermediate tempers

4. Dimensional Specifications & Tolerances

Standard Available Forms:

• Large Diameter Round Bar: Diameters 100-500mm
• Cut-to-length service available
• Special tolerances available upon request
• Precision ground or turned bars for critical applications
• Custom lengths and surface finishes available

5. Temper Designations & Work Hardening Options

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

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

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

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:

• Large marine structural members
• Ship equipment shafts, rods
• Offshore platform structures
• Desalination equipment parts
  • Energy & Chemical:
• Storage tank and pressure vessel components
• Heat exchanger components
• Piping system flanges and connectors
• Internal structures for chemical equipment
  • General Machinery Manufacturing:
• Large machine structural frames
• Drive shafts, rollers
• Jigs and fixtures
• Various mechanical parts
  • Architecture & Infrastructure:
• Curtain wall structural supports
• Bridge and large building connectors
• Outdoor sculptures and decorative elements
  • Rail Transit:
• Subway and train structural components
• Bogie components
• Electrified railway conductive components

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