5083 Aluminum Round Bar

1. Material Composition & Manufacturing Process

5083 aluminum alloy is a high-performance non-heat-treatable Al-Mg alloy renowned for its exceptional strength, weldability, and superior corrosion resistance in marine environments. The round bar configuration offers optimized properties for critical structural and marine applications:

• Primary Alloying Elements:
  • Magnesium (Mg): 4.0-4.9% (solid solution strengthening)
  • Manganese (Mn): 0.4-1.0% (grain structure control)
  • Chromium (Cr): 0.05-0.25% (corrosion resistance enhancement)
• Base Material:
  • Aluminum (Al): ≥92.4% (balance)
• Controlled Impurities:
  • Iron (Fe): ≤0.40% max
  • Silicon (Si): ≤0.40% max
  • Copper (Cu): ≤0.10% max
  • Zinc (Zn): ≤0.25% max
  • Titanium (Ti): ≤0.15% max
  • Other elements: ≤0.05% each, ≤0.15% total

Premium Manufacturing Process:

1. Melt Preparation:
   1. Primary high-purity aluminum (99.7% minimum)
   1. Precise alloying element additions
   1. Melt filtration through ceramic foam filters (20-30 ppi)
   1. Advanced degassing treatment (hydrogen < 0.1 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 8-16 hours
   1. Uniform temperature control: ±5°C
   1. Controlled cooling rate: 25-40°C/hour
   1. Mn-dispersoid optimization
3. Hot Working:
   1. Initial breakdown: 380-420°C
   1. Intermediate rolling/forging: 350-400°C
   1. Final hot working: 320-370°C
   1. Careful temperature control to prevent cracking
4. Cold Working:
   1. H111: Minimal strain hardening after hot working
   1. H112: Slightly strained during production
   1. H116: Marine-optimized temper
   1. H32: Quarter-hard condition (strain hardened)
5. Finishing:
   1. Surface conditioning
   1. Precision straightening
   1. Stress relieving treatment for H32 temper
   1. Dimensional verification
   1. Surface quality inspection

Full manufacturing traceability with comprehensive documentation for critical applications.

2. Mechanical Properties of 5083 Aluminum Round Bar

Property	H111 (min)	H111 (typical)	H32 (min)	H32 (typical)	Test Method
Ultimate Tensile Strength	275 MPa	290-310 MPa	305 MPa	315-335 MPa	ASTM E8
Yield Strength (0.2%)	125 MPa	130-150 MPa	215 MPa	225-245 MPa	ASTM E8
Elongation (2 inch)	16%	18-22%	10%	12-16%	ASTM E8
Hardness (Brinell)	75 HB	75-85 HB	85 HB	85-95 HB	ASTM E10
Fatigue Strength (5×10⁸)	125 MPa	130-145 MPa	140 MPa	145-160 MPa	ASTM E466
Shear Strength	170 MPa	175-190 MPa	185 MPa	190-205 MPa	ASTM B769
Compressive Yield Strength	130 MPa	135-155 MPa	220 MPa	230-250 MPa	ASTM E9
Modulus of Elasticity	71.0 GPa	71.0 GPa	71.0 GPa	71.0 GPa	ASTM E111

Property Distribution:

• Longitudinal to transverse property ratio: 1.00:0.90-0.95
• Variation across diameter: <3% for bars up to 100mm, <5% for bars >100mm
• Core to surface hardness variation: <5 HB
• Property retention after welding: Superior 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 6-8 (45-22μm)
   1. Uniform grain distribution across section
2. Precipitate Distribution:
   1. Al₆Mn dispersoids: 50-200nm, uniform distribution
   1. Al₈Mg₅ beta phase: Controlled volume fraction
   1. Al-Fe-Mn intermetallics: Refined distribution
   1. Cr-rich dispersoids: Enhances recrystallization control
3. Texture Development:
   1. Moderate deformation texture in H32 temper
   1. Near-random orientation in H111 condition
   1. Controlled directionality for optimal properties
4. Special Features:
   1. Fine Mg₂Si precipitates at grain boundaries
   1. Absence of PFZs (precipitate-free zones)
   1. Low dislocation density in H111 condition
   1. Higher dislocation density in H32 temper

4. Dimensional Specifications & Tolerances

Parameter	Standard Range	Precision Tolerance	Commercial Tolerance	Test Method
Diameter	10-500 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	2000-6500 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 10-500mm
• 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 & Strain Hardening Options

Temper Code	Process Description	Optimal Applications	Key Characteristics
F	As fabricated	Non-critical applications	No mechanical property guarantees
O	Annealed, softened	Applications requiring maximum formability	Maximum ductility, lowest strength
H111	Slightly strain hardened beyond O	Marine structural components	Good balance of strength and formability
H112	Strain hardened from shaping processes	General purpose structural applications	Slightly higher strength than H111
H116	Marine temper	Marine and offshore applications	Optimized for seawater corrosion resistance
H32	Strain hardened and partially annealed	High-strength applications	Higher strength with moderate ductility

Temper Selection Guidance:

• H111/H112: General purpose marine applications
• H116: Critical marine exposure applications
• H32: Higher strength requirements
• O: Maximum formability applications

6. Machining & Fabrication Characteristics

Operation	Tool Material	Recommended Parameters	Comments
Turning	Carbide, PCD	Vc=200-450 m/min, f=0.1-0.4 mm/rev	Good chip breaking with proper tooling
Drilling	HSS-Co, Carbide	Vc=60-120 m/min, f=0.15-0.35 mm/rev	Good hole quality, moderate build-up edge
Milling	Carbide, PCD	Vc=250-600 m/min, fz=0.1-0.25 mm	Use climb milling for best finish
Tapping	HSS, TiCN coated	Vc=15-25 m/min	Good thread quality with proper lubrication
Reaming	Carbide, PCD	Vc=40-100 m/min, f=0.2-0.5 mm/rev	H8 tolerance achievable
Sawing	Carbide-tipped	Vc=1500-2500 m/min	Moderate tooth pitch for best results

Fabrication Guidance:

• Machinability Rating: 60% (1100 aluminum = 100%)
• Surface Finish: Good (Ra 1.6-3.2μm readily achievable)
• Chip Formation: Long, stringy chips; chip breakers recommended
• Coolant: Water-soluble emulsion preferred (8-10% concentration)
• Tool Wear: Moderate with proper parameters
• Weldability: Excellent with TIG, MIG, and friction stir welding
• Cold Working: Good formability in O/H111 condition
• Hot Working: 350-450°C recommended temperature range
• Cold Bending: Minimum radius 1× diameter (O temper), 1.5× diameter (H temper)

7. Corrosion Resistance & Protection Systems

Environment Type	Resistance Rating	Protection Method	Expected Performance
Industrial Atmosphere	Very Good	Clean surface	10-15+ years
Marine Atmosphere	Excellent	Clean surface	15-20+ years
Seawater Immersion	Very Good	Cathodic protection	10-15+ years with maintenance
High Humidity	Excellent	Standard cleaning	20+ years
Stress Corrosion	Excellent in H116	Proper temper selection	Superior to 6xxx series
Exfoliation	Excellent	Proper temper selection	Superior to 6xxx series

Surface Protection Options:

• Anodizing:
  • Type II (Sulfuric): 10-25μm thickness
  • Type III (Hard): 25-75μm thickness
  • Note: May slightly reduce corrosion resistance in marine environments
• Mechanical Finishing:
  • Polishing: Enhanced appearance and reduced corrosion initiation sites
  • Glass bead blasting: Uniform matte appearance
• Painting Systems:
  • Epoxy primer + polyurethane topcoat
  • Marine-grade systems available
• Specialized Marine Protection:
  • Impressed current cathodic protection
  • Sacrificial anodes (zinc or aluminum)

8. Physical Properties for Engineering Design

Property	Value	Design Consideration
Density	2.66 g/cm³	Weight calculation for marine components
Melting Range	574-638°C	Welding parameters
Thermal Conductivity	117-121 W/m·K	Thermal management design
Electrical Conductivity	28-32% IACS	Electrical applications design
Specific Heat	900 J/kg·K	Thermal mass calculations
Thermal Expansion (CTE)	23.8 ×10⁻⁶/K	Thermal stress analysis
Young’s Modulus	71.0 GPa	Deflection and stiffness calculations
Poisson’s Ratio	0.33	Structural analysis parameter
Damping Capacity	Better than 6xxx/7xxx series	Vibration-sensitive applications

Design Considerations:

• Operating Temperature Range: -196°C to +200°C
• Cryogenic Performance: Excellent (increased strength at low temperatures)
• Corrosion Allowance: Typically 0.15mm/year in marine environments
• Galvanic Compatibility: Isolation recommended with carbon steel
• Magnetic Properties: Non-magnetic
• Low-temperature impact resistance: Excellent (no ductile-to-brittle transition)

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 and transverse)
   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. Corrosion testing (ASTM G67 for exfoliation)
   1. Intergranular corrosion testing (ASTM G66)
   1. Stress corrosion testing (ASTM G47)

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 Engineering:
  • Ship propeller shafts
  • Rudder stocks and pintles
  • Marine hardware components
  • Offshore platform components
• Transportation:
  • Naval and coast guard vessel structures
  • High-speed ferry components
  • Shipbuilding structural elements
  • Submarine components
• Industrial Components:
  • Chemical processing equipment
  • Pressure vessels for marine environments
  • Cryogenic applications
  • Highly corrosive environment components
• Defense Applications:
  • Naval gun mounts
  • Ammunition handling equipment
  • Radar and sensor support structures
  • Torpedo components
• Specialized Uses:
  • Bolts and fasteners for marine use
  • Valve stems and components
  • Nuclear industry components
  • Desalination plant components

Design Advantages:

• Exceptional corrosion resistance in marine environments
• Excellent weldability without post-weld heat treatment
• Superior stress corrosion cracking resistance
• Good strength retention at cryogenic temperatures
• Non-sparking properties for explosive environments
• Excellent fatigue properties
• Good machinability for complex components
• Excellent formability in annealed condition
• High strength-to-weight ratio
• Proven history in demanding marine applications

Design Limitations:

• Lower strength compared to 7xxx and 2xxx series
• Not heat-treatable for strength enhancement
• Higher cost than general-purpose alloys
• Limited availability in very large diameters
• Work hardening during fabrication must be considered
• Limited high-temperature strength above 200°C

Economic Considerations:

• Higher initial cost offset by long service life
• Reduced maintenance costs in marine environments
• Better life-cycle cost compared to stainless steel alternatives
• Excellent recyclability and scrap value
• Lower fabrication costs compared to titanium alternatives