Aluminum ER5254
ASTM AWS A5.10 ER5254
ER5254 is an Al-Mg (5000 series) welding filler to AWS A5.10, based on 5356-type chemistry but with tightened trace-element control so deposits are compatible with hydrogen peroxide storage.
Reference datasheet — ER5254 is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the AW condition
ER5254 tempers and conditions
ER5254 is supplied in 4 conditions, soft to hard. AW is the default FabDigit quotes; the values on this page are for it.
Compare all 4 conditionsHide
| Condition · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness | Conductivity |
|---|---|---|---|---|---|---|
Annealed | Annealed 1.6–4.0 mm cut lengths for manual GTAW; softest, easiest to straighten and least prone to spring-back. | 115 | 240 | 27 | 58 HB | 35 % IACS |
AWDefault As-welded deposit | Use these numbers for design of GMAW/GTAW joints made with ER5254 in 5154/5254/5454 structures. | 120 | 250 | 20 | 58 HB | 35 % IACS |
Strain hardened, half hard | Intermediate temper sometimes used for larger-diameter spooled wire needing a compromise of stiffness and coilability. | 230 | 290 | 8 | 73 HB | 34 % IACS |
Strain hardened, extra hard | Standard delivery condition for 0.9–1.6 mm spooled wire; the high drawn strength gives stiff, feedable wire for push-pull guns. | 270 | 315 | 4 | 80 HB | 34 % IACS |
What is ER5254?
ER5254 is an Al-Mg (5000 series) welding filler to AWS A5.10, based on 5356-type chemistry but with tightened trace-element control so deposits are compatible with hydrogen peroxide storage. It is supplied as drawn GMAW spool wire and GTAW cut rod, with as-welded properties near 250 MPa tensile, 120 MPa yield, 20 % elongation and 58 HB, plus 126 W/m·K thermal conductivity. Continuous service is limited to about 65 °C to avoid magnesium grain-boundary sensitization, and Mn- or Cu-bearing fillers must never be substituted in peroxide service. ER5654 is the closest alternative where even tighter purity control is specified. ER5254 has a density of 2.66 g/cm³ (0.0961 lb/in³), lighter than 84% of aluminum grades. It melts at 593°C (1,099 °F). ER5254 has a yield strength of 120 MPa (17.4 ksi) and a tensile strength of 250 MPa (36.3 ksi) — weaker than 77% of aluminum grades. Elongation at break is 20% and the elastic modulus is 70.3 GPa (10.2 Msi).
What is ER5254 used for?
- Hydrogen peroxide storage tanks
- Chemical process tankage
- Welded 5254 and 5652 vessel shells
- High-purity chemical piping welds
- Tank trailer barrels in peroxide service
- Field repair welds on peroxide equipment
Advantages
- Good corrosion resistance — 78/100, better than 94% of aluminum grades
- Ductile — tolerates forming and impact — 20%, better than 89% of aluminum grades
- Forms and bends easily — 75/100, better than 86% of aluminum grades
- Readily welded — 88/100, better than 85% of aluminum grades
Limitations
- Limited service temperature — 65°C (149 °F), worse than 97% of aluminum grades
- Low strength — 120 MPa (17.4 ksi), worse than 77% of aluminum grades
ER5254 properties
Typical room-temperature values for ER5254-AW; bars are the position among aluminum grades.
Physical3
ER5254 has a density of 2.66 g/cm³ (0.0961 lb/in³), lighter than 84% of aluminum grades. It melts at 593°C (1,099 °F).
Mechanical11
ER5254 has a yield strength of 120 MPa (17.4 ksi) and a tensile strength of 250 MPa (36.3 ksi) — weaker than 77% of aluminum grades. Elongation at break is 20% and the elastic modulus is 70.3 GPa (10.2 Msi).
Thermal6
ER5254 is rated for continuous service to 65°C (149 °F). It conducts heat at 126 W/m·K (72.8 BTU/hr·ft·°F), worse than 70% of aluminum grades. Thermal expansion is 23.9 µm/m·K (13.3 µin/in·°F).
Electrical3
ER5254 conducts electricity at 35 % IACS, better than 52% of aluminum grades.
Chemical & Environmental3
Corrosion resistance is very good (78/100), better than 94% of aluminum grades.
Sustainability4
Producing a kilogram of ER5254 takes about 200 MJ of energy and emits 12.5 kg of CO₂ — less than 60% of aluminum grades. Typical recycled content is 15%.
Manufacturability7
ER5254's machinability is fair (48/100, worse than 68% of aluminum grades); weldability excellent (88/100); formability very good (75/100).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the aluminum family
Yield strength against density for every aluminum grade FabDigit runs. ER5254 is highlighted; hover a dot for its name, or open the interactive family chart.
Working with ER5254
Is ER5254 easy to machine?
Weld beads machine like annealed 5154 — gummy and prone to built-up edge; use sharp polished-flute carbide, high speed and generous flood coolant.
Can ER5254 be welded?
GMAW/GTAW with pure Ar (Ar-He for thick sections), scrupulous degreasing and stainless-brush oxide removal; keep interpass below ~120 °C and never substitute Mn- or Cu-bearing fillers in peroxide service.
Can ER5254 be formed, bent or molded?
Supplied as drawn wire or rod; anneal at 340 °C if straightened or re-coiled, and avoid cold work followed by warm service to prevent Mg-boundary sensitization.
ER5254 chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| Mgprincipal solid-solution strengthener | 3.1 – 3.9 | 3.5 |
| Cr | 0.15 – 0.35 | 0.25 |
| Si+Fecombined limit | ≤ 0.45 | |
| Cuheld low to avoid catalysing H₂O₂ decomposition | ≤ 0.05 | |
| Mnrestricted vs 5154 — key peroxide-service limit | ≤ 0.01 | |
| Zn | ≤ 0.2 | |
| Ti | ≤ 0.05 | |
| Betypical filler-wire beryllium restriction | ≤ 8×10⁻⁴ | |
| Others (each)0.15 total | ≤ 0.05 | |
| Al | balance |
What surface finishes work on ER5254?
Passivate/clean per peroxide-tank practice (nitric-acid or acidified-water treatment) rather than painting; anodizes well but weld beads shade slightly darker than parent metal.
Surface treatments FabDigit runs on aluminum parts — pick them in the quote configurator or call them out on the drawing. Each links to its datasheet in the surface-finish library (thickness, specs, call-out, material verdicts).
Organic Coating
Equivalent designations
Standards and trade names that resolve to Aluminum ER5254 in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- ASTM
- AWS A5.10 ER5254
- Other
- 5254
How much does ER5254 cost?
ER5254 is a high-cost aluminum ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
ER5254 — frequently asked
What is ER5254 used for?
ER5254 is typically used for hydrogen peroxide storage tanks, chemical process tankage, welded 5254 and 5652 vessel shells, high-purity chemical piping welds, tank trailer barrels in peroxide service and field repair welds on peroxide equipment. In short: peroxide-service Al-Mg filler; trace-element-controlled 5356 chemistry; matched to 5254/5652 tankage.
What is the yield strength of ER5254?
ER5254 has a typical yield strength of 120 MPa (17.4 ksi) and a tensile strength of 250 MPa (36.3 ksi) — weaker than 77% of aluminum grades. Strength varies by condition: see the 4 listed tempers.
Is ER5254 easy to machine?
Reasonably — machinability is rated fair (48/100, worse than 68% of aluminum grades). Weld beads machine like annealed 5154 — gummy and prone to built-up edge; use sharp polished-flute carbide, high speed and generous flood coolant.
Can ER5254 be welded?
Yes — weldability is rated excellent (88/100). GMAW/GTAW with pure Ar (Ar-He for thick sections), scrupulous degreasing and stainless-brush oxide removal; keep interpass below ~120 °C and never substitute Mn- or Cu-bearing fillers in peroxide service.
What surface finishes work on ER5254?
Passivate/clean per peroxide-tank practice (nitric-acid or acidified-water treatment) rather than painting; anodizes well but weld beads shade slightly darker than parent metal.
Can ER5254 be formed, bent or molded?
Supplied as drawn wire or rod; anneal at 340 °C if straightened or re-coiled, and avoid cold work followed by warm service to prevent Mg-boundary sensitization.
What is the maximum service temperature of ER5254?
ER5254 is rated for continuous use to about 65°C (149 °F). Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between ER5254-AW and ER5254-H19?
AW is the default condition — use these numbers for design of GMAW/GTAW joints made with ER5254 in 5154/5254/5454 structures. H19: standard delivery condition for 0.9–1.6 mm spooled wire; the high drawn strength gives stiff, feedable wire for push-pull guns. Yield strength is 120 MPa in AW versus 270 MPa in H19.
How much does ER5254 cost?
ER5254 is a high-cost aluminum ($$$$), pricier than about 78% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- AWS A5.10/A5.10M — Bare Aluminum and Aluminum-Alloy Welding Electrodes and Rods — AWS (2021)
- International Alloy Designations and Chemical Composition Limits for Wrought Aluminum (Teal Sheets) — The Aluminum Association (2018)
- ASM Handbook Vol.2 — Properties and Selection: Nonferrous Alloys — ASM International (1990)
- ASM Handbook Vol.13B — Corrosion: Materials — ASM International (2005)
- AWS D1.2/D1.2M — Structural Welding Code, Aluminum — AWS (2014)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.