Aluminum ER5254-AW (As-welded deposit)
Heat-treated state · default condition
ASTM AWS A5.10 ER5254
Use these numbers for design of GMAW/GTAW joints made with ER5254 in 5154/5254/5454 structures.
Values for the AW condition
Other ER5254 tempers and conditions
ER5254 is listed in 4 conditions; see the grade overview at ER5254.
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 |
AWDefaultThis page 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-AW?
ER5254-AW is ER5254 heat treated to AW — use these numbers for design of GMAW/GTAW joints made with ER5254 in 5154/5254/5454 structures. ER5254-AW 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). ER5254-AW 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).
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-AW properties
Typical room-temperature values for ER5254-AW; 11 are specific to this condition. Other listed values are ER5254 reference data and may not represent this condition. Bars are the position among aluminum grades.
Physical3
ER5254-AW 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-AW 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-AW 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-AW 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-AW 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-AW'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. Confirm any required mill or lot documentation when quoting.
Working with ER5254-AW
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.
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.
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 | — |
ER5254-AW — frequently asked
What is ER5254-AW used for?
ER5254-AW 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-AW?
ER5254-AW 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-AW 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-AW 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-AW?
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-AW 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-AW?
ER5254-AW 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.
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. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.