Aluminum 1100 vs 5025
Aluminum · grade comparison
Aluminum 1100 and 5025 are both aluminum grades, both corrosion resistant al. 5025 is the stronger of the two: yield strength 155 MPa (22.5 ksi) against 115 MPa (16.7 ksi) for 1100, about 35% more; tensile strength follows at 195 MPa (28.3 ksi) vs 125 MPa (18.1 ksi). In exchange, 1100 is the more ductile: elongation 12% versus 10% for 5025, and 5025 is harder (55 HB vs 32 HB). 1100 conducts heat better (222 W/m·K vs 185 W/m·K).
1100Choose it when the part is bent, formed or impact-loaded.
5025Choose it when strength drives the design.
1100 vs 5025: propertiesHow to read these bars
- One bar per material. A full bar is the highest value among all aluminum grades in the FabDigit library; each bar is drawn as a share of that.
- The better value (by the usual engineering direction) is in bold. Rows with no direction — density, thermal conductivity — have no bold.
- Values are typical room-temperature figures for the condition named on each card.
- Confirm against the certified mill or resin datasheet before design release.
How to read these bars
- One bar per material. A full bar is the highest value among all aluminum grades in the FabDigit library; each bar is drawn as a share of that.
- The better value (by the usual engineering direction) is in bold. Rows with no direction — density, thermal conductivity — have no bold.
- Values are typical room-temperature figures for the condition named on each card.
- Confirm against the certified mill or resin datasheet before design release.
Mechanical
Strength, stiffness, ductility and hardness at room temperature.
Elastic (Young's) Modulus
Bulk Modulus
Tensile Strength (Ultimate)
Yield Strength (0.2% offset)
Elongation at Break
Shear Strength
Fatigue Strength (Endurance Limit)
Hardness, Brinell
Hardness, Vickers
Same in both: Shear Modulus 26 GPa3.8 Msi · Poisson's Ratio 0.33
Physical
Density and transition temperatures.
Density
Melting Point (Solidus)
Liquidus Temperature
Thermal
How each material carries heat and how hot it can run.
Thermal Conductivity
Specific Heat Capacity
Thermal Expansion (CTE, 20–100 °C)
Latent Heat of Fusion
Min Service Temperature
Same in both: Max Service Temperature (continuous) 120°C248 °F
Electrical
Conductivity and insulation.
Electrical Conductivity
Electrical Resistivity
Chemical & Environmental
Corrosion and environmental resistance (0–100 scores).
Galvanic Potential (seawater, vs SCE)
Corrosion Resistance
Manufacturability
FabDigit workshop ratings (0–100 scores) — how each material behaves on the machine.
Weldability
Formability (cold)
Castability
Brazeability / Solderability
Polishability
Same in both: Machinability 38 / 100 · Machinability Rating (AISI 1212 = 100 %) 30%
Sustainability
Primary-production footprint per kilogram.
Embodied Energy (primary production)
Typical Recycled Content
Same in both: Embodied Carbon (primary production) 12.5 kg CO₂/kg · Embodied Water 1,200 L/kg144 gal/lb
Common Calculations
Ratios derived from the values above.
Specific Strength (UTS / density)
Specific Stiffness (E / density)
Modulus of Resilience
Thermal Diffusivity
Thermal Shock Resistance Index
Strength versus weight
Yield strength against density for every aluminum grade in the FabDigit library; the compared grades are highlighted. Up and left is stronger for its weight.
Manufacturing and finishing
| Capability | 1100 | 5025 |
|---|---|---|
| Default condition | — | — |
| Relative cost | $ Budget | $ Budget |
| Min. machined wall | 0.5 mm | 0.5 mm |
| Best machined surface | Ra 0.8 µm | Ra 0.8 µm |
Both are offered for CNC machining and Sheet metal. Both take the same 16 finishes: Anodizing Type II, Cerakote, Chem Film (Alodine), DLC, E-Coating, Electroless Nickel (EN), Electropolishing, Epoxy Coating, Gold Plating, Hard Anodize Type III w/ PTFE, Hard Anodizing Type III, Nickel Plating and 4 more.
1100 vs 5025 — frequently asked
Is 5025 stronger than 1100?
Yes. 5025 has a typical yield strength of 155 MPa (22.5 ksi) against 115 MPa (16.7 ksi) for 1100 — about 35% more. Tensile strength is 195 MPa (28.3 ksi) vs 125 MPa (18.1 ksi).
Which is cheaper, 1100 or 5025?
Both sit in the same relative cost tier ($, budget); the part price will be decided by machining time, tolerance and quantity rather than by the material.
Which welds better, 1100 or 5025?
1100. Its weldability rates excellent (95/100) against excellent (88/100) for 5025.
Ready to make it?
Upload a CAD file and FabDigit prices the part in 1100 and 5025 side by side — material, machining time, tolerance and finish in one quote. Certified material data ships with the order on request.
Typical handbook values for the conditions named above, normalised for comparison. Hardness on non-Brinell scales is converted approximately for charting only. Request certified data with your order for design-critical properties.