Aluminum 1100 vs ER5254
Aluminum · grade comparison
Aluminum 1100 and ER5254 are both aluminum grades. ER5254 is the stronger of the two: tensile strength 250 MPa (36.3 ksi) against 125 MPa (18.1 ksi) for 1100, about 100% more. ER5254 is the more ductile: elongation 20% versus 12% for 1100, and ER5254 is harder (58 HB vs 32 HB). 1100 runs hotter in service (120°C vs 65°C continuous) and 1100 conducts heat better (222 W/m·K vs 126 W/m·K). On the shop floor, ER5254 machines more easily (48 vs 38 out of 100) and 1100 sits in a lower cost tier (budget, $) than ER5254 (high, $$$$).
1100Choose it when the part sees heat, or when cost is the deciding factor.
ER5254Choose it when strength drives the design, or when the part is bent, formed or impact-loaded.
1100 vs ER5254: 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
Shear Modulus
Bulk Modulus
Tensile Strength (Ultimate)
Yield Strength (0.2% offset)
Elongation at Break
Shear Strength
Fatigue Strength (Endurance Limit)
Hardness, Brinell
Hardness, Vickers
Charpy V-Notch Impact (RT)
Same in both: 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
Max Service Temperature (continuous)
Min Service Temperature
Electrical
Conductivity and insulation.
Electrical Conductivity
Electrical Resistivity
Chemical & Environmental
Corrosion and environmental resistance (0–100 scores).
Galvanic Potential (seawater, vs SCE)
Same in both: Corrosion Resistance 78 / 100
Manufacturability
FabDigit workshop ratings (0–100 scores) — how each material behaves on the machine.
Machinability
Machinability Rating (AISI 1212 = 100 %)
Weldability
Formability (cold)
Castability
Brazeability / Solderability
Polishability
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 | ER5254 |
|---|---|---|
| CNC machining | Yes | — |
| Sheet metal | Yes | — |
| Default condition | — | — |
| Relative cost | $ Budget | $$$$ High |
| Min. machined wall | 0.5 mm | — |
| Best machined surface | Ra 0.8 µm | — |
| Anodizing Type II | Yes | — |
| Cerakote | Yes | — |
| Chem Film (Alodine) | Yes | — |
| DLC | Yes | — |
| E-Coating | Yes | — |
| Electropolishing | Yes | — |
| Hard Anodize Type III w/ PTFE | Yes | — |
| Hard Anodizing Type III | Yes | — |
| Nickel Plating | Yes | — |
| PTFE Coating | Yes | — |
| Painting | Yes | — |
| Powder Coating | Yes | — |
They share 4 finishes: Electroless Nickel (EN), Epoxy Coating, Gold Plating, Silver Plating.
1100 vs ER5254 — frequently asked
Is ER5254 stronger than 1100?
Yes. ER5254 has a typical tensile strength of 250 MPa (36.3 ksi) against 125 MPa (18.1 ksi) for 1100 — about 100% more.
Which is cheaper, 1100 or ER5254?
1100 is the lower-cost material: it sits in the budget tier ($) while ER5254 is high ($$$$). Part price depends far more on geometry, tolerance and quantity than on raw stock — upload a CAD file for a live quote.
Which is easier to machine, 1100 or ER5254?
ER5254, by a small margin. Both rate fair for machinability — 48/100 against 38/100 for 1100; for welding the order is 1100 first (excellent, 95/100) then ER5254 (excellent, 88/100).
Ready to make it?
Upload a CAD file and FabDigit prices the part in 1100 and ER5254 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.