Aluminum 7204-O vs 7204-T6511
Aluminum · 7204 temper comparison
7204-O and 7204-T6511 are two conditions of the same aluminum grade, 7204: O (annealed) versus T6511 (T6, stress relieved by stretching, minor straightening). The chemistry is identical, so every difference below comes from the condition. 7204-T6511 is the stronger of the two: yield strength 305 MPa (44.2 ksi) against 90 MPa (13.1 ksi) for 7204-O, about 3.4 times as much; tensile strength follows at 355 MPa (51.5 ksi) vs 195 MPa (28.3 ksi). In exchange, 7204-O is the more ductile: elongation 20% versus 10% for 7204-T6511, and 7204-T6511 is harder (100 HB vs 48 HB). 7204-O runs hotter in service (150°C vs 120°C continuous) and 7204-O conducts heat better (175 W/m·K vs 155 W/m·K). On the shop floor, 7204-T6511 machines more easily (good vs fair).
7204-OChoose it when the part is bent, formed or impact-loaded, or when the part sees heat.
7204-T6511Choose it when strength drives the design, or when the part is machined in volume.
7204-O vs 7204-T6511: 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.
Tensile Strength (Ultimate)
Yield Strength (0.2% offset)
Elongation at Break
Compressive Strength
Shear Strength
Fatigue Strength (Endurance Limit)
Hardness, Brinell
Same in both: Elastic (Young's) Modulus 70 GPa10.2 Msi · Shear Modulus 26.5 GPa3.8 Msi · Bulk Modulus 69 GPa10 Msi · Poisson's Ratio 0.33 · Fracture Toughness (K_IC) 32 MPa·√m29.1 ksi·√in · Hardness, Vickers 110 HV
Physical
Density and transition temperatures.
Same in both: Density 2.78 g/cm³0.1 lb/in³ · Melting Point (Solidus) 605°C1,121 °F · Liquidus Temperature 645°C1,193 °F
Thermal
How each material carries heat and how hot it can run.
Thermal Conductivity
Max Service Temperature (continuous)
Same in both: Specific Heat Capacity 900 J/kg·K0.21 BTU/lb·°F · Thermal Expansion (CTE, 20–100 °C) 23.4 µm/m·K13 µin/in·°F · Latent Heat of Fusion 390 J/g168 BTU/lb · Min Service Temperature -196°C-321 °F
Electrical
Conductivity and insulation.
Electrical Conductivity
Electrical Resistivity
Chemical & Environmental
Corrosion and environmental resistance (0–100 scores).
Corrosion Resistance
Same in both: Galvanic Potential (seawater, vs SCE) -0.86 V
Manufacturability
FabDigit workshop ratings (0–100 scores) — how each material behaves on the machine.
Machinability
Machinability Rating (AISI 1212 = 100 %)
Weldability
Formability (cold)
Same in both: Castability 35 / 100 · Brazeability / Solderability 20 / 100 · Polishability 60 / 100
Sustainability
Primary-production footprint per kilogram.
Same in both: Embodied Energy (primary production) 205 MJ/kg88,134 BTU/lb · Embodied Carbon (primary production) 12.5 kg CO₂/kg · Embodied Water 1,150 L/kg138 gal/lb · Typical Recycled Content 30%
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.
7204-O vs 7204-T6511 — frequently asked
Is 7204-T6511 stronger than 7204-O?
Yes. 7204-T6511 has a typical yield strength of 305 MPa (44.2 ksi) against 90 MPa (13.1 ksi) for 7204-O — about 3.4 times as much. Tensile strength is 355 MPa (51.5 ksi) vs 195 MPa (28.3 ksi).
Which condition does FabDigit quote by default, O or T6511?
T6 is the default 7204 condition in the FabDigit quote flow (neither O nor T6511). The other condition is available on request or by drawing note — specify it in the material field or the part notes and the quote is priced for it.
Which is easier to machine, 7204-O or 7204-T6511?
7204-T6511. Its machinability rates good (62/100) against fair (35/100) for 7204-O.
Ready to make it?
Upload a CAD file and FabDigit prices the part in 7204-O and 7204-T6511 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.