Solder & Low-Melting Alloy Sn60Pb40Sb vs Sn96Ag2.5Bi1Cu0.5
Solder & Low-Melting Alloy · grade comparison
Solder & Low-Melting Alloy Sn60Pb40Sb and Sn96Ag2.5Bi1Cu0.5 are both solder & low-melting alloy grades. Sn96Ag2.5Bi1Cu0.5 is the stronger of the two: yield strength 40 MPa (5.8 ksi) against 32 MPa (4.64 ksi) for Sn60Pb40Sb, about 25% more. In exchange, Sn60Pb40Sb is the more ductile: elongation 35% versus 30% for Sn96Ag2.5Bi1Cu0.5, and Sn60Pb40Sb is harder (16 HV vs 15 HV). Sn96Ag2.5Bi1Cu0.5 is lighter (7.4 g/cm³ vs 8.5 g/cm³ for Sn60Pb40Sb) and Sn96Ag2.5Bi1Cu0.5 is stiffer (48 GPa vs 31 GPa). On the shop floor, Sn60Pb40Sb machines more easily (fair vs poor).
Sn60Pb40SbChoose it when the part is bent, formed or impact-loaded, or when the part is machined in volume.
Sn96Ag2.5Bi1Cu0.5Choose it when strength drives the design, or when weight is the constraint.
Sn60Pb40Sb vs Sn96Ag2.5Bi1Cu0.5: propertiesHow to read these bars
- One bar per material. A full bar is the highest value among all solder & low-melting alloy 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 solder & low-melting alloy 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
Poisson's Ratio
Yield Strength (0.2% offset)
Elongation at Break
Shear Strength
Fatigue Strength (Endurance Limit)
Charpy V-Notch Impact (RT)
Hardness, Brinell
Hardness, Vickers
Same in both: Tensile Strength (Ultimate) 52 MPa7.5 ksi
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)
Same in both: Min Service Temperature -55°C-67 °F
Electrical
Conductivity and insulation.
Electrical Conductivity
Electrical Resistivity
Chemical & Environmental
Corrosion and environmental resistance (0–100 scores).
Same in both: Galvanic Potential (seawater, vs SCE) -0.5 V · Corrosion Resistance 45 / 100
Manufacturability
FabDigit workshop ratings (0–100 scores) — how each material behaves on the machine.
Machinability
Weldability
Formability (cold)
Castability
Brazeability / Solderability
Polishability
Sustainability
Primary-production footprint per kilogram.
Embodied Energy (primary production)
Embodied Carbon (primary production)
Embodied Water
Typical Recycled Content
Common Calculations
Ratios derived from the values above.
Specific Strength (UTS / density)
Specific Stiffness (E / density)
Thermal Diffusivity
Same in both: Modulus of Resilience 17 kJ/m³ · Thermal Shock Resistance Index 3
Strength versus weight
Yield strength against density for every solder & low-melting alloy grade in the FabDigit library; the compared grades are highlighted. Up and left is stronger for its weight.
Manufacturing and finishing
| Capability | Sn60Pb40Sb | Sn96Ag2.5Bi1Cu0.5 |
|---|---|---|
| Default condition | — | — |
| Relative cost | $$$$ High | $$$$ High |
| Min. machined wall | — | — |
| Best machined surface | — | — |
Sn60Pb40Sb vs Sn96Ag2.5Bi1Cu0.5 — frequently asked
Is Sn96Ag2.5Bi1Cu0.5 stronger than Sn60Pb40Sb?
Yes. Sn96Ag2.5Bi1Cu0.5 has a typical yield strength of 40 MPa (5.8 ksi) against 32 MPa (4.64 ksi) for Sn60Pb40Sb — about 25% more. Tensile strength is 52 MPa (7.54 ksi) vs 52 MPa (7.54 ksi).
Which is cheaper, Sn60Pb40Sb or Sn96Ag2.5Bi1Cu0.5?
Both sit in the same relative cost tier ($$$$, high); the part price will be decided by machining time, tolerance and quantity rather than by the material.
Which is easier to machine, Sn60Pb40Sb or Sn96Ag2.5Bi1Cu0.5?
Sn60Pb40Sb. Its machinability rates fair (35/100) against poor (25/100) for Sn96Ag2.5Bi1Cu0.5.
Ready to make it?
Upload a CAD file and FabDigit prices the part in Sn60Pb40Sb and Sn96Ag2.5Bi1Cu0.5 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.