Steel 4161 vs 5160
Steel · grade comparison
Steel 4161 and 5160 are both steel grades. 4161 is the stronger of the two: yield strength 415 MPa (60.2 ksi) against 275 MPa (39.9 ksi) for 5160, about 51% more. 4161 is harder — 217 HB against 197 HB for 5160 — which matters for wear surfaces and threads. 4161 runs hotter in service (400°C vs 250°C continuous). On the shop floor, 5160 forms better (45 vs 35 out of 100) and 4161 sits in a lower cost tier (budget, $) than 5160 (premium, $$$).
4161Choose it when strength drives the design, or when surface hardness matters.
4161 vs 5160: propertiesHow to read these bars
- One bar per material. A full bar is the highest value among all steel 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 steel 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
Reduction in Area
Compressive Strength
Shear Strength
Fatigue Strength (Endurance Limit)
Fracture Toughness (K_IC)
Charpy V-Notch Impact (RT)
Hardness, Brinell
Hardness, Rockwell B
Hardness, Vickers
Same in both: Elastic (Young's) Modulus 205 GPa29.7 Msi · Shear Modulus 80 GPa11.6 Msi · Bulk Modulus 160 GPa23.2 Msi · Poisson's Ratio 0.29
Physical
Density and transition temperatures.
Melting Point (Solidus)
Liquidus Temperature
Same in both: Density 7.85 g/cm³0.28 lb/in³
Thermal
How each material carries heat and how hot it can run.
Thermal Conductivity
Specific Heat Capacity
Max Service Temperature (continuous)
Min Service Temperature
Same in both: Thermal Expansion (CTE, 20–100 °C) 12.3 µm/m·K6.8 µin/in·°F · Latent Heat of Fusion 250 J/g107 BTU/lb
Electrical
Conductivity and insulation.
Same in both: Electrical Conductivity 7.8 % IACS · Electrical Resistivity 2.2×10⁻⁷ Ω·m8.66 µΩ·in
Chemical & Environmental
Corrosion and environmental resistance (0–100 scores).
Corrosion Resistance
Same in both: Galvanic Potential (seawater, vs SCE) -0.61 V
Manufacturability
FabDigit workshop ratings (0–100 scores) — how each material behaves on the machine.
Machinability
Machinability Rating (AISI 1212 = 100 %)
Weldability
Formability (cold)
Polishability
Castability
Same in both: Brazeability / Solderability 55 / 100
Sustainability
Primary-production footprint per kilogram.
Embodied Water
Typical Recycled Content
Same in both: Embodied Energy (primary production) 30 MJ/kg12,898 BTU/lb · Embodied Carbon (primary production) 2.2 kg CO₂/kg
Common Calculations
Ratios derived from the values above.
Specific Strength (UTS / density)
Modulus of Resilience
Thermal Diffusivity
Same in both: Specific Stiffness (E / density) 26.1 MN·m/kg · Thermal Shock Resistance Index 13
Strength versus weight
Yield strength against density for every steel grade in the FabDigit library; the compared grades are highlighted. Up and left is stronger for its weight.
Manufacturing and finishing
| Capability | 4161 | 5160 |
|---|---|---|
| CNC machining | — | Yes |
| Sheet metal | — | Yes |
| Default condition | — | Annealed |
| Relative cost | $ Budget | $$$ Premium |
| Min. machined wall | — | 0.8 mm |
| Best machined surface | — | Ra 1.6 µm |
| AlCrN | — | Yes |
| AlTiN | — | Yes |
| Black Oxide | — | Yes |
| CVD Al2O3 | — | Yes |
| CVD TiCN | — | Yes |
| CVD TiN | — | Yes |
| Cerakote | — | Yes |
| Chrome Plating | — | Yes |
| CrN | — | Yes |
| DLC | — | Yes |
| E-Coating | — | Yes |
| HVOF Coating | — | Yes |
| Hot-Dip Galvanizing | — | Yes |
| MoS2 | — | Yes |
| Multilayer CVD | — | Yes |
| Nickel Plating | — | Yes |
| PTFE Coating | — | Yes |
| Painting | — | Yes |
They share 9 finishes: Copper Plating, Electroless Nickel (EN), Epoxy Coating, Gold Plating, Hard Chrome Plating, Manganese Phosphate, Plasma Spray, Silver Plating, Zinc Phosphate.
4161 vs 5160 — frequently asked
Is 4161 stronger than 5160?
Yes. 4161 has a typical yield strength of 415 MPa (60.2 ksi) against 275 MPa (39.9 ksi) for 5160 — about 51% more. Tensile strength is 760 MPa (110 ksi) vs 725 MPa (105 ksi).
Which is cheaper, 4161 or 5160?
4161 is the lower-cost material: it sits in the budget tier ($) while 5160 is premium ($$$). 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, 4161 or 5160?
5160. Its machinability rates good (55/100) against fair (48/100) for 4161; for welding the order is 5160 first (poor, 25/100) then 4161 (poor, 20/100).
Ready to make it?
Upload a CAD file and FabDigit prices the part in 4161 and 5160 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.