Steel 5160 vs 9255
Steel · grade comparison
Steel 5160 and 9255 are both steel grades. 9255 is the stronger of the two: yield strength 1,620 MPa (235 ksi) against 275 MPa (39.9 ksi) for 5160, about 5.9 times as much; tensile strength follows at 1,760 MPa (255 ksi) vs 725 MPa (105 ksi). In exchange, 5160 is the more ductile: elongation 17% versus 8% for 9255, and 9255 is harder (495 HB vs 197 HB). 5160 conducts electricity better (7.8 % IACS vs 5.7 % IACS). On the shop floor, 5160 machines more easily (good vs poor), 5160 welds better (25 vs 15 out of 100), and 9255 sits in a lower cost tier (budget, $) than 5160 (premium, $$$).
5160Choose it when the part is bent, formed or impact-loaded, or when the part is machined in volume.
9255Choose it when strength drives the design, or when cost is the deciding factor.
5160 vs 9255: 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.
Shear Modulus
Tensile Strength (Ultimate)
Yield Strength (0.2% offset)
Elongation at Break
Reduction in Area
Shear Strength
Fatigue Strength (Endurance Limit)
Charpy V-Notch Impact (RT)
Hardness, Brinell
Hardness, Rockwell B
Compressive Strength
Fracture Toughness (K_IC)
Hardness, Rockwell C
Hardness, Vickers
Same in both: Elastic (Young's) Modulus 205 GPa29.7 Msi · Bulk Modulus 160 GPa23.2 Msi · Poisson's Ratio 0.29
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)
Same in both: Latent Heat of Fusion 250 J/g107 BTU/lb · Max Service Temperature (continuous) 250°C482 °F · Min Service Temperature -40°C-40 °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.
Machinability
Machinability Rating (AISI 1212 = 100 %)
Weldability
Formability (cold)
Castability
Brazeability / Solderability
Same in both: Polishability 70 / 100
Sustainability
Primary-production footprint per kilogram.
Embodied Carbon (primary production)
Typical Recycled Content
Same in both: Embodied Energy (primary production) 30 MJ/kg12,898 BTU/lb · Embodied Water 60 L/kg7.2 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 steel grade in the FabDigit library; the compared grades are highlighted. Up and left is stronger for its weight.
Manufacturing and finishing
| Capability | 5160 | 9255 |
|---|---|---|
| CNC machining | Yes | — |
| Sheet metal | Yes | — |
| Default condition | Annealed | — |
| Relative cost | $$$ Premium | $ Budget |
| 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.
5160 vs 9255 — frequently asked
Is 9255 stronger than 5160?
Yes. 9255 has a typical yield strength of 1,620 MPa (235 ksi) against 275 MPa (39.9 ksi) for 5160 — about 5.9 times as much. Tensile strength is 1,760 MPa (255 ksi) vs 725 MPa (105 ksi).
Which is cheaper, 5160 or 9255?
9255 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, 5160 or 9255?
5160. Its machinability rates good (55/100) against poor (25/100) for 9255; for welding the order is 5160 first (poor, 25/100) then 9255 (poor, 15/100).
Ready to make it?
Upload a CAD file and FabDigit prices the part in 5160 and 9255 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.