5052-H39 Aluminum Honeycomb
also AMS-C-7438, MIL-C-7438
5052-H39 Aluminum Honeycomb is an expanded aluminium foil core to AMS-C-7438 and MIL-C-7438, made in 1/8 in to 1/4 in cells and 0.0007 in to 0.0025 in foil gauges giving nominal densities from 1.6 to 8.1 pcf (49.7 kg/m³ typical).
Reference datasheet — 5052-H39 Aluminum Honeycomb is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the 3.1-1/8-.0007 condition
5052-H39 Aluminum Honeycomb grades and fills
5052-H39 Aluminum Honeycomb is supplied in 8 conditions, soft to hard. 3.1-1/8-.0007 is the default FabDigit quotes; the values on this page are for it.
Compare all 8 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
1.6 pcf | Lowest-density standard core for weight-critical, lightly loaded panels (radomes, interior partitions). | 0.45 | 1 | ||
2.3 pcf | Good stiffness-per-weight compromise for large-area architectural and transport sandwich panels. | 0.83 | 2 | ||
3.1-1/8-.0007Default 3.1 pcf | The industry-standard aerospace core density — best all-round strength, skin support and bond area. | 1 | 3 | ||
Cold rolled | Chromate-conversion or resin-coated foil for marine, floor-panel and high-humidity service where bare foil would pit. | 1 | 2 | 5 | |
Flex-Core | Non-hexagonal flexible cell shape that conforms to compound curvature without cell buckling or node fracture. | 2 | 4 | ||
4.5 pcf | Higher-load floor panels, cargo liners and tooling plates where local crush resistance matters. | 2 | 5 | ||
5.7 pcf | Heavily loaded aircraft floor and helicopter deck panels needing high shear strength. | 3 | 7 | ||
8.1 pcf | Local reinforcement, energy-absorbing crush cores and hard-point regions of sandwich panels. | 6 | 11 |
Supply forms, finishes and certifications
Ways 5052-H39 Aluminum Honeycomb is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
PERF | Perforated (vented) core | Surface finish |
OX | Overexpanded core | Supply option |
What is 5052-H39 Aluminum Honeycomb?
5052-H39 Aluminum Honeycomb is an expanded aluminium foil core to AMS-C-7438 and MIL-C-7438, made in 1/8 in to 1/4 in cells and 0.0007 in to 0.0025 in foil gauges giving nominal densities from 1.6 to 8.1 pcf (49.7 kg/m³ typical). It is the default lightweight core for adhesively bonded sandwich panels, with about 0.52 GPa modulus and 2.5 W/m·K thermal conductivity, and is available perforated, corrosion-coated, overexpanded (OX) and Flex. The foil dents and crushes easily during handling, node bonds set the temperature limit, and it is electrically and thermally conductive and galvanically active against carbon-fibre skins; 5056 core is the choice when higher shear strength is needed. 5052-H39 Aluminum Honeycomb has a density of 0.05 g/cm³ (0.0018 lb/in³), lighter than 95% of composite grades. 5052-H39 Aluminum Honeycomb has a yield strength of 1 MPa (0.189 ksi) and a tensile strength of 3 MPa (0.406 ksi) — weaker than 95% of composite grades. The elastic modulus is 0.52 GPa (0.0754 Msi).
What is 5052-H39 Aluminum Honeycomb used for?
- aircraft floor and control-surface panels
- radome cores
- shipping containers
- elevator and door panels
- wind tunnel/test fixtures
Advantages
- Lightweight — 0.05 g/cm³ (0.0018 lb/in³), better than 95% of composite grades
- Good UV / weathering resistance — 95/100, better than 78% of composite grades
Limitations
- Low strength — 1 MPa (0.189 ksi), worse than 95% of composite grades
- Low stiffness — 0.52 GPa (0.0754 Msi), worse than 87% of composite grades
5052-H39 Aluminum Honeycomb properties
Typical room-temperature values for 5052-H39 Aluminum Honeycomb-3.1-1/8-.0007; bars are the position among composite grades.
Physical1
5052-H39 Aluminum Honeycomb has a density of 0.05 g/cm³ (0.0018 lb/in³), lighter than 95% of composite grades.
Mechanical8
5052-H39 Aluminum Honeycomb has a yield strength of 1 MPa (0.189 ksi) and a tensile strength of 3 MPa (0.406 ksi) — weaker than 95% of composite grades. The elastic modulus is 0.52 GPa (0.0754 Msi).
Thermal7
5052-H39 Aluminum Honeycomb is rated for continuous service to 177°C (351 °F). It conducts heat at 2.5 W/m·K (1.44 BTU/hr·ft·°F), better than 61% of composite grades. Thermal expansion is 23.8 µm/m·K (13.2 µin/in·°F).
Electrical1
5052-H39 Aluminum Honeycomb has an electrical resistivity of 2.7×10⁻⁶ Ω·m.
Chemical & Environmental3
Corrosion resistance is good (66/100), worse than 70% of composite grades. UV resistance is excellent.
Sustainability4
Producing a kilogram of 5052-H39 Aluminum Honeycomb takes about 215 MJ of energy and emits 14 kg of CO₂ — more than 50% of composite grades. Typical recycled content is 10%.
Manufacturability1
5052-H39 Aluminum Honeycomb's machinability is fair (38/100, better than 54% of composite grades).
Common Calculations5
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the composite family
Yield strength against density for every composite grade FabDigit runs. 5052-H39 Aluminum Honeycomb is highlighted; hover a dot for its name, or open the interactive family chart.
Working with 5052-H39 Aluminum Honeycomb
Is 5052-H39 Aluminum Honeycomb easy to machine?
Cut with high-speed router, ultrasonic knife, waterjet or crush-free CNC blade; stabilize with potting compound, wax or ice-fill to prevent cell collapse and clean residue before bonding.
Can 5052-H39 Aluminum Honeycomb be welded?
Not weldable as a core — panels are assembled with film adhesive, foaming adhesive or brazing (special brazed-core grades only); node bonds define the temperature limit.
Can 5052-H39 Aluminum Honeycomb be formed, bent or molded?
Regular hex core forms only to gentle single curvature; use OX (overexpanded) or Flex-Core for tight single or compound curvature, or heat-form the cured panel.
5052-H39 Aluminum Honeycomb chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| Mgprincipal solid-solution strengthener | 2.2 – 2.8 | 2.5 |
| Cr | 0.15 – 0.35 | 0.25 |
| Si | ≤ 0.25 | |
| Fe | ≤ 0.4 | |
| Cu | ≤ 0.1 | |
| Mn | ≤ 0.1 | |
| Zn | ≤ 0.1 | |
| Others (each)total 0.15 max | ≤ 0.05 | |
| Al | balance |
What surface finishes work on 5052-H39 Aluminum Honeycomb?
Foil is supplied bare, chromate-converted or resin-coated; edges are usually closed with edge-fill, potting compound or metal channel, and exposed core should be sealed against moisture ingress.
Equivalent designations
Standards and trade names that resolve to 5052-H39 Aluminum Honeycomb in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- Trade names
- AMS-C-7438MIL-C-7438
- Other
- 5052
How much does 5052-H39 Aluminum Honeycomb cost?
5052-H39 Aluminum Honeycomb is a premium-cost composite ($$$), cheaper than about 51% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
5052-H39 Aluminum Honeycomb — frequently asked
What is 5052-H39 Aluminum Honeycomb used for?
5052-H39 Aluminum Honeycomb is typically used for aircraft floor and control-surface panels, radome cores, shipping containers, elevator and door panels and wind tunnel/test fixtures. In short: standard aerospace aluminum core; lower cost than 5056; wide cell and density range.
What is the yield strength of 5052-H39 Aluminum Honeycomb?
5052-H39 Aluminum Honeycomb has a typical yield strength of 1 MPa (0.189 ksi) and a tensile strength of 3 MPa (0.406 ksi) — weaker than 95% of composite grades. Strength varies by condition: see the 8 listed tempers.
Is 5052-H39 Aluminum Honeycomb easy to machine?
Not especially — machinability is rated fair (38/100, better than 54% of composite grades). Cut with high-speed router, ultrasonic knife, waterjet or crush-free CNC blade; stabilize with potting compound, wax or ice-fill to prevent cell collapse and clean residue before bonding.
Can 5052-H39 Aluminum Honeycomb be welded?
Not weldable as a core — panels are assembled with film adhesive, foaming adhesive or brazing (special brazed-core grades only); node bonds define the temperature limit.
What surface finishes work on 5052-H39 Aluminum Honeycomb?
Foil is supplied bare, chromate-converted or resin-coated; edges are usually closed with edge-fill, potting compound or metal channel, and exposed core should be sealed against moisture ingress.
Can 5052-H39 Aluminum Honeycomb be formed, bent or molded?
Regular hex core forms only to gentle single curvature; use OX (overexpanded) or Flex-Core for tight single or compound curvature, or heat-form the cured panel.
What is the maximum service temperature of 5052-H39 Aluminum Honeycomb?
5052-H39 Aluminum Honeycomb is rated for continuous use to about 177°C (351 °F), and briefly to 250°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between 5052-H39 Aluminum Honeycomb 3.1-1/8-.0007 and 5052-H39 Aluminum Honeycomb Flex?
3.1-1/8-.0007 is the default condition — the industry-standard aerospace core density — best all-round strength, skin support and bond area. Flex: non-hexagonal flexible cell shape that conforms to compound curvature without cell buckling or node fracture. Yield strength is 1 MPa in 3.1-1/8-.0007 versus 2 MPa in Flex.
How much does 5052-H39 Aluminum Honeycomb cost?
5052-H39 Aluminum Honeycomb is a premium-cost composite ($$$), cheaper than about 51% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- AMS-C-7438 / MIL-C-7438 Core Material, Aluminum, for Sandwich Construction — SAE International / US DoD (2018)
- HexWeb Honeycomb Attributes and Properties (5052 aluminum core) — Hexcel (2019)
- PAMG-XR1 5052 Aluminum Honeycomb Data Sheet — Plascore (2020)
- ASTM C365 / C273 — Flatwise Compressive and Shear Properties of Sandwich Cores — ASTM International (2016)
- Aluminum Standards and Data (Teal Sheets), 5052 alloy — The Aluminum Association (2015)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.