Aluminum is a common part manufacturing material due to its excellent properties, especially its high strength-to-weight ratio. It comes in different alloys, each with a unique elemental composition that helps make them distinct in their applications.
Common among these aluminum alloys are 5052 and 6063 alloys and as a part manufacturer considering using either of the two materials, choosing depends on your understanding of their differences.
As a result, this article will guide you by exploring the differences between 5052 vs 6063 aluminum while providing tips on choosing the right one.
Summary: Key Characteristics of 5052 vs 6063 Aluminum
5052 aluminum is a weldable, corrosion-resistant, and tough aluminum material. It is not heat-treatable, although you can strengthen it using a work-hardening process, which makes it the strongest non-heat-treatable alloy.
5052 aluminum is highly formable, which is evident in its versatile use. Furthermore, its corrosion resistance makes it an ideal material for marine environments.
6063 aluminum alloy suits architectural projects because of its corrosion resistance and high aesthetic value (excellent surface finishing). Being from the 6XXX series, it responds well to anodizing, hence its architectural and structural applications.
6063 aluminum is castable and heat-treatable. It is a popular aluminum alloy for extrusion projects. Furthermore, it can be formed into several shapes and has appealing surface finishes.
Aluminum 5052 vs. 6063: What are the Differences?
Aluminum alloys 5052 and 6063 differ based on several factors highlighted in this section. Using the differences between both alloys, you can decide which one is right.
5052 vs 6063 Aluminum: Appearance
Aluminum 5052 has a silvery-white appearance, while aluminum 6063 alloy has a smooth surface finish with a slight sheen.
5052 vs 6063 Aluminum: Composition
5052 aluminum alloy belongs to the 5000 series and contains magnesium (2.2%) and chromium (0.15%) as the main alloying elements alongside aluminum. Other elements include silicon, copper, manganese, and zinc.
6063 aluminum alloy belongs to the 6000 series and contains magnesium and silicon as its main alloying elements alongside aluminum. Other elements include iron, copper, manganese, chromium, tin, and zinc.
Comparing 5052 vs 6063 Aluminum Alloys Alloying Elements
| Alloy | Si | Fe | Cu | Mn | Mg | Cr | Zn | Ti |
| 5052 | .45 | 0.0 | 0.1 | 0.1 | 2.2 | 0.15 | 0.1 | 0.0 |
| 6063 | .20 | .35 | 0.1 | 0.1 | 0.45 | .01 | 0.1 | 0.1 |
5052 vs 6063 Aluminum: Mechanical Properties
The major differences between 5052 and 6063 aluminum are in their mechanical properties. 5052 aluminum alloy is stronger and more suitable for structural applications, while 6063 alloy has high extrudability.
| Property | Aluminum 5052 | Aluminum 6063 |
| Tensile Strength | 38-42 ksi | 27-30 ksi |
| Yield Strength | 28-31 ksi | 16-18 ksi |
| Elongation | 12-20% | 8-12% |
| Density | 2.68 g/cm³ | 2.70 g/cm³ |
| Hardness (Brinell) | 60 HB | 73 HB |
| Thermal Conductivity | 138 W/m·K | 201 W/m·K |
| Modulus of Elasticity | 70.3 GPa (10.2 x 10^6 psi) | 68.9 GPa (10 x 10^6 psi) |
| Fatigue Strength | 125 MPa | 96 MPa |
| Melting Point | 607-650°C | 655°C |
5052 vs 6063 Aluminum: Welding and Machining
Welding and machining are another major indication of the difference between aluminum 5052 and 6063 alloys.
Both alloys have good formability and workability in terms of machining. However, 5052 is a 5,000-series metal, making it non-heat-treatable. On the other hand, 6063 is a 6,000-series metal and is heat-treatable.
5052 is tougher and more workable. Furthermore, it has good drawing properties, i.e., it can be drawn or formed into complex shapes. 6063 aluminum is workable, although it is better used for its extrusion properties.
In terms of weldability, 5052 and 6063 aluminum differ. 5052 aluminum is weldable due to the presence of magnesium. On the other hand, 6063 aluminum is difficult to weld due to the presence of silicon.
5052 vs 6063 Aluminum Alloys: Applications
The two aluminum alloys have wide applications, from everyday household items to advanced aerospace components. This section compares their common applications 5052 vs. 6063. Using it, you can possibly get a few hints on whether you can use the material for your part.
Aluminum 5052 Alloy Applications
Aluminum 5052 has excellent corrosion resistance, good weldability, and high fatigue strength, which are responsible for its common application in the following industries:
Marine Environments
The alloy is applicable in making the hulls and decks of small boats and superstructures of big ships due to its excellent mechanical properties and corrosion resistance.
Automotive Industry
5052 aluminum is applicable in fuel tanks because it is resistant to fuel and oil corrosion. Furthermore, its high formability and strength make it suitable for fabricating automotive panels and components.
Aerospace Industry
The aerospace industry also uses the material to make fuel tanks and other structural parts of aircraft due to its corrosion resistance, moderate strength, and excellent fatigue resistance.
Architecture
Aluminum 5052 can be used to make building facades and roofing, as it can withstand harsh weather conditions without corroding. Its good formability and resistance to atmospheric conditions make it suitable for window frames and similar architectural elements.
Food and Beverage Industry
5052 aluminum is non-toxic, making it a good choice for storage tanks or any packaging container used in the food and beverage industry.
Aluminum 6063 Alloy Applications
Aluminum 6063 has excellent extrudability, good mechanical properties, and fine finish, which are responsible for its common application in the following industries:
Construction and Architecture
Aluminum 6063 is widely used for window and door frames, railings, and fences due to its good surface finish and extrudability.
Electrical Industry
The alloy’s good thermal conductivity makes it an excellent choice for heat sinks in electronic devices to dissipate heat. Also, its combination of strength, corrosion resistance, and conductivity makes it the best material for making conduits and wiring.
Transportation
Due to its strength, the transportation industry uses Aluminum 6063 to make automotive trim, luggage racks, and other load-bearing components. It can also undergo anodization, which improves its surface finish quality
Consumer Goods
6063 aluminum is used in furniture production, particularly in lightweight, durable frames for chairs and tables. Also, it is suitable for sport equipment like bicycle frames and components because of its good strength-to-weight ratio and corrosion resistance.
Piping and Tubing
6063 excellent extrudability makes it ideal for creating piping and tubing for various industrial applications.
Tips for Choosing Aluminum 5052 vs. 6063
Effectively choosing between both aluminum alloys involved considering the differences above. Here are some tips to help you make an informed decision:
Part’s strength Requirement
If the part will have a high strength requirement, especially in structural parts, 5052 aluminum is the better option. However, for the moderate strength requirement, 6063 is better.
Part complexity
For applications that have complex shapes, 6063 aluminum is a better choice.
Environment of use
Due to its superior corrosion resistance, 5052 aluminum alloy suits marine or highly corrosive environments. For less corrosive environments, 6063 aluminum can still provide adequate resistance.
Workability
For projects that involve forming, machining, or welding, 5052 aluminum is the better option. On the other hand, for projects that require extrusion, 6063 aluminum is the better choice.
Surface Finish Requirements
Aluminum parts that require excellent surface finish, especially those used in architectural applications, are often made using 6063 aluminum. However, if the surface finish is less critical, 5052 aluminum’s moderate finish quality is sufficient.
Cost Considerations
Both materials are affordable, but aluminum 5052 is more expensive than 6063. However, this depends on other factors such as supplier, availability, and location.
Conclusion
5052 and 6063 are popular alloys with wide applications. As a part manufacturer considering using one of the materials, this article explored the differences between 5052 and 6063 aluminum and provided tips on choosing the right one.
