5052 aluminum round bar is a medium-strength non-heat-treatable aluminum-magnesium alloy that offers an exceptional balance of formability, weldability, and corrosion resistance, making it ideal for marine applications and general-purpose fabrication:

Primary Alloying Elements:

Magnesium (Mg): 2.2-2.8% (solid solution strengthening)

Chromium (Cr): 0.15-0.35% (corrosion resistance enhancement)

Base Material:

Aluminum (Al): ≥95.7% (balance)

Controlled Impurities:

Iron (Fe): ≤0.40% max

Silicon (Si): ≤0.25% max

Copper (Cu): ≤0.10% max

Manganese (Mn): ≤0.10% max

Zinc (Zn): ≤0.10% max

Other elements: ≤0.05% each, ≤0.15% total

Premium Manufacturing Process:

Melt Preparation:

High-purity primary aluminum (99.7% minimum)

Precise alloying element additions

Melt filtration through ceramic foam filters (20-30 ppi)

Advanced degassing treatment (hydrogen < 0.15 ml/100g)

Grain refinement with Al-Ti-B master alloy

Direct-chill (DC) semi-continuous casting

Homogenization:

450-480°C for 6-12 hours

Uniform temperature control: ±5°C

Controlled cooling rate: 30-50°C/hour

Hot Working:

Initial breakdown: 380-420°C

Intermediate rolling/forging: 350-380°C

Final hot working: 320-350°C

Careful temperature control to ensure uniform properties

Cold Working:

H32: Quarter-hard condition (strain hardened)

H34: Half-hard condition (strain hardened)

H38: Full-hard condition (strain hardened)

Annealing (for O temper):

340-360°C for 1-3 hours

Controlled cooling to achieve optimal grain structure

Finishing:

Surface conditioning

Precision straightening

Dimensional verification

Surface quality inspection

Full manufacturing traceability with comprehensive documentation for all production steps.

 

Property	O (Annealed)	H32	H34	H38	Test Method
Ultimate Tensile Strength	170-215 MPa	230-265 MPa	255-290 MPa	290-320 MPa	ASTM E8
Yield Strength (0.2%)	65-95 MPa	160-190 MPa	180-210 MPa	220-250 MPa	ASTM E8
Elongation (2 inch)	18-30%	12-18%	8-14%	5-10%	ASTM E8
Hardness (Brinell)	45-55 HB	60-70 HB	68-78 HB	75-85 HB	ASTM E10
Fatigue Strength (5×10⁸)	90-110 MPa	120-140 MPa	130-150 MPa	140-160 MPa	ASTM E466
Shear Strength	110-130 MPa	140-160 MPa	150-170 MPa	165-185 MPa	ASTM B769
Modulus of Elasticity	70.3 GPa	70.3 GPa	70.3 GPa	70.3 GPa	ASTM E111

 

Property Distribution:

Longitudinal to transverse property ratio: 1.00:0.95

Variation across diameter: <3% for bars up to 50mm, <5% for bars >50mm

Core to surface hardness variation: <5 HB

Property retention after welding: Excellent compared to heat-treatable alloys

Key Microstructural Features:

Grain Structure:

Equiaxed grains in annealed condition

Elongated grains in strain-hardened tempers

ASTM grain size 5-8 (63-22μm)

Uniform grain distribution across section

Precipitate Distribution:

Al₁₂Mg₂Cr dispersoids: 50-200nm, uniform distribution

Al-Fe-Si intermetallics: Refined distribution

Cr-rich dispersoids: Enhances corrosion resistance

Texture Development:

Near-random orientation in O condition

Moderate deformation texture in H32/H34 tempers

Strong deformation texture in H38 temper

Special Features:

Fine Mg₂Si precipitates at grain boundaries (minimal)

Low dislocation density in O condition

Higher dislocation density in strain-hardened tempers

Excellent recrystallization control in intermediate tempers

 

 

 

Parameter	Standard Range	Precision Tolerance	Commercial Tolerance	Test Method
Diameter	6-200 mm	±0.20mm up to 30mm	±0.30mm up to 30mm	Micrometer
		±0.6% above 30mm	±1.0% above 30mm
Ovality	N/A	50% of diameter tolerance	75% of diameter tolerance	Micrometer
Length	2000-6000 mm	±3mm	±6mm	Tape measure
Straightness	N/A	0.5mm/m	1.0mm/m	Straightedge
Surface Roughness	N/A	3.2 μm Ra max	6.3 μm Ra max	Profilometer
Cut End Squareness	N/A	0.5° max	1.0° max	Protractor

 

Standard Available Forms:

Round Bar: Diameters 6-200mm

Cut-to-length service available

Special tolerances available upon request

Precision ground bars for critical applications

Custom lengths and surface finishes available

 

 

Temper Code	Process Description	Optimal Applications	Key Characteristics
O	Fully annealed, softened	Applications requiring maximum formability	Maximum ductility, lowest strength
H32	Quarter-hard (strain hardened)	General purpose fabrication	Good balance of strength and formability
H34	Half-hard (strain hardened)	Moderate strength applications	Higher strength with moderate ductility
H36	Three-quarter hard	High-strength requirements	High strength with reduced formability
H38	Full-hard (strain hardened)	Maximum strength applications	Highest strength with minimum formability

 

Temper Selection Guidance:

O: Maximum forming, bending, or drawing operations

H32: General purpose fabrication with moderate forming

H34: Applications requiring higher strength with some formability

H36/H38: Applications requiring maximum strength with minimal forming

 

Operation	Tool Material	Recommended Parameters	Comments
Turning	HSS, Carbide	Vc=180-400 m/min, f=0.1-0.4 mm/rev	Good surface finish with proper tooling
Drilling	HSS, Carbide	Vc=60-120 m/min, f=0.15-0.35 mm/rev	Good hole quality, minimal burring
Milling	HSS, Carbide	Vc=180-500 m/min, fz=0.1-0.2 mm	Use climb milling for best finish
Tapping	HSS, TiN coated	Vc=15-30 m/min	Good thread quality with proper lubrication
Reaming	HSS, Carbide	Vc=40-90 m/min, f=0.2-0.5 mm/rev	H8 tolerance achievable
Sawing	HSS, Carbide-tipped	Vc=1000-2000 m/min	Fine tooth pitch for best results

 

Fabrication Guidance:

Machinability Rating: 70% (1100 aluminum = 100%)

Surface Finish: Very Good (Ra 0.8-3.2μm readily achievable)

Chip Formation: Medium-length chips; chip breakers beneficial

Coolant: Water-soluble emulsion preferred (5-8% concentration)

Tool Wear: Low with proper parameters

Weldability: Excellent with TIG, MIG, and resistance welding

Cold Working: Excellent formability in O condition

Hot Working: 340-420°C recommended temperature range

Cold Bending: Minimum radius 1× diameter (O temper), 1.5× diameter (H32), 2× diameter (H34/H38)

 

Environment Type	Resistance Rating	Protection Method	Expected Performance
Industrial Atmosphere	Excellent	Clean surface	15-20+ years
Marine Atmosphere	Very Good	Clean surface	10-15+ years
Seawater Immersion	Good	Cathodic protection	5-10+ years with maintenance
High Humidity	Excellent	Standard cleaning	15-20+ years
Stress Corrosion	Excellent	Proper temper selection	Superior to 6xxx/7xxx series
Galvanic Corrosion	Good	Proper isolation	Careful design with dissimilar metals

 

Surface Protection Options:

Anodizing:

Type II (Sulfuric): 10-25μm thickness

Type III (Hard): 25-50μm thickness

Color anodizing: Excellent color retention

Mechanical Finishing:

Polishing: Enhanced appearance and reduced corrosion initiation sites

Brushed finish: Decorative and functional

Bead blasting: Uniform matte appearance

Painting Systems:

Chromate conversion coating pretreatment

Epoxy primer + polyurethane topcoat

Marine-grade systems available

Chemical Conversion:

Alodine/Iridite chromate conversion

RoHS-compliant alternatives

 

 

 

Property	Value	Design Consideration
Density	2.68 g/cm³	Weight calculation for components
Melting Range	607-649°C	Welding parameters
Thermal Conductivity	138 W/m·K	Thermal management design
Electrical Conductivity	35-37% IACS	Electrical applications design
Specific Heat	880 J/kg·K	Thermal mass calculations
Thermal Expansion (CTE)	23.8 ×10⁻⁶/K	Thermal stress analysis
Young’s Modulus	70.3 GPa	Deflection and stiffness calculations
Poisson’s Ratio	0.33	Structural analysis parameter
Damping Capacity	Moderate	Vibration-sensitive applications

 

Design Considerations:

Operating Temperature Range: -80°C to +200°C

Cryogenic Performance: Good (increased strength at low temperatures)

Magnetic Properties: Non-magnetic

Recyclability: 100% recyclable with high scrap value

Environmental Impact: Low carbon footprint compared to steel alternatives

 

Standard Testing Procedures:

Chemical Composition:

Optical emission spectroscopy

Verification of all major elements and impurities

Mechanical Testing:

Tensile testing (longitudinal)

Hardness testing (Brinell)

Dimensional Inspection:

Diameter measurements at multiple locations

Straightness verification

Ovality measurement

Visual Inspection:

Surface defects assessment

Finish quality verification

Specialized Testing (When Required):

Ultrasonic inspection per ASTM E114

Grain size determination (ASTM E112)

Corrosion testing (ASTM B117 salt spray)

Conductivity testing (eddy current)

Standard Certifications:

Mill Test Report (EN 10204 3.1)

Chemical analysis certification

Mechanical properties certification

Dimensional inspection report

Material traceability documentation

 

 

 

Primary Applications:

Marine Components:

Small boat hardware

Fittings and fasteners

Railings and ladders

Non-structural marine components

Electrical & Electronics:

Electronic chassis and enclosures

Transformer components

Terminal blocks and connectors

Heat sinks for moderate thermal loads

Food & Beverage:

Food processing equipment

Commercial kitchen components

Beverage dispensing equipment

Storage tank components

Architectural:

Interior decorative elements

Signage components

Furniture components

Non-load bearing fixtures

General Fabrication:

Sheet metal components

Brackets and mounting hardware

Covers and panels

Machinery guards

Design Advantages:

Excellent corrosion resistance in most environments

Superior formability, especially in O temper

Excellent weldability without post-weld heat treatment

Good fatigue resistance

Attractive appearance with various finishes

Non-magnetic properties for electronic applications

Non-sparking properties for safety applications

Good machinability for complex components

Lightweight alternative to stainless steel

Moderate strength with excellent ductility

Design Limitations:

Lower strength compared to 6xxx and 7xxx series alloys

Not heat-treatable for strength enhancement

Moderate wear resistance

May experience stress relaxation under sustained loading

Not recommended for high-temperature applications above 200°C

Limited strength retention after welding in strain-hardened tempers

Economic Considerations:

Cost-effective alternative to stainless steel

Good balance of properties and cost

Lower maintenance costs in corrosive environments

Reduced finishing costs due to natural corrosion resistance

Excellent recyclability and high scrap value

Lower fabrication costs compared to harder materials

Sustainability Aspects:

100% recyclable with no loss of properties

Energy-efficient alternative to steel

Long service life reduces replacement frequency

No harmful substances or RoHS-restricted elements

Low environmental impact throughout lifecycle

High percentage of recycled content available

Material Selection Guidance:

Choose 5052 when corrosion resistance and formability are priorities

Select harder tempers (H34/H38) for increased strength requirements

Consider 6061-T6 when higher strength is required with moderate corrosion resistance

Consider 5083 for higher strength marine applications

Consider 3003 for less demanding applications with cost constraints

Processing Recommendations:

Allow for springback in forming operations (increases with harder tempers)

Use appropriate radius in bending operations based on temper

Employ proper cleaning procedures before welding