6061 Aluminum Vs. 5454 Aluminum: What’s The Difference?

The main differences between 6061 Aluminum vs. 5454 Aluminum lie in their composition, properties, and typical applications.

Alloy Composition:

Element	6061 Aluminum	5454 Aluminum
Al	97.9% – 98.9%	94.7% – 98.7%
Mg	1.0% – 1.2%	2.4% – 3.0%
Si	0.4% – 0.8%	0.25% – 0.40%
Cu	0.15% – 0.40%	0.1% (max)
Cr	0.04% – 0.35%	0.05% – 0.25%
Zn	0.25% (max)	0.25% (max)
Mn	0.1% (max)	2.2% – 2.8%
Other Elements	0.05% (each, max)	Trace amounts of other alloying elements

Please note that this is a general chemical composition range and may vary depending on the aluminum metal manufacturer and specific alloy specifications. In practical applications, the selection of the appropriate aluminum alloy depends on the required properties and the specific use.

Prices of 6061 Aluminum vs. 5454 Aluminum:

6061 aluminum is generally more common and may be more readily available in certain markets, potentially influencing cost compared to 5454 aluminum, which might be in higher demand for specific applications.

Comparison of Material Properties Between 6061 Aluminum vs. 5454 Aluminum Alloys:

Performance Feature	6061 Aluminum	5454 Aluminum
Strength	High	Medium
Corrosion Resistance	Moderate	Excellent, especially in marine environments
Weldability	Good	Good
Machinability	Excellent	Good
Applications	Aerospace, automotive, structural	Marine applications, pressure vessels

Note: The data in the table represents general characteristics, and actual performance may vary based on heat treatment, specific alloy specifications, and application conditions. It is recommended to refer to technical specifications and requirements when choosing materials.

Other Comparisons:

Applications: 6061 aluminum finds widespread use in aerospace, automotive, and structural applications, while 5454 aluminum is primarily utilized in marine applications such as shipbuilding and pressure vessels.
Strength-to-Weight Ratio: The high strength and relatively low weight of 6061 aluminum make it popular in applications requiring both strength and lightweight characteristics. While 5454 aluminum may have slightly lower strength, its corrosion resistance could be more critical in certain scenarios.