5052 is the sheet-metal and formability specialist of the aluminum family. With 2.5% magnesium and no copper, it offers the best salt-water corrosion resistance of any common aluminum alloy — outperforming 6061 significantly in marine and coastal environments. Its non-heat-treatable nature means work-hardening (H32, H34 tempers) controls strength, and its excellent formability makes it the default choice for chassis, enclosures, fuel tanks, and electronic housings that require bending or drawing operations.
The decision between 5052 and 6061 usually comes down to what you're doing to the material after you cut it. If the part is a block that stays a block — housings, brackets, structural fittings — 6061 wins on strength and machinability. But if the part is a sheet that needs to bend, form, or draw into shape, 5052 is the correct choice and 6061 will crack. 6061-T6 has a minimum bend radius of 2–3× material thickness; 5052-H32 can handle 0.5–1× thickness bends without cracking, and annealed 5052-O can be drawn like steel.
The second decision factor is environment. 5052's high magnesium content and absence of copper make it the most corrosion-resistant common aluminum — it's the standard for fuel tanks, marine hulls, and outdoor enclosures exposed to salt spray. 6061 contains copper in its alloying recipe, which improves strength but creates galvanic corrosion sites. In coastal applications where paint may chip, 5052 outlasts 6061 by a factor of 3–5×.
5052 is a sheet/plate alloy — typically stocked in 0.5 mm to 25 mm thicknesses. If your design is a machined block thicker than 100 mm, you likely want 6061 or 5083 instead. Request 5083 specifically for thick marine plate; it's 5052's thicker cousin.
| Element | Min % | Max % | Role |
|---|---|---|---|
| Aluminum (Al) | Bal. | Bal. | Matrix |
| Magnesium (Mg) | 2.2 | 2.8 | Solid-solution strengthening |
| Chromium (Cr) | 0.15 | 0.35 | Grain control, stress-corrosion resistance |
| Manganese (Mn) | — | 0.10 | Impurity limit |
| Iron (Fe) | — | 0.40 | Impurity limit |
| Silicon (Si) | — | 0.25 | Impurity limit |
| Copper (Cu) | — | 0.10 | Kept low for corrosion resistance |
| Zinc (Zn) | — | 0.10 | Impurity limit |
| Property | 5052-O (annealed) | 5052-H32 | 5052-H34 | Test method |
|---|---|---|---|---|
| Tensile strength (UTS) | 193 MPa | 228 MPa | 262 MPa | ASTM E8 |
| Yield strength (0.2%) | 90 MPa | 193 MPa | 214 MPa | ASTM E8 |
| Elongation (50mm) | 25% | 12% | 10% | ASTM E8 |
| Hardness | 47 HB | 60 HB | 68 HB | ASTM E10 |
| Shear strength | 124 MPa | 138 MPa | 145 MPa | ASTM B831 |
| Fatigue strength (5×10⁸) | 110 MPa | 117 MPa | 124 MPa | ASTM E466 |
| Modulus of elasticity | 70.3 GPa | 70.3 GPa | 70.3 GPa | ASTM E111 |
| Melting range | 607–649°C | 607–649°C | 607–649°C | — |
Temper notation: O = annealed (softest, most formable), H32 = strain-hardened and stabilized to ¼-hard, H34 = ½-hard. For sheet forming with tight bend radii, specify H32 or O. For structural parts, H32 is the default stocked temper.
5052 is softer and gummier than 6061 — it tends to stick to tooling and build up edges if parameters are wrong. Use sharp uncoated carbide or polished ZrN-coated tools. Flood coolant with high-pressure chip evacuation is critical. Conventional milling (not climb) helps avoid chip re-cutting in thin sheet.
| Operation | Tool | Surface speed (SFM) | Feed per tooth (mm) | DOC (mm) |
|---|---|---|---|---|
| Face milling | Uncoated carbide, polished | 1400–1800 | 0.10–0.18 | 1.0–3.0 |
| End milling (roughing) | 3-flute ZrN-coated | 1200–1600 | 0.08–0.15 | 0.5×D axial |
| End milling (finishing) | 3-flute polished | 1500–2000 | 0.05–0.10 | 0.2 mm radial |
| Drilling | Polished HSS or carbide | 300–500 | 0.10–0.20/rev | — |
| Tapping | Spiral-point tap, coated | 30–60 | — | — |
| Turning | Positive-rake carbide, polished | 800–1200 | 0.10–0.25/rev | 0.5–3.0 |
Minimum bend radius is the most-asked specification for 5052. These values assume air bending with a standard V-die, grain direction perpendicular to the bend line (transverse). Bending parallel to the grain direction requires ~1.5× these radii.
| Thickness | 5052-O (min R) | 5052-H32 (min R) | 5052-H34 (min R) |
|---|---|---|---|
| 0.5 mm | 0 (flat crush) | 0.5 mm | 0.8 mm |
| 1.0 mm | 0 (1T fold) | 1.0 mm | 1.5 mm |
| 1.5 mm | 0.5 mm | 1.5 mm | 2.3 mm |
| 2.0 mm | 1.0 mm | 2.0 mm | 3.0 mm |
| 3.0 mm | 1.5 mm | 3.0 mm | 4.5 mm |
| 5.0 mm | 2.5 mm | 5.0 mm | 7.5 mm |
Linear dimensions ≤ 100 mm. Default tolerance on all features unless drawing specifies tighter. Included in baseline pricing.
Requires controlled-environment fixturing. +15% on price. Note: 5052 has higher thermal expansion than 6061 — very tight tolerances on long features are harder.
Standard press-brake angular tolerance. ±0.5° achievable with dedicated tooling setup on repeat orders.
Baseline finish from cutter. 5052 tends to show tool marks more than 6061 due to its softer gummy nature. Deburred edges included.
5052 anodizes to a slight grey-green tint rather than 6061's clear — this is normal due to magnesium content. Color matching across batches requires specification.
MIL-DTL-5541 Class 1A or 3. Corrosion-resistant prep for painting. Gold or clear finish. Most common for 5052 aerospace parts.
Standard RAL colors. Requires chemical-conversion pretreat on 5052 for best adhesion. Common for outdoor enclosures.
Uniform matte finish hides tool marks that are prominent on 5052. Glass bead #100 or #120 standard. Often combined with anodize.
Linear-grain finish for cosmetic enclosures. Direction specified on drawing. Often combined with clear anodize.
Boat fuel tanks, hatches, deck hardware, coastal signage. 5052's salt-spray resistance outperforms 6061 by 3–5× in unpainted service.
Sheet-metal chassis for industrial controls, telecom cabinets, outdoor IoT housings. Combines formability with EMI shielding.
Automotive fuel tanks (pre-plastic era, still used in race and industrial), hydraulic reservoirs, aviation fluid tanks.
Non-structural aircraft skin, panels, brackets. AMS-QQ-A-250/8 qualified. Less strength than 7075 but far better fatigue life and corrosion.
Signage, façade panels, window frames in coastal cities. Anodized 5052 is the standard for exterior architectural aluminum that must survive salt air.
Portable diagnostic equipment cases, cart enclosures. Formable, paintable, sterilizable. Non-magnetic for MRI-adjacent equipment.
| Property | 5052-H32 | 6061-T6 | 3003-H14 |
|---|---|---|---|
| Yield strength | 193 MPa | 276 MPa | 145 MPa |
| Formability | Excellent | Fair | Excellent |
| Machinability | Fair (40%) | Good (70%) | Poor (30%) |
| Corrosion (marine) | Excellent | Good | Fair |
| Weldability | Excellent | Good | Excellent |
| Anodize appearance | Slight grey | Clear/natural | Muddy |
| Cost (relative) | 1.0× | 0.95× | 0.85× |
| Default choice for | Formed sheet, marine | Machined blocks | Drawn cups, heat exchangers |
Quick decision rule: If your part is machined from bar or plate and never bends, use 6061. If your part is bent, drawn, or will see salt water, use 5052. If your part is deep-drawn with no strength requirement, use 3003.
The default general-purpose aluminum. See side-by-side specs.
High-strength aerospace alloy — when 6061 isn't strong enough.
How we machine aluminum sheet and plate.
Sheet metal design rules, bend radii, hole-to-edge spacing.
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