Welding
ER5554 filler is designed for 5454 in warm service; ER5356 is common where service is at ambient temperature. Avoid fillers above 3 % Mg if the weld will run hot.
Warm-service automotive extrusions
5454 H112 Automotive Aluminium Extrusion Profile
5454 is an aluminium-magnesium-manganese alloy with about 2.7 % magnesium, formulated to stay resistant to stress corrosion in service up to roughly 65 – 120 °C, where higher-magnesium alloys become sensitised. As H112 extrusions it is used for chassis and frame members, tanker structures, wheel and brake-area brackets, rails and trim on vehicles. Metline supplies 5454 profiles to ASTM B221, EN 755 and GB/T 33910, worldwide.
- Alloy
- 5454 (Al-2.7Mg-0.8Mn)
- Temper
- H112, O, H111
- Min. strength
- about 215 / 85 MPa (ASTM B221)
- Service
- Warm environments
Why 5454 is chosen for vehicle parts
5454 contains 2.4 – 3.0 % magnesium, 0.5 – 1.0 % manganese and a small chromium addition. That magnesium level is deliberately kept below about 3 %, the point above which aluminium-magnesium alloys can precipitate a continuous film of β-phase on grain boundaries during long exposure to warm temperatures. The result is a strong, weldable alloy that tolerates heat far better than 5083 or 5182.
This is why 5454 is the traditional alloy for hot-product tankers (asphalt, heated chemicals), for parts near engines and brakes, and for wheels made from sheet. As an extrusion, it offers the same benefit in profile form: frame members, rails, brackets and tank structures that must be welded, resist corrosion and stay safe in warm service.
H112 is the as-extruded condition with tested properties. Because 5454 is non-heat-treatable, the extruded strength comes from the alloy itself, and welding causes little loss of strength in the heat-affected zone.
5454 chemical composition (wt %)
Limits follow the Aluminum Association registration, used in ASTM B221, EN 573-3 (EN AW-5454, AlMg3Mn) and GB/T 3190.
| Element | Minimum | Maximum | Role in the alloy |
|---|---|---|---|
| Silicon (Si) | — | 0.25 | Impurity |
| Iron (Fe) | — | 0.40 | Impurity |
| Copper (Cu) | — | 0.10 | Kept low for corrosion resistance |
| Manganese (Mn) | 0.50 | 1.0 | Strength and grain control |
| Magnesium (Mg) | 2.4 | 3.0 | Main strengthening element, capped for warm service |
| Chromium (Cr) | 0.05 | 0.20 | Stress-corrosion resistance |
| Zinc (Zn) | — | 0.25 | |
| Titanium (Ti) | — | 0.20 | Grain refiner |
| Others, each / total | — | 0.05 / 0.15 | |
| Aluminium (Al) | Remainder | About 94.5 – 97.1 % |
Mechanical properties of 5454 extrusions
ASTM B221 specifies minimums for 5454 extrusions in O, H111 and H112. EN 755-2 gives comparable values; some older automotive tables quote slightly lower figures (around 180 MPa tensile). The certificate reports the tested values for each lot.
| Temper | Tensile strength | Yield strength 0.2 % | Elongation | Basis |
|---|---|---|---|---|
| O | 215 – 285 MPa (31 – 41 ksi) | ≥ 85 MPa (12 ksi) | ≥ 14 % | ASTM B221 minimum |
| H111 | at least the O-temper minimum | higher than O (slight strain) | ≥ 12 % | ASTM B221 minimum |
| H112 | ≥ 215 MPa (31 ksi) | ≥ 85 MPa (12 ksi) | ≥ 12 % | ASTM B221 minimum |
| H112, typical | about 250 MPa | about 120 MPa | about 18 – 20 % | Typical result |
Physical properties (approximate)
- Density
- 2.69 g/cm³
- Melting range
- about 602 – 646 °C
- Thermal conductivity
- about 134 W/m·K
- Electrical conductivity
- about 34 % IACS
- Coefficient of thermal expansion
- about 23.6 µm/m·°C
- Modulus of elasticity
- about 70 GPa
5454 profile sizes and finishes
Typical supply range for 5454 profiles
- Temper
- H112 (as extruded); O and H111 on request
- Section types
- Round, square and rectangular tube; angle, channel, T and I sections; flat bar; hollow and multi-cavity custom profiles to drawing
- Size envelope
- Small trim and tube sections up to large structural profiles; the feasible circumscribing circle and wall depend on the die and press, and are confirmed at quotation
- Wall thickness
- From about 1 mm on small sections; thicker walls on structural shapes
- Length
- Standard 6 m mill lengths; cut-to-length parts and longer lengths on request
- Finish
- Mill finish, anodised, anodised and electrophoretic lacquer, powder coated or wet painted
- Processing
- Precision sawing, punching, CNC machining, bending and deburring to drawing
Every custom profile is drawing-specific. Send the section drawing with critical dimensions and tolerances so feasibility can be confirmed.
Tolerances and inspection
Unless the drawing states tighter values, profile dimensions follow the general tolerance tables of the order standard. Automotive programmes often add their own limits on critical features such as mounting faces, wall thickness at crush zones and twist over the part length.
Tolerance and inspection references
- Cross-section tolerances
- EN 755-9 (profiles), ASTM B221 with ANSI H35.2, or GB/T 14846 for orders to Chinese standards
- Straightness and twist
- Per the same tables, or as agreed for long automotive parts
- Surface quality
- Visible faces free of die lines, pick-up and blisters beyond the agreed limit sample
- Mechanical testing
- Tensile test per lot to ISO 6892-1 or ASTM B557; hardness checks on request
- Certification
- EN 10204 3.1 mill test certificate with chemistry and mechanical results
Welding, forming and finishing
Bending
H112 and O profiles bend well with suitable radii; mandrel bending is used for tube.
Machining
Fair; sharp, high-rake tools and good chip clearing are needed.
Corrosion
Very good in salt spray and humid conditions; isolate from steel fasteners.
Finishing
Accepts paint, powder coat and anodising; anodised colour is slightly grey.
Temperature
Recommended for sustained service up to about 120 °C, depending on stress and design code.
Where 5454 profiles are used
- Tanker structures: frames, rails and stiffeners for hot-product tankers
- Chassis and frame members: welded frames on trucks, trailers and buses
- Wheel- and brake-area brackets: parts exposed to heat from brakes or exhausts
- Rails and guides: seat rails, sliding-door guides and luggage racks
- Trim and frames: windscreen and window frames, door trim profiles on commercial vehicles
5454 compared with 5052, 5083 and 6061
| Property | 5052 | 5454 | 5083 | 6061-T6 |
|---|---|---|---|---|
| Magnesium (%) | 2.2 – 2.8 | 2.4 – 3.0 | 4.0 – 4.9 | 0.8 – 1.2 |
| Typical tensile (extruded, as used) | about 195 MPa | about 250 MPa | about 290 MPa | about 310 MPa |
| Warm service | Good | Very good (designed for it) | Not recommended | Good |
| Weld strength retention | Good | Very good | Excellent | Reduced |
| Extrudability | Fair | Fair | Difficult | Good |
How to order 5454 profiles
- SpecifyAlloy and temper (5454-H112), section drawing, length, finish, quantity and annual volume.
- Confirm the standardASTM B221, EN 755-2 or GB/T 33910, plus any service-temperature or welding requirements.
- QuoteWe confirm availability, tolerances, certification and delivery terms (EXW, FOB, CIF or DAP) for your plant or port.
- Process and inspectProfiles are cut, inspected for dimensions and properties, and packed with separators.
- Document and shipEach lot ships with an EN 10204 3.1 mill test certificate, lot traceability and a packing list, in seaworthy export packing. Third-party inspection can be arranged on request.
References and standards
- The Aluminum Association – International Alloy Designations and Chemical Composition Limits (Teal Sheets)
- ASTM B221 – Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes
- EN 755-2 – Extruded rod/bar, tube and profiles: mechanical properties
- GB/T 33910-2017 – Aluminium and aluminium alloy extruded profiles for automobiles
- ASM Handbook Vol. 2 – Properties and Selection: Nonferrous Alloys and Special-Purpose Materials
5454 automotive aluminium (aluminum) extrusions: frequently asked questions
Why use 5454 instead of 5083?
Because 5454 keeps its magnesium below 3 %, it does not become sensitised in warm service. 5083 is stronger but is not recommended above about 65 °C.
What strength does 5454-H112 extrusion have?
ASTM B221 specifies at least 215 MPa (31 ksi) tensile and 85 MPa (12 ksi) yield; typical results are higher.
What filler should I use for welding 5454?
ER5554 for parts that will run warm; ER5356 is acceptable at ambient temperature.
Is 5454 heat-treatable?
No. Strength comes from magnesium and manganese in the alloy; annealing only softens it.
Is 5454 suitable for tankers?
Yes. It is the traditional alloy for hot-product tankers, in plate for shells and as extrusions for frames and stiffeners.
Do you supply 5454 profiles internationally?
Yes. Metline ships 5454 extrusions worldwide from Mumbai with EN 10204 3.1 certificates, on EXW, FOB, CIF or DAP terms.
Need 5454 profiles for warm-service parts?
Send the drawing, temper and volume. We will reply with feasibility, certification and a delivered price.
