Deep drawing
Aluminium has a lower r-value and modulus than steel, so draw dies need larger radii, slightly different blank-holder forces and allowance for more springback. 5754-O draws well when lubrication is controlled.
Automotive body sheet
5754-O Aluminium Sheet for Auto Body Structures
5754 in the soft O or H111 temper is the standard aluminium sheet for car body inner panels and structural pressings: it draws deeply, welds well and resists road-salt corrosion without paint-bake hardening. Metline supplies 5754-O sheet, blanks and coil for body-in-white, chassis and heat-shield parts, certified to EN 485 and ASTM B209, to vehicle and component makers worldwide.
- Alloy
- 5754 (Al-3Mg)
- Tempers
- O, H111, H22
- Gauge
- about 0.7 – 3.5 mm
- Standards
- EN 485 · ASTM B209
Why 5754 is used inside the car body
Aluminium body structures use two families of sheet. Heat-treatable 6xxx alloys (6016, 6014, 6111) form the visible outer panels because they harden in the paint oven and resist denting. Non-heat-treatable 5xxx alloys, chiefly 5754 and 5182, form the hidden inner panels and structural parts, where deep drawing, crash energy absorption and corrosion resistance matter more than surface appearance.
5754 contains about 3 % magnesium. That gives it a good balance: strong enough for door inners, floor pans and structural reinforcements, ductile enough for deep draws, and with magnesium below the level where long-term sensitisation (beta-phase grain-boundary precipitation) becomes a serious risk at warm service temperatures. 5182, with about 4.5 % magnesium, is stronger but more susceptible to sensitisation and is therefore kept away from hot zones.
A common drawback of Al-Mg alloys is stretcher-strain marking (Lüders lines) during pressing. In 5754-O this is acceptable on hidden parts, which is exactly where it is used. Outer skins stay in 6xxx alloys that do not show these marks.
5754 chemical composition (wt %)
Registered limits from the Aluminum Association and EN 573-3 (EN AW-5754, AlMg3). Automotive sheet is often made to tighter internal ranges agreed with the vehicle maker; the certificate reports the actual analysis.
| Element | Minimum | Maximum | Role |
|---|---|---|---|
| Magnesium (Mg) | 2.6 | 3.6 | Solid-solution strength and work hardening |
| Manganese (Mn) | — | 0.50 | Grain control and strength |
| Chromium (Cr) | — | 0.30 | Grain control |
| Mn + Cr | 0.10 | 0.60 | Combined limit |
| Silicon (Si) | — | 0.40 | Impurity |
| Iron (Fe) | — | 0.40 | Impurity; affects formability |
| Copper (Cu) | — | 0.10 | Kept low for corrosion resistance |
| Zinc (Zn) | — | 0.20 | |
| Titanium (Ti) | — | 0.15 | Grain refiner |
| Others, each / total | — | 0.05 / 0.15 | |
| Aluminium (Al) | Remainder | About 94 – 97 % |
Some older data sheets quote 5754 with copper or silicon minimums; the registered alloy has none. Order to the standard limits above or to the OEM's specification.
Mechanical properties of 5754-O / H111 sheet
EN 485-2 sets the same tensile window for O and H111. Elongation minimums rise with thickness. Typical values for automotive gauges sit comfortably above the minimums.
| Property | EN 485-2 requirement (O / H111) | Typical, 1 – 2 mm automotive sheet |
|---|---|---|
| Tensile strength Rm | 190 – 240 MPa | about 210 – 225 MPa |
| Proof stress Rp0.2 | 80 MPa min | about 95 – 110 MPa |
| Elongation A50, 0.5 – 1.5 mm | 14 % min | about 22 – 26 % |
| Elongation A50, 1.5 – 3 mm | 16 % min | about 24 – 28 % |
| Elongation A50, 3 – 6 mm | 18 % min | — |
| Hardness | — | about 52 HB |
Physical properties
- Density
- 2.67 g/cm³
- Modulus of elasticity
- about 70 GPa
- Thermal conductivity
- about 130 – 140 W/m·K
- Electrical conductivity
- about 33 % IACS
- Coefficient of thermal expansion
- about 23.8 µm/m·°C
- Melting range
- about 600 – 640 °C
Unlike 6xxx outer-panel sheet, 5754 does not gain strength in the paint oven. Its final strength in the part comes from the work hardening introduced during pressing, which can raise local yield strength well above the as-delivered value in heavily drawn areas.
5754 automotive sheet and coil sizes
Supply range
- Thickness
- about 0.7 – 3.5 mm for body parts; up to 6 mm for chassis and structural plates
- Width
- up to about 2,000 – 2,400 mm depending on gauge
- Form
- Coil, slit coil, cut sheet and laser- or press-cut blanks
- Tempers
- O and H111 for pressing; H22 or H32 where extra stiffness is wanted
- Surface
- Mill finish or electro-discharge textured (EDT) surface; dry lubricant or oil on request
- Pre-treatment
- Titanium-zirconium or similar conversion coating for adhesive bonding, on request
Exact width and gauge combinations depend on the rolling route; send your blank drawing for confirmation.
| Thickness (mm) | kg per m² | 1250 × 2500 mm sheet (kg) |
|---|---|---|
| 0.8 | 2.14 | 6.7 |
| 1 | 2.67 | 8.3 |
| 1.2 | 3.20 | 10.0 |
| 1.5 | 4.00 | 12.5 |
| 2 | 5.34 | 16.7 |
| 2.5 | 6.67 | 20.9 |
| 3 | 8.01 | 25.0 |
| 4 | 10.68 | 33.4 |
Pressing, joining and corrosion behaviour
Lüders lines
Al-Mg sheet can show stretcher-strain marks at low strain. Use 5754 on hidden parts, or specify a temper or levelling route that reduces the effect if appearance matters.
Spot and laser welding
Resistance spot welding needs higher currents and frequent electrode dressing compared with steel. MIG and laser welding with 5xxx filler (ER5356, ER5183) work well.
Bonding and riveting
Many aluminium body structures combine adhesive with self-piercing rivets or flow-drill screws. A conversion pre-treatment improves long-term bond durability.
Sensitisation limit
Keep sustained service temperatures below about 65 °C where possible. 5754 is far less prone to intergranular attack than 5182, but the rule still applies near exhausts.
Mixed-metal joints
Isolate aluminium from steel and carbon-fibre parts with sealants, coatings or insulating fasteners to avoid galvanic corrosion.
Typical 5754 automotive parts
| Part | Why 5754-O is chosen |
|---|---|
| Door, bonnet and tailgate inner panels | Deep draws and good spot weldability; hidden from view |
| Floor pans and wheel-house panels | Corrosion resistance in wet underbody zones |
| Structural reinforcements and brackets | Work hardening raises local strength after forming |
| Fuel and fluid tanks | Weldable and corrosion-resistant |
| Heat shields and underbody panels | Formable and stable at moderate temperatures |
| Truck cabs, trailer and bus panels | Weldable sheet with good fatigue behaviour |
| EV battery-box covers and closures | Formability plus corrosion resistance |
A typical aluminium bonnet pairs a 6016-T4 outer skin, which hardens in the paint oven for dent resistance, with a 5754-O or 5182-O inner that is deep drawn into the stiffening pattern. The two are hemmed and bonded together.
5754 compared with 5182, 6016 and 5052
| Property | 5754-O | 5182-O | 6016-T4 | 5052-O |
|---|---|---|---|---|
| Magnesium | 2.6 – 3.6 % | 4.0 – 5.0 % | 0.25 – 0.6 % (+ Si) | 2.2 – 2.8 % |
| Typical yield | about 100 MPa | about 130 MPa | about 110 – 120 MPa | about 90 MPa |
| Paint-bake hardening | No | No | Yes | No |
| Sensitisation risk | Low | Higher | None | Low |
| Surface marks when pressed | Lüders lines possible | Lüders lines likely | None | Possible |
| Typical role | Inner and structural panels | High-strength inner panels | Outer skins | General sheet, tanks |
Pick 5754 as the default inner and structural sheet. Move to 5182 only when extra strength is essential and the part stays cool; choose 6016 or 6014 for outer skins that need a perfect painted surface.
How to order 5754 body sheet from Metline
- SpecifyAlloy and temper (5754-O or H111), thickness, width or blank drawing, surface texture, lubrication and pre-treatment, and coil inner diameter and weight limits.
- Confirm the standardEN 485 / EN 573-3, ASTM B209, or the vehicle maker's material specification.
- QuoteWe confirm availability, tolerances, certification and delivery terms (EXW, FOB, CIF or DAP) for your plant or port.
- Process and inspectCoils are slit or cut to blanks, checked for gauge, flatness and surface, and packed eye-to-sky or eye-to-wall as required.
- 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
- EN 485-2 – Sheet, strip and plate: mechanical properties
- EN 573-3 – Aluminium and aluminium alloys: chemical composition and form of wrought products
- ASTM B209 – Aluminum and Aluminum-Alloy Sheet and Plate
- The Aluminum Association – International Alloy Designations and Chemical Composition Limits (Teal Sheets)
- IATF 16949 – Quality management system requirements for automotive production and relevant service parts organisations
5754 automotive aluminium sheet: frequently asked questions
Why is 5754-O used for inner panels rather than outer panels?
5754 draws deeply and resists corrosion, but it can show stretcher-strain (Lüders) marks and does not harden in the paint oven. Those traits are acceptable on hidden inner and structural parts, while 6xxx sheet is used for visible skins.
What is the difference between 5754-O and 5754-H111?
Both are annealed. H111 receives a small amount of strain from levelling or stretching after annealing. EN 485-2 gives them the same tensile limits, so they are often interchangeable for pressing.
Does 5754 harden during paint baking?
No. It is a non-heat-treatable Al-Mg alloy. Strength in the finished part comes from work hardening during pressing, not from the paint cycle.
Can 5754 aluminum sheet be spot welded?
Yes. Resistance spot welding works with higher current than steel and regular electrode dressing. Many body structures also use self-piercing rivets and structural adhesive.
Is 5754 safe to use near the exhaust?
For short excursions, yes. For sustained temperatures above about 65 °C, Al-Mg alloys can sensitise over time; 5754 is less prone than 5182, but heat shields or other alloys are preferred in hot zones.
What certificate comes with the sheet?
Each lot ships with an EN 10204 3.1 mill test certificate showing chemistry and tensile results, traceable to the coil.
Need 5754-O sheet for body parts?
Send gauge, blank size, surface and volume. Our team will reply with availability, certification and a delivered price.
