5754-H28 Aluminum vs. 5754-O Aluminum

Last Updated : Feb. 08, 2025

5754-H28 aluminum has the highest strength and hardness, suitable for high-load structures, while 5754-O aluminum offers the best ductility and formability, making it ideal for deep drawing and complex processing.

• 5754-H28 is suitable for high-strength, fatigue-resistant structural parts.
• 5754-O is suitable for components requiring deep drawing and high formability.

Both have excellent corrosion resistance and weldability, but with different focuses on strength and ductility.

5754-H28 vs. 5754-O Aluminum Alloy Performance Comparison

5754-H28 is suitable for structural parts that require high strength, while 5754-O is more suitable for applications requiring deep drawing and bending processes.

Comparison of 5754-H28 Aluminum vs. 5754-O Aluminum

5754-H28 Aluminum vs. 5754-O Aluminum Manufacturing Process

• 5754-H28 aluminum is manufactured using strain hardening (cold working) processes and partially annealed, allowing it to maintain high strength and hardness while still having certain machinability. During the cold working process, the crystal structure of the aluminum alloy is deformed, increasing its tensile strength and hardness, while partial annealing helps to relieve some internal stresses, giving it both strength and some ductility. Therefore, 5754-H28 aluminum is suitable for structural applications requiring high strength but still needing limited machinability.
• 5754-O aluminum is fully annealed, restoring the internal lattice structure to a state close to its original condition, eliminating residual stresses caused by cold working, and providing it with the highest ductility and excellent formability. During annealing, the strength of the material decreases, but plasticity significantly improves, making it particularly suitable for applications requiring deep drawing, bending, or other complex forming processes.

5754-H28 Aluminum vs. 5754-O Aluminum Mechanical Properties

• 5754-H28 aluminum, due to strain hardening, has much higher tensile strength and yield strength compared to the O state, making it an ideal choice for applications requiring high strength and high wear resistance. Its higher hardness also improves its performance against mechanical impact or wear, effectively extending the product's service life. Therefore, this state of 5754 aluminum is widely used in industrial equipment, automotive structural parts, pressure vessels, and other high-load applications.
• 5754-O aluminum, due to its full annealing treatment, has the highest ductility and toughness. The material can undergo significant deformation under external force without breaking, making it excellent for deep drawing, bending, or other plastic forming processes. Despite its lower strength, its excellent ductility makes it particularly suitable for complex forming applications, such as ship skin, food can bodies, and various fuel tanks.

5754-H28 Aluminum vs. 5754-O Aluminum Formability

• 5754-H28 aluminum, due to strain hardening, has significantly improved hardness and strength, meaning more external force is required to change its shape during processing. Although this state of aluminum can be shaped by machining, its bending and deep drawing properties are relatively poor, and cracks can easily occur during processing. Therefore, during manufacturing, 5754-H28 is mainly used for parts with high strength but simple shapes and is not suitable for manufacturing complex shapes.
• 5754-O aluminum has excellent processing properties, capable of deep drawing, bending, and rolling forming with ease. After full annealing, its ductility greatly improves, allowing the material to undergo significant plastic deformation without breaking during forming. This makes 5754-O state ideal for manufacturing components with complex geometries, especially for applications requiring high plasticity, such as automotive fuel tanks, food can bodies, and ship components.

5754-H28 Aluminum vs. 5754-O Aluminum Applications

• 5754-H28 aluminum, due to its high strength and good wear resistance, is widely used in structural components and mechanical equipment manufacturing. Typical applications include automotive frames, load-bearing parts, pressure vessels, and industrial equipment housings. In these applications, the material’s high strength helps improve product durability and reliability, and its excellent corrosion resistance also makes it suitable for long-term use in outdoor or harsh environments.
• 5754-O aluminum is primarily used in applications requiring extremely high ductility and good formability, such as ship skin, food packaging cans, fuel tanks, and other products requiring deep drawing. Due to its excellent plasticity, this material can be used to produce various precision components through complex forming processes while maintaining good mechanical integrity. Therefore, 5754-O aluminum is widely used in the food industry, maritime equipment, and liquid storage containers.

5754-H28 Aluminum vs. 5754-O Aluminum Welding and Corrosion Resistance

• 5754-H28 aluminum has good weldability and is suitable for various welding methods, such as TIG and MIG welding. However, due to its higher hardness and lower ductility, the welding process is more prone to heat-affected zone issues, which may cause welding cracks compared to the O state. Therefore, when welding H28 state materials, appropriate process parameters must be used to reduce stress concentration during welding.
• 5754-O aluminum has the best weldability, allowing it to be easily welded without cracking or embrittlement in the heat-affected zone. Due to the lower internal stresses in the O state, deformation or residual stress is less likely to occur during welding. Additionally, both 5754-H28 and 5754-O aluminum alloys have excellent corrosion resistance, particularly in marine and chemical environments, resisting salt spray corrosion and oxidation, ensuring long-term stability of the material.

5754-H28 Aluminum vs. 5754-O Aluminum Fatigue Resistance

• 5754-H28 aluminum, due to its higher tensile strength and yield strength, performs excellently in high-stress cyclic environments, making it suitable for applications that undergo long-term load changes. For example, in aerospace, automotive, and industrial equipment, H28 state aluminum can withstand repeated stress variations without experiencing fatigue failure, making it widely used in load-bearing structural parts and mechanical components.
• 5754-O aluminum, due to its lower strength, has weaker fatigue resistance under sustained or cyclic stress. Although it has high ductility and can undergo large deformations, its structural integrity may be compromised under prolonged high-stress conditions. Therefore, this material is mainly suitable for low-stress environments or applications that do not involve high-frequency stress cycles, such as liquid storage containers or ship skin.

5754-H28 aluminum is suitable for structural applications requiring high strength and wear resistance, capable of withstanding high-stress loads, but with relatively poor formability. On the other hand, 5754-O aluminum has excellent ductility and processing properties, making it suitable for applications requiring deep drawing, bending, or complex shape manufacturing, while its welding performance is superior. Therefore, when choosing between different states of 5754 aluminum alloys, it is necessary to weigh the specific application scenarios and processing requirements to ensure the material's performance meets the application needs.

Further reading: 5456 5454 5754 Marine Grade Aluminum Bar 5754 Marine Grade Aluminum Plate Sheet Marine Grade Aluminum Round Bar 5754 5454 5456

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