What Is 5454-H111 Aluminum Plate
5454 aluminum plate is a non-heat-treatable alloy from the 5xxx series, alloyed with magnesium and manganese. The H111 temper indicates that the material was annealed and then lightly strain hardened, giving it slightly higher strength than the fully annealed O temper while keeping excellent ductility. The combination of alloy chemistry and temper makes 5454-H111 a dependable choice for applications where moderate strength, easy forming and reliable welding are more important than maximum load capacity.
Composition and Temper Basics
According to common alloy registration data, 5454 contains 2.4-3.0% magnesium and 0.50-1.0% manganese, with the balance aluminum and small limits on iron, silicon and other impurities. Magnesium provides solid-solution strengthening, while manganese adds further strength and improves corrosion behavior. Unlike 2xxx and 6xxx alloys, 5454 cannot be strengthened by heat treatment; its properties come from composition and cold working. The H111 condition is produced by annealing followed by a light working or controlled stretching step, which removes yield point effects and improves flatness without hardening the material excessively.
Mechanical Properties and Thermal Behavior
Typical mill reference values for 5454-H111 under standards such as ASTM B209 and EN 485-2 show tensile strength in the range of 240-290 MPa, a minimum yield strength of about 105 MPa and elongation of 14% or more in the standard direction. The material has a density of approximately 2.69 g/cm3. One of the most useful features of 5454 is its behavior at elevated temperature: because the magnesium content is kept below about 3%, the alloy resists the sensitization that can make higher-magnesium alloys such as 5083 susceptible to stress corrosion cracking above roughly 65 C. 5454 is therefore accepted for continuous service at temperatures up to about 150 C in many design codes.
Applications in Industry
5454-H111 plate is most often associated with transport and storage of liquids. Tanker truck bodies benefit from its weldability, corrosion resistance and weight saving compared with steel. Stationary storage tanks, silos and process vessels use the alloy for formed cylindrical shells where roll-forming of 5-8 mm plate is required. In marine and offshore work, 5454 appears in non-structural bulkheads, deck fittings and hatch components that operate in damp, salt-laden air without paint protection. Heat exchanger casings and air-cooled equipment take advantage of its resistance to stress corrosion at moderate temperatures. The alloy is also used in road transport trailers, dump bodies and general engineering fabrication where a strong, weldable, corrosion-resistant plate is needed.
Welding and Fabrication
5454 welds readily with TIG and MIG processes. For structural joints, aluminum-magnesium filler such as ER5554 is recommended because it matches the base alloy closely and keeps the weld zone corrosion resistant. The H111 temper allows cold bending and roll-forming with moderate bend radii; press-brake forming of 6-8 mm plate is common without intermediate annealing. Machining produces clean chips with standard tooling. For demanding pressure applications, welded joints should be qualified according to the relevant code, and design stresses should follow the applicable standard for the operating temperature.
Quality and Inspection Considerations
Plates supplied to ASTM B209 or EN 485 are checked for chemical composition, mechanical properties, dimensions and surface quality. Thickness tolerances for a 6 mm plate under EN 485-3 are typically within plus or minus 0.30 mm. Where ultrasonic examination is required for thicker material, testing is normally performed to standards such as EN 10160. A mill test certificate in line with EN 10204 3.1 gives the buyer full traceability of heat, composition and mechanical results, which is important for tank and pressure-vessel fabrication.
FAQ
What is the maximum service temperature for 5454-H111?
Continuous service up to about 150 C is commonly accepted because the controlled magnesium content reduces the risk of stress corrosion cracking that can affect higher-magnesium alloys at lower temperatures.
What filler wire should be used for welding 5454?
ER5554 filler is the standard recommendation for TIG and MIG welding of 5454, as it matches the alloy chemistry and preserves corrosion resistance in the weld zone.
How does 5454 differ from 5083?
5083 contains more magnesium and is stronger, but it is more sensitive to sustained elevated-temperature service. 5454 offers lower strength with better resistance to stress corrosion cracking above about 65 C and easier forming.
Can 5454-H111 plates be anodized?
Yes, 5454 can be anodized, though the anodic film appearance differs from that of pure aluminum alloys. For architectural or decorative finishes, other surface treatments may be preferred.
Is 5454 suitable for marine use?
It performs well in marine atmospheres and is used for non-structural and moderately loaded components. For heavily loaded hull structures, higher-strength marine tempers such as 5083-H116 are normally specified.
What thickness ranges are common for 5454 plates?
5454 plates are commonly supplied from about 3 mm up to 50 mm and beyond, with width and length customized to the application and rolling capability of the mill.