Introduction: 5052 Aluminum Sheet Thickness Chart
When you're planning a project with 5052 aluminum sheet, one of the most critical decisions you'll make is selecting the right thickness.
It's a choice that directly impacts the material's weight, strength, formability, and cost.
Choosing too thin can lead to failure, while choosing too thick adds unnecessary weight and expense.
This is where a 5052 aluminum sheet thickness chart becomes an indispensable tool.
But a chart is just a collection of data. To truly use it effectively, you need to understand the context behind the numbers.
This comprehensive guide will not only provide you with a detailed thickness chart but will also empower you to interpret it.
We will explore how to read the chart, how to choose the ideal thickness based on your application, and how 5052 compares to other popular alloys.
By the end, you'll be able to select the perfect 5052 aluminum sheet with confidence.
A Quick Refresher: Why Choose 5052 Aluminum?
Before we dive into the chart, it's worth remembering why 5052 aluminum is such a popular and trusted choice.
Known as "marine-grade" aluminum, its standout feature is its exceptional resistance to corrosion, especially in saltwater and other harsh environments.
Furthermore, 5052 (most commonly in an H32 temper) offers a fantastic combination of good formability and higher strength than other common non-heat-treatable alloys like the 3003 series.
This makes it a versatile workhorse for a huge range of fabrication jobs.
Chemical Composition
5052 is a wrought aluminum-magnesium alloy primarily known for its excellent corrosion resistance and moderate-to-high strength.
Its typical chemical composition is as follows:
| Element | Percentage (%) |
|---|---|
| Magnesium (Mg) | 2.2 – 2.8 |
| Chromium (Cr) | 0.15 – 0.35 |
| Aluminum (Al) | Remainder |
| Iron (Fe) | ≤ 0.40 |
| Silicon (Si) | ≤ 0.25 |
| Copper (Cu) | ≤ 0.10 |
| Manganese (Mn) | ≤ 0.10 |
| Zinc (Zn) | ≤ 0.10 |
| Other (Each) | ≤ 0.05 |
| Other (Total) | ≤ 0.15 |
Key Mechanical Properties
5052 aluminum is classified as a non-heat-treatable alloy, hardened instead by cold working.
Its mechanical properties vary slightly by temper but generally fall into the following ranges:
| Property | Typical Value (H32 Temper) |
|---|---|
| Ultimate Tensile Strength | 210 – 260 MPa (30 – 38 ksi) |
| Yield Strength | ≥ 193 MPa (28 ksi) |
| Elongation at Break | ≥ 7–12% (depending on thickness) |
| Hardness (Brinell) | 60–70 HB |
| Density | 2.68 g/cm³ |
| Modulus of Elasticity | ~70 GPa (10.2 × 10⁶ psi) |
Key advantages:
- Strength: Greater than 1100, 3003, and 6061 in some applications
- Ductility: Good elongation allows for bending and forming
Corrosion Resistance: Excellent in saltwater and chemical environments
Common Tempers
5052 aluminum sheet is available in multiple tempers that suit varying mechanical and fabrication needs. The most common include:
| Temper | Description |
|---|---|
| H32 | Strain-hardened and partially annealed to a stable condition. Most commonly used for sheet and plate with balanced strength/formability. |
| H34 | Greater strain-hardening than H32; higher strength but reduced ductility. Ideal for applications needing more rigidity. |
| H36 | Even more strain-hardened; stronger than H34 with further reduced elongation. Used in stiff, thin structural components. |
| O | Fully annealed for maximum ductility and softness. Used in applications requiring deep drawing or complex forming. |
The 5052 Aluminum Sheet Thickness Chart
The chart below provides a practical reference for the most common thicknesses of 5052 aluminum sheet.
It includes the gauge number, the decimal equivalent in inches, the dimension in millimeters, and the approximate weight per square foot.
This weight is crucial for logistics, structural calculations, and project planning.
| Gauge | Thickness (Inches) | Thickness (mm) | Approx. Weight (lbs/sq. ft.) |
| 24 ga | 0.020" | 0.51 mm | 0.283 |
| 22 ga | 0.025" | 0.64 mm | 0.354 |
| 20 ga | 0.032" | 0.81 mm | 0.453 |
| 18 ga | 0.040" | 1.02 mm | 0.566 |
| 16 ga | 0.050" | 1.27 mm | 0.708 |
| 14 ga | 0.063" | 1.60 mm | 0.892 |
| 12 ga | 0.080" | 2.03 mm | 1.132 |
| 11 ga | 0.090" | 2.29 mm | 1.274 |
| 10 ga | 0.100" | 2.54 mm | 1.415 |
| 8 ga | 0.125" (1/8") | 3.18 mm | 1.769 |
| -- | 0.188" (3/16") | 4.76 mm | 2.654 |
| -- | 0.250" (1/4") | 6.35 mm | 3.538 |
Note: The "gauge" system becomes less common for thicknesses above 0.125". At that point, it's standard practice to refer to the material by its fractional or decimal inch measurement.
How to Choose the Right Thickness for Your Project
The chart provides the data, but your application dictates the choice.
Here is a practical breakdown to help you match a thickness to your specific needs.
Thin Gauges (0.020" - 0.050" / 0.5mm - 1.3mm)
These sheets are very lightweight and easy to bend and shape by hand or with simple tools.
However, they offer minimal structural strength and are prone to denting.
- Common Uses: Signage, lightweight ductwork, decorative paneling, automotive interior panels, electronic enclosures, and splash guards.
Medium Gauges (0.063" - 0.125" / 1.6mm - 3.2mm)
This is the "sweet spot" for many fabrication projects. This range offers a superb balance of moderate strength, rigidity, and good formability without being excessively heavy. It's the most common range for general-purpose work.
Common Uses: Small boat hulls, truck toolboxes, trailer skin and fenders, chassis panels, durable enclosures, and general fabrication brackets. The 0.125" (1/8") thickness is particularly popular for flooring and decking applications when specified as a checkered plate.
Thick Gauges (0.188" - 0.250" / 4.7mm - 6.4mm)
When strength and rigidity are the primary requirements, you move into these thicker plates.
They are significantly heavier and require more powerful equipment to cut and form.
- Common Uses: Heavy-duty marine components, structural brackets, boat transoms, base plates for machinery, and applications requiring high impact resistance.
A Note on Thickness Tolerances
It's important for precise projects to understand that the stated thickness is a "nominal" dimension.
Manufacturers produce sheet metal within a specific tolerance range. For example, a 0.125" sheet might have a tolerance of ±0.005", meaning the actual thickness could be anywhere from 0.120" to 0.130".
While this is a minor variance for most projects, it can be critical for applications requiring tight fits or exact weight calculations.
Always consult your supplier's specification sheet if precision is paramount.
Common Applications by Thickness Range
5052 aluminum sheet is valued across industries due to its exceptional balance of strength, corrosion resistance, and formability.
Its utility varies with thickness, allowing for application-specific engineering in sectors like automotive, marine, construction, and industrial equipment.
Thin Sheets (0.5–1.5 mm)
Applications:
- Automotive body panels: 5052's lightweight and corrosion-resistant nature makes it suitable for fender liners, trim, and interior skins.
- Signage and nameplates: The alloy's excellent surface finish and ease of printing/engraving are ideal for traffic signs, advertising boards, and decorative plates.
Consumer electronics: Used in casings and heat dissipation components due to its thermal conductivity and aesthetic finish.
Medium Sheets (2.0–4.0 mm)
Applications:
- Marine panels: Its saltwater corrosion resistance is a top reason why it's often used for hull cladding, cabins, and hatch covers.
- Electrical and equipment enclosures: Offers durability, electromagnetic shielding, and resistance to industrial environments.
- Fuel tanks and pressure vessels: Moderate strength and weldability make it suitable for low-pressure fluid containment.
Thick Sheets (5.0–10.0 mm+)
Applications:
- Industrial platforms and base plates: The rigidity and load-bearing capacity of thicker 5052 sheets support heavy machinery and floor structures.
- Armored and structural components: Though not as hard as ballistic alloys, 5052 can still serve in light defense structures or reinforced cabins.
- Truck beds and trailers: Its formability and resistance to road salts and moisture make it ideal for vehicle underbodies and cargo platforms.
How Thickness Affects 5052 vs. Other Alloys
The thickness you need is also influenced by the alloy you choose. A direct thickness-for-thickness comparison shows how 5052 stacks up against other common aluminum sheets.
- 5052 vs. 3003 Aluminum:
The 3003 alloy is softer and less strong than 5052. To achieve the same level of rigidity as a 5052 sheet, you would often need to use a slightly thicker gauge of 3003.
However, 3003 is more easily formed and is a more economical choice for applications where high strength and corrosion resistance are not the top priorities. - 5052 vs. 6061 Aluminum:
The 6061-T6 alloy is a heat-treated structural aluminum that is significantly stronger and more rigid than 5052-H32.
Consequently, you can often use a thinner sheet of 6061 to achieve the same structural strength as a thicker sheet of 5052.
The trade-off is that 6061 is much less formable (it's prone to cracking on tight bends) and has inferior corrosion resistance, especially in marine environments.
Conclusion
The 5052 aluminum sheet thickness chart is more than just a table of numbers; it's a foundational tool for successful project design and execution.
By combining the data in the chart with a clear understanding of your project's specific demands-strength, weight, formability, and environment-you can make an informed and effective choice.
Ultimately, 5052 aluminum's balanced profile makes it a reliable and versatile material.
Armed with this knowledge, you can confidently select the perfect thickness to ensure your project is durable, efficient, and built to last.
Frequently Asked Questions (FAQs)
1. What is the thickness range available for 5052 aluminum sheets?
5052 aluminum sheets are commonly available in thicknesses ranging from 0.2 mm to over 10 mm.
Standard gauges typically fall between 0.5 mm and 6 mm, with custom and industrial applications extending up to 25 mm or more.
2. How can I convert aluminum sheet thickness between mm and gauge?
Aluminum gauge charts are based on weight per square foot and may vary slightly between standards (AWG vs. manufacturers). For example:
- 0.8 mm ≈ 20 gauge
- 1.2 mm ≈ 18 gauge
- 2.0 mm ≈ 14 gauge
3. Is there a difference in mechanical properties by sheet thickness?
While the base alloy properties remain the same, sheet thickness affects structural stiffness and load-bearing capacity.
Thicker sheets naturally offer higher rigidity, while thinner sheets are better suited for lightweight and formable applications.
4. Can I bend or form thick 5052 aluminum sheets?
Yes. 5052 aluminum is known for excellent bendability, especially in H32 and H34 tempers.
However, as thickness increases, bending radius must increase to avoid cracking. Use proper tooling and radius guidelines.
5. Is there a standard tolerance for 5052 aluminum sheet thickness?
Yes. Thickness tolerances are governed by standards such as ASTM B209.
For example, for sheets under 3 mm, the tolerance is often ±0.05 mm, while thicker plates (e.g., 10 mm) may have a tolerance of ±0.15 mm or more, depending on the manufacturer.
6. How do I select the right thickness for my project?
Consider the following:
- Structural load or weight-bearing needs
- Forming method (bending, deep drawing)
- End-use environment (e.g., marine, automotive, architectural)
- Required surface finish and corrosion protection
Consult an engineer or supplier for load calculations if the application is critical.