Aluminum 1100-O vs. Plastic ABS (bulk/injection)

Compare Aluminum 1100-O vs. Plastic ABS (bulk/injection) strength, stiffness, weight and thermal properties.

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Plastic ABS (bulk/injection)Bulk polymer (molded or machined)

Mechanical
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Yield strength	35MPasourcetypical, O, 0.0625 in specimen	45MPasourcetypical, tensile stress at yield 23 °C
Ultimate tensile strength	90MPasourcetypical, O	not sourced
Flexural strength	not sourced	65MPasourcetypical, 23 °C
Elongation at break	35%sourcetypical, O, in 4D	10%sourcenominal strain at break, 23 °C
Young's modulus (stiffness)	69GPasourcetypical30x stiffer	2.3GPasourcetypical
Density	2,710kg/m³sourcenominal, 20 °C	1,040kg/m³sourcetypical
Strength to weight	12.9kN·m/kg	43.3kN·m/kg3.35x higher
Stiffness to weight	25.5MN·m/kg11.5x higher	2.21MN·m/kg
Poisson's ratio	not sourced	0.39sourcetypical, ABS family (Covestro Part and Mold Design guide, Table 3-1)
Shear modulus	not sourced	0.827GPa
Bulk modulus	not sourced	3.48GPa
Speed of sound	5,046m/s	1,487m/s
Thermal
Thermal conductivity	222W/m·Ksourcetypical, O, 20 °C	0.17W/m·Ksourcetypical
Thermal expansion	23.6µm/m·Ksourcetypical, mean 20-100 °C	80–110µm/m·Ksourcerange
100 mm part over a 50 °C swing	118µm growth4.03x less	475µm growth
Specific heat	901J/kg·Ksourcebase material: commercially pure aluminium EN AW-1050A (Hydro), 20 °C	not sourced
Heats up and cools (diffusivity)	90.9mm²/s	not sourced
Thermal shock resistance	not sourced	21.4W/m
Melting point	640–655°Csourcemelting range	not sourced
Max service temperature	not sourced	94°CsourceHDT 1.8 MPa (annealed 4 h/80 °C)
Values for	1100-O (annealed) commercially pure aluminium, Kaiser Aluminum Tube & Pipe Alloy 1100 Technical Data (Rev. 05/06), typical properties; specific heat from Hydro EN AW-1050A (99.5% Al) extruded-products datasheet (10/2018).	INEOS Styrolution Terluran GP-22 general-purpose injection-molding ABS, ISO typical values (TDS revision 08/01/2022)

Every value links to the document that states it. "Not sourced" means no citable source states it (or only a specification minimum); figures computed from it are left out too.

Questions

Is Aluminum 1100-O stronger than Plastic ABS (bulk/injection)?

Plastic ABS (bulk/injection) is stronger: its yield strength is 45 MPa against 35 MPa for Aluminum 1100-O (29%).

Which is lighter, Aluminum 1100-O or Plastic ABS (bulk/injection)?

Plastic ABS (bulk/injection) is lighter: 1,040 kg/m³ against 2,710 kg/m³ for Aluminum 1100-O.

Which is stiffer, Aluminum 1100-O or Plastic ABS (bulk/injection)?

Aluminum 1100-O is stiffer: Young's modulus 69 GPa against 2.3 GPa for Plastic ABS (bulk/injection), so the same part in Aluminum 1100-O deflects less under the same load.

Which is lighter for the same job, Aluminum 1100-O or Plastic ABS (bulk/injection)?

For the same stiffness or strength: Aluminum 1100-O is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate; Plastic ABS (bulk/injection) is lighter for a strong rod or tie, strong beam, strong panel or plate.

Part that must be	Aluminum 1100-O	Plastic ABS (bulk/injection)
Stiff rod or tie (tension)	lighter	11.5x heavier
Stiff beam (bending)	lighter	2.1x heavier
Stiff panel or plate	lighter	19% heavier
Strong rod or tie	3.35x heavier	lighter
Strong beam	3.08x heavier	lighter
Strong panel or plate	2.95x heavier	lighter

For the same stiffness or strength, mass scales with density over stiffness (or strength) raised to a power set by how the part is loaded: 1 for a rod in tension, 1/2 for a beam in bending, 1/3 for a panel (the standard material-selection indices).

Which conducts heat better, Aluminum 1100-O or Plastic ABS (bulk/injection)?

Aluminum 1100-O conducts heat better: 222 W/m·K against 0.17 W/m·K for Plastic ABS (bulk/injection).

Which expands less with temperature?

Aluminum 1100-O expands less: 23.6 µm/m·K against 95 µm/m·K for Plastic ABS (bulk/injection).

Among 72 materials

Stiffness against density

Strength against density