Aluminum 3003-O vs. Plastic ABS (bulk/injection)

Compare Aluminum 3003-O vs. Plastic ABS (bulk/injection) strength, stiffness, weight and thermal properties.

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

Mechanical	Aluminum 3003-O	Plastic ABS (bulk/injection)
Yield strength	40MPa1	45MPa213% stronger
Ultimate tensile strength	110MPa1	not stated (yield given)
Flexural strength	not sourced	65MPa2
Elongation at break	30%13x more ductile	10%2
Young's modulus (stiffness)	69GPa130x stiffer	2.3GPa2
Density	2,730kg/m³1	1,040kg/m³22.63x lighter
Strength to weight	14.7kN·m/kg	43.3kN·m/kg2.95x higher
Stiffness to weight	25.3MN·m/kg11.4x higher	2.21MN·m/kg
Poisson's ratio	not sourced	0.393
Shear modulus	not sourced	0.827GPa
Bulk modulus	not sourced	3.48GPa
Speed of sound	5,027m/s3.38x faster	1,487m/s

Stiffness against densityHigher and further left: stiffer for its weight

Strength against densityHigher and further left: stronger for its weight

Thermal	Aluminum 3003-O	Plastic ABS (bulk/injection)
Thermal conductivity	193W/m·K11,135x more heat through a fin	0.17W/m·K2
Thermal expansion	23.2µm/m·K1	range80–110µm/m·K2
100 mm part over a 50 °C swing	116µm growth4.09x less	475µm growth
Specific heat	not sourced	not sourced
Heats up and cools (diffusivity)	not sourced	not sourced
Thermal shock resistance	not sourced	21.4W/m
Melting point	melting range640–655°C1	not sourced
Max service temperature	not sourced	HDT 1.8 MPa94°C2

Thermal conductivity against densityHigher and further left: spreads more heat for its weight

Thermal expansion against thermal conductivityLower and further right: warps less when heated

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Sources3 documents: Kaiser Aluminum, INEOS Styrolution, Covestro

Aluminum 3003-O: 3003-O (annealed) aluminium-manganese alloy, the heat-exchanger tube and brazing alloy, Kaiser Aluminum Tube & Pipe Alloy 3003 Technical Data (Rev. 05/06), typical properties; specific heat from the NIST cryogenic 3003-F fit at 293 K.
Plastic ABS (bulk/injection): INEOS Styrolution Terluran GP-22 general-purpose injection-molding ABS, ISO typical values (TDS revision 08/01/2022)

1
Alloy 3003 Tube & Pipe Technical Data, Rev. 05/06Kaiser Aluminumarchived copyAluminum 3003-O · Yield strength: typical, O, 0.0625 in specimenAluminum 3003-O · Ultimate tensile strength: typical, OAluminum 3003-O · Elongation at break: typical, O, in 4DAluminum 3003-O · Young's modulus (stiffness): typicalAluminum 3003-O · Density: nominal, 20 °CAluminum 3003-O · Thermal conductivity: typical, O, 20 °CAluminum 3003-O · Thermal expansion: typical, mean 20-100 °CAluminum 3003-O · Melting point: melting range
2
Terluran GP-22 (ABS) Product Data SheetINEOS StyrolutionPlastic ABS (bulk/injection) · Yield strength: typical, tensile stress at yield 23 °CPlastic ABS (bulk/injection) · Flexural strength: typical, 23 °CPlastic ABS (bulk/injection) · Elongation at break: nominal strain at break, 23 °CPlastic ABS (bulk/injection) · Young's modulus (stiffness): typicalPlastic ABS (bulk/injection) · Density: typicalPlastic ABS (bulk/injection) · Thermal conductivity: typicalPlastic ABS (bulk/injection) · Thermal expansion: rangePlastic ABS (bulk/injection) · Max service temperature: HDT 1.8 MPa (annealed 4 h/80 °C)
3
Engineering Polymers Part and Mold Design: Thermoplastics, A Design GuideCovestroarchived copyPlastic ABS (bulk/injection) · Poisson's ratio: typical, ABS family (Covestro Part and Mold Design guide, Table 3-1)

Each number points to the document that states it, with the exact basis. Values without a number are computed from the sourced ones. "Not sourced" means no citable source states it (or only a specification minimum); figures computed from it are left out too.

Questions

Mechanical

Is Aluminum 3003-O stronger than Plastic ABS (bulk/injection)?

Plastic ABS (bulk/injection) is stronger: its yield strength is 45 MPa against 40 MPa for Aluminum 3003-O (13%).

Which is lighter, Aluminum 3003-O or Plastic ABS (bulk/injection)?

Plastic ABS (bulk/injection) is lighter: 1,040 kg/m³ against 2,730 kg/m³ for Aluminum 3003-O.

Which is stiffer, Aluminum 3003-O or Plastic ABS (bulk/injection)?

Aluminum 3003-O is stiffer: Young's modulus 69 GPa against 2.3 GPa for Plastic ABS (bulk/injection), so the same part in Aluminum 3003-O deflects less under the same load.

Which is lighter for the same job, Aluminum 3003-O or Plastic ABS (bulk/injection)?

For the same stiffness or strength: Aluminum 3003-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 3003-O	Plastic ABS (bulk/injection)
Stiff rod or tie (tension)	lighter	11.4x heavier
Stiff beam (bending)	lighter	2.09x heavier
Stiff panel or plate	lighter	18% heavier
Strong rod or tie	2.95x heavier	lighter
Strong beam	2.84x heavier	lighter
Strong panel or plate	2.78x 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 is more ductile, Aluminum 3003-O or Plastic ABS (bulk/injection)?

Aluminum 3003-O stretches further before it breaks: 30% elongation at break against 10% for Plastic ABS (bulk/injection).

Thermal

Which conducts heat better, Aluminum 3003-O or Plastic ABS (bulk/injection)?

Aluminum 3003-O conducts heat better: 193 W/m·K against 0.17 W/m·K for Plastic ABS (bulk/injection).

Which expands less with temperature?

Aluminum 3003-O expands less: 23.2 µm/m·K against 95 µm/m·K for Plastic ABS (bulk/injection).