Aluminum 6063-T6 vs. Plastic ABS (bulk/injection)

Compare Aluminum 6063-T6 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	215MPasourcetypical, T6, 0.0625 in specimen	45MPasourcetypical, tensile stress at yield 23 °C
Ultimate tensile strength	240MPasourcetypical, T6	not sourced
Flexural strength	not sourced	65MPasourcetypical, 23 °C
Elongation at break	12%sourcetypical, T6, in 4D	10%sourcenominal strain at break, 23 °C
Young's modulus (stiffness)	69GPasourcetypical30x stiffer	2.3GPasourcetypical
Density	2,700kg/m³sourcenominal, 20 °C	1,040kg/m³sourcetypical
Strength to weight	79.6kN·m/kg1.84x higher	43.3kN·m/kg
Stiffness to weight	25.6MN·m/kg11.6x 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	5,055m/s	1,487m/s
Thermal
Thermal conductivity	201W/m·Ksourcetypical, T6, 20 °C	0.17W/m·Ksourcetypical
Thermal expansion	23.4µm/m·Ksourcetypical, mean 20-100 °C	80–110µm/m·Ksourcerange
100 mm part over a 50 °C swing	117µm growth4.06x less	475µm growth
Specific heat	901J/kg·Ksourcetypical, 20 °C (Hydro EN AW-6063)	not sourced
Heats up and cools (diffusivity)	82.6mm²/s	not sourced
Thermal shock resistance	not sourced	21.4W/m
Melting point	615–655°Csourcemelting range	not sourced
Max service temperature	not sourced	94°CsourceHDT 1.8 MPa (annealed 4 h/80 °C)
Values for	6063-T6 extruded tube, Kaiser Aluminum Tube & Pipe Alloy 6063 Technical Data (Rev. 05/06), typical properties; specific heat from Hydro EN AW-6063 extruded-products datasheet (Rev.4, 03/2023).	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 6063-T6 stronger than Plastic ABS (bulk/injection)?

Aluminum 6063-T6 is stronger: its yield strength is 215 MPa against 45 MPa for Plastic ABS (bulk/injection) (4.78x).

Which is lighter, Aluminum 6063-T6 or Plastic ABS (bulk/injection)?

Plastic ABS (bulk/injection) is lighter: 1,040 kg/m³ against 2,700 kg/m³ for Aluminum 6063-T6.

Which is stiffer, Aluminum 6063-T6 or Plastic ABS (bulk/injection)?

Aluminum 6063-T6 is stiffer: Young's modulus 69 GPa against 2.3 GPa for Plastic ABS (bulk/injection), so the same part in Aluminum 6063-T6 deflects less under the same load.

Which is lighter for the same job, Aluminum 6063-T6 or Plastic ABS (bulk/injection)?

For the same stiffness or strength: Aluminum 6063-T6 is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate, strong rod or tie, strong beam; Plastic ABS (bulk/injection) is lighter for a strong panel or plate.

Part that must be	Aluminum 6063-T6	Plastic ABS (bulk/injection)
Stiff rod or tie (tension)	lighter	11.6x heavier
Stiff beam (bending)	lighter	2.11x heavier
Stiff panel or plate	lighter	20% heavier
Strong rod or tie	lighter	1.84x heavier
Strong beam	lighter	9% heavier
Strong panel or plate	19% 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 6063-T6 or Plastic ABS (bulk/injection)?

Aluminum 6063-T6 conducts heat better: 201 W/m·K against 0.17 W/m·K for Plastic ABS (bulk/injection).

Which expands less with temperature?

Aluminum 6063-T6 expands less: 23.4 µm/m·K against 95 µm/m·K for Plastic ABS (bulk/injection).

Among 72 materials

Stiffness against density

Strength against density