Aluminum vs. Solder SAC305

Compare Aluminum vs. Solder SAC305 strength, stiffness, weight and thermal properties.

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Mechanical
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Yield strength	276MPasourcetypical, 0.2% offset, .500 in dia specimen	22MPasourcetypical
Ultimate tensile strength	310MPasourcetypical7.83x stronger	39.6MPasourcetypical
Elongation at break	17%sourcetypical, in 4D, 0.500 in dia specimen	49%sourcetypical
Young's modulus (stiffness)	68.3GPasourcetypical	6.9GPasourcetypical, temperature and strain rate not stated
Density	2,700kg/m³sourcenominal	7,350kg/m³sourcetypical
Strength to weight	102kN·m/kg34.2x higher	2.99kN·m/kg
Stiffness to weight	25.3MN·m/kg26.9x higher	0.939MN·m/kg
Poisson's ratio	0.33sourcetypical (handbook physical constant)	0.35sourcetypical
Shear modulus	25.7GPa10x stiffer in shear	2.56GPa
Bulk modulus	67GPa	7.67GPa
Speed of sound	5,030m/s	969m/s
Thermal
Thermal conductivity	167W/m·Ksourcetypical, 20 °C	61W/m·Ksourcetypical, temperature not stated
Thermal expansion	23.6µm/m·Ksourcetypical, mean 20-100 °C	21.9µm/m·Ksourcemean, 20-100 °C (MacDermid Alpha)
100 mm part over a 50 °C swing	118µm growth	110µm growth8% less
Specific heat	896J/kg·Ksourcetypical, at 100 °C	232J/kg·Ksourcetypical (MacDermid Alpha)
Heats up and cools (diffusivity)	69mm²/s1.93x faster	35.8mm²/s
Thermal shock resistance	19,159W/m3.32x more resistant	5,773W/m
Melting point	582–652°Csourcesolidus-liquidus	217–220°Csourcesolidus-liquidus
Values for	6061-T6/T651, Kaiser Aluminum typical properties (sheet, coil & plate datasheet); Poisson from MIL-HDBK-5J	SAC305 (Sn96.5Ag3.0Cu0.5) solder alloy, bulk; Indium Corporation Indalloy 256 (SAC305) for Preforms product data sheet (Form No. 100346 R0, 2024), selected properties, test temperature not stated; expansion and specific heat from MacDermid Alpha VACULOY SAC TDS (06 September 2023).

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 stronger than Solder SAC305?

Aluminum is stronger: its yield strength is 276 MPa against 22 MPa for Solder SAC305 (12.5x).

Which is lighter, Aluminum or Solder SAC305?

Aluminum is lighter: 2,700 kg/m³ against 7,350 kg/m³ for Solder SAC305.

Which is stiffer, Aluminum or Solder SAC305?

Aluminum is stiffer: Young's modulus 68.3 GPa against 6.9 GPa for Solder SAC305, so the same part in Aluminum deflects less under the same load.

Which is lighter for the same job, Aluminum or Solder SAC305?

For the same stiffness or strength: Aluminum is lighter for a stiff rod or tie (tension), stiff beam (bending), stiff panel or plate, strong rod or tie, strong beam, strong panel or plate.

Part that must be	Aluminum	Solder SAC305
Stiff rod or tie (tension)	lighter	26.9x heavier
Stiff beam (bending)	lighter	8.56x heavier
Stiff panel or plate	lighter	5.84x heavier
Strong rod or tie	lighter	34.2x heavier
Strong beam	lighter	14.7x heavier
Strong panel or plate	lighter	9.64x heavier

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 or Solder SAC305?

Aluminum conducts heat better: 167 W/m·K against 61 W/m·K for Solder SAC305.

Which expands less with temperature?

Solder SAC305 expands less: 21.9 µm/m·K against 23.6 µm/m·K for Aluminum.

Among 72 materials

Stiffness against density

Strength against density