Table 9.2.3-1

MIL-HDBK-5J, Metallic Materials and Elements for Aerospace Vehicle Structures

Last Updated 29 Oct 2026

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23 tables appear under this heading.

1. PDF page 1418

Property to be Determined or Procedure to be Followed	Designation	Title of Testing Standard	Relevant Section(s) within Guidelines
Bearing	ASTM E 238	Method for Pin-Type Bearing Test of Metallic Materials	9.2.3.2, 1.4.7.1, 3.1.2
Classification of Extensometers	ASTM E 83	Method of Verification and Classification of Extensometers	9.1.3.3, 9.2.4.4.2
Coefficient of Thermal Expansion	ASTM E 228	Test Method for Linear Thermal Expansion of Solid Materials with a Vitreous Silica Dilatometer	9.2.3.4
Compression	ASTM E 9	Compression Testing of Metallic Materials	1.7.1
Creep and Rupture	ASTM E 139	Rec. Practice for Conducting Creep, Creep-Rupture, & Stress-Rupture Tests of Metallic Materials	9.2.3.9
Density	ASTM C 693	Test Method for Density of Glass by Buoyancy	9.2.3.4
Elastic Modulus - Compression	ASTM E 111	Test Method for Young's Modulus, Tangent Modulus, and Chord Modulus	9.2.3.3, 9.8.1.3.1
Elastic Modulus - Shear	ASTM E 143	Test Method for Shear Modulus at Room Temperature	9.8.1.3.1
Elastic Modulus - Tension	ASTM E 111	Test Method for Young's Modulus, Tangent Modulus, and Chord Modulus	9.2.3.3, 9.8.1.3.1
Elongation	ASTM E 8	Test Method for Tension Testing of Metallic Materials	1.4.3.5
Exfoliation Corrosion	ASTM G 34	Test Method for Exfoliation Corrosion Susceptibility in 2XXX and 7XXX Series Aluminum Alloys (EXCO Test)	3.1.2.3.1
Fastener Mechanical Properties	NASM-1312	Fastener Test Methods	9.2.3.10.1
Fatigue Load Control	ASTM E 466	Recommended Practice for Constant Amplitude Axial Fatigue Tests of Metallic Materials	9.6.1
Fatigue Strain Control	ASTM E 606	Recommended Practice for Constant Amplitude Low Cycle Fatigue Testing	9.6.1
Fatigue Crack Growth	ASTM E 647	Test Method for Measurement of Fatigue Crack Growth Rates	9.2.3.6

2. PDF page 1419

Property to be Determined or Procedure to be Followed	Designation	Title of Testing Standard	Relevant Section(s) within Guidelines
Fracture Toughness - Plane Strain	ASTM E 399	Test Method for Plane-Strain Fracture Toughness of Metallic Materials	9.6.3
Fracture Toughness - Plane Stress	ASTM E 561	Recommended Practice for R Curve Determination	9.6.3
Poisson's Ratio	ASTM E 132	Test Method for Poisson's Ratio at Room Temperature	9.8.1.3.1
Shear Pin	ASTM B 769	Test Method for Shear Testing of Aluminum Alloys	9.2.3.2, 3.1.2
Shear Slotted	ASTM B 831	Standard Test Method for Shear Testing of Thin Aluminum Alloy Products	9.2.2
Specific Heat	ASTM D 2766	Test Method for Specific Heat of Liquids and Solids	9.2.3.4
Stress Corrosion Cracking	ASTM G 47	Test Method for Determining Susceptibility to Stress-Corrosion Cracking of High Strength Aluminum Alloy Products	3.1.2.3.1
Tension	ASTM E 8	Test Method for Tension Testing of Metallic Materials	1.4.4.1
	ASTM A 370	Standard Test Methods and Definitions for Mechanical Testing of Steel Products	1.4.4.1
	ASTM B 557	Test Methods of Tension Testing Wrought and Cast Aluminum- and Magnesium-Alloy Products	1.4.4.1
Tension Elevated Temperatures	ASTM E 21	Recommended Practice for Elevated Temperature Tension Tests of Metallic Materials	1.4.4.1
Thermal Conductivity	ASTM C 714	Test Method for Thermal Diffusivity of Carbon and Graphite by a Thermal Pulse Method	9.2.3.4

3. PDF page 1422

Property	Units	Symbol	Recommended ASTM Test Procedures
Density	lb/in.³	ω	C 693
Specific heat	Btu/lb-°F	C	D 2766
Thermal conductivity	Btu(hr-ft²-°F/ft)	K	C 714^a
Mean coefficient of thermal expansion	10^-6(in./in./°F)	α	E 228

4. PDF page 1432

Mechanical or Physical Property	Customary Statistical Basis	Relative Importance in MIL-HDBK-5	Extenuating Circumstances for Special Material Usage Requirements	Minimum Data Requirements			Applicable Handbook Sections
Mechanical or Physical Property	Customary Statistical Basis	Relative Importance in MIL-HDBK-5		Sample Size	No. of Heats	No. of Lots	Applicable Handbook Sections
Bearing Yield and Ultimate Strength^a (Derived)	Same as Tensile Properties	Mandatory	Except for elevated temperature applications	20	3	10	1.4.7.1, 3.1.2, 9.2.3.2, 9.2.3.3
Coefficient of Thermal Expansion	Typical	Strongly recommended	Especially for anticipated range of usage	Triplicate measurements			9.2.3.4.2, 9.2.4.4
Compression Yield Strength^a (Derived)	Same as Tensile Properties	Mandatory		20	3	10	1.7.1, 9.2.3.2, 9.2.3.3
Creep and Rupture	Raw Data w/ Best-Fit Curves	Recommended	Especially for elevated temperature applications	6 tests per creep strain level and temp, at least 4 temps over usage range			9.2.3.5.4, 9.2.5.2
Density	Typical	Mandatory		Duplicate measurements			9.2.3.4.2, 9.2.4.4
Effect of Temperature Curves	Same as Room Temperature Properties	Recommended	Especially for elevated temperature applications	5^b	2	5	9.2.3.3, 9.2.4.4.3
Effect of Thermal Exposure	Same as Baseline Properties	Recommended	Especially for elevated temperature applications	5^b	2	5	9.8.5.5, 9.8.5.6
Elastic Modulus (Tension and Compression)	Typical	Mandatory	Clad materials must have primary and secondary modulus properties defined	9	3	Multi- ple	9.2.3.4.1, 9.2.4.4.1, 9.8.3.2
Elastic Modulus (T and C) -Elevated Temperatures	Typical	Mandatory	For anticipated usage range	9	3	Multi- ple	9.8.3.2
Elongation	S-basis	Mandatory	Two-inch gage length preferred	30	3^c	10	1.4.3.5
Fastener Yield and Ultimate Load	B-basis	Mandatory		100		10	9.2.3.6, 9.2.4.6.1
Fastener Shear Strength	B-basis	Mandatory	At least 15 tests per fastener diameter	100	3	10	9.2.3.6, 9.2.4.6.1, 9.7.1

5. PDF page 1433

Mechanical or Physical Property	Customary Statistical Basis	Relative Importance in MIL-HDBK-5	Extenuating Circumstances for Special Material Usage Requirements	Minimum Data Requirements			Applicable Handbook Sections
Mechanical or Physical Property	Customary Statistical Basis	Relative Importance in MIL-HDBK-5		Sample Size	No. of Heats	No. of Lots	Applicable Handbook Sections
Fatigue-Load Control	Raw Data w/ Best-Fit Curves	Recommended	Especially for high-cycle fatigue critical applications	6 tests per R ratio, 3 R ratios, no minimum heat or lot requirements			9.2.5.1
Fatigue-Strain Control	Raw Data w/ Best-Fit Curves	Recommended	Especially for low-cycle fatigue critical applications	10 tests for R-1.0, 6 tests other strain ratios			9.2.5.1
Fatigue Crack Growth	Raw Data w/ Best-Fit Curves	Recommended	Especially for damage tolerance critical applications	Duplicate da/dN results for relevant stress ratios and stress intensity range			9.2.4.5.2
Fracture Toughness - Plane Strain	Max., Avg., Min., Coef. of Variance, S-basis	Recommended	Mandatory for materials with spec. min. requirements for plain strain fracture toughness	30	3	10	9.2.3.5.3, 9.2.4.6.1, 9.6.3, 9.9.3.1
Fracture Toughness - Plane Stress	Raw Data w/ Best-Fit Curves	Recommended	Mandatory for materials with spec minimum requirements for plane stress fracture toughness		2	5	9.2.3.5.3, 9.2.4.5.3, 9.6.3, 9.9.3.2
Poisson's Ratio	Typical	Strongly recommended		Duplicate measurements			9.8.3.2
Reduction In Area	Typical	Recommended		When tested, use same criteria as for elongation			9.8.3
Shear Ultimate Strength^a	Same as Tensile Properties	Mandatory	Except for elevated temperature applications	20	3	10	1.4.6.4, 9.2.3.2
Specific Heat	Typical	Strongly recommended	Important to document over anticipated usage range	Duplicate measurements			9.2.3.4.2, 9.2.4.4

6. PDF page 1434

Mechanical or Physical Property	Customary Statistical Basis	Relative Importance in MIL-HDBK-5	Extenuating Circumstances for Special Material Usage Requirements	Minimum Data Requirements			Applicable Handbook Sections
Mechanical or Physical Property	Customary Statistical Basis	Relative Importance in MIL-HDBK-5		Sample Size	No. of Heats	No. of Lots	Applicable Handbook Sections
Stress Corrosion Cracking	Letter Rating	Recommended	Especially for susceptible aluminum alloys	Conform to replication requirements in G47			3.1.2.3
Stress/Strain Curves (To Yield)	Typical	Mandatory	Desirable to have accurate plastic strain offsets from 10% to 3 x 10-2	6	3	6	9.8.4.1
Stress/Strain Curves (Full Range)	Typical	Mandatory		6	3	6	9.8.4.1, 9.8.4.3
Tension Yield and Ultimate Strength	S-basis	Mandatory		30	3	Multiple	1.4.4.1
Tension Yield and Ultimate Strength	A- and B-basis	Strongly recommended	Especially for strength critical applications; a parametric representation of data is possible	100	10	10	1.4.4.1
Tension Yield and Ultimate Strength	A- and B-basis	Strongly recommended	Especially for strength critical applications; a parametric representation of data is not possible	299	10	10	1.4.4.1
Tension Yield and Ultimate Strength Elevated Temps	Typical	Recommended	Mandatory for elevated temperature applications	e	2	5	1.4.4.1
Thermal Conductivity	Typical	Strongly recommended	Important to document over anticipated usage range	Duplicate measurements			9.2.3.4.2, 9.2.4.4

7. PDF page 1435

Lot Number^a,b,c	Test Specimen Requirements
	TUS & TYS^d,e,f,g			CYS^d,e,g			SUS^h			BUS & BYS¹, e/D = 1.5		BUS & BYS¹, e/D = 2.0
	L	LT	ST^j	L	LT	ST	L	LT	ST	L	LT^j	L	LT
A	2^k	2	2			2	2	2	2	2	2		2
B	2	2	2	222222	22N	2	2	2	2		2	2222222222	2
C	2	2	2				2	2	2		2		2
Ꭰ	2	2			2		2	2	2		2		2
E	2	2	222			2222	2	2	2				2
F	2	2			2222		2	2	2	2222222	NN		2
G	2	2	2	2		2	2	2	2		2		2
H	2	2	2	2		2	2	2	2		2		2
I	2	2	2	2	2	2	2	2	2	2	2		2
J	2	2	2	2	2	2	2	2	2	2	2		2

8. PDF page 1455

BASE MATERIAL
Alloy:	6061 Aluminum per AMS-QQ-A-250/11
Form:	Sheet
Preweld Heat Treat Condition:	T4 or T6
Postweld Heat Treat Condition:	As-Welded
Material Thickness:	0.09 inch
Filler Material:	4043 per QQ-B-655
WELDING VARIABLES
Joint Preparation
Joint Type:	Butt
Edge Preparation:	Square Groove
Cleaning:	Deoxidize, solvent wipe and hand scrape
Tooling:	None Specified
Welding Conditions
Process:	Mechanized GTA
Sequence:	Single Pass
Position:	Flat
Heat Input:	Not Specified
Weld Repair:	None
WELDMENT QUALITY
Inspection Methods
	Visual
	Radiographic, Mil-Std-453
	Penetrant, Mil-I-6866
Acceptance Levels
External
Weld Beads:	Removed Flush
Underfill and Undercut:	None Allowed
Cracks:	None Allowed
Pores:	*Maximum size 0.02-inch, one per inch
Mismatch:	10% of Thickness Maximum
Internal
Pores and Inclusions:	*Maximum Size 50% T or 0.12 inch whichever is lesser. Maximum accumulated amount less than 2% of cross section area.
*Sharp-tailed or crack-like indications not allowed, appropriate acceptance levels will be added.

9. PDF page 1458

Alloy Trade Name	The information to be entered be-tween these two columns	Heat No.	Lot N.	UTS, ksi	TYS, ksi	Elongation %	Red. of Area, %	Elastic Modulus, ksi




	depends upon the product form, see Table 9.3.3.

10. PDF page 1469

or	TUS = a + bx,
	(SUS/TUS) = a + bx,
or	(SUS/TUS) = a + bx + cx²,

11. PDF page 1475

Symbol	Definition	Section
$\alpha$	true intercept of the regression equation
$\beta$	true coefficient of the linear term in the regression equation
$\gamma$	true coefficient of the quadratic term in the regression equation
$\epsilon$	measurement or experimental error by which y differs from the ideal linear relationship

12. PDF page 1478

Degrees of Freedom
Source of Variation	Linear	Quadratic	Sum of Squares, SS	Mean Squares, MS	F_calc
Regression	1	2	SSR	MSR	F₁
Error	n-2	n-3	SSE	MSE	F₁
Lack of Fit	k-2	k-3	SSLF	MSLF	F₂
Pure Error	n-k	n-k	SSPE	MSPE	F₂
Total	n-1	n-1	SST

13. PDF page 1480

X	Y
0.100	121
0.100	119
0.200	114
0.200	108
0.300	112
0.300	108
0.400	112
0.400	106
0.500	101
0.500	99

14. PDF page 1485

	Product A	Product B
Sample size	n_A	n_B
Sample standard deviation	s_A	s_B
Sample mean	¯X_A	¯X_B

15. PDF page 1486

	Product A	Product B
Sample size	n_A	n_B
Sample standard deviation, ksi	s_A	s_B
Sample mean, ksi	X̄_A	X̄_B

16. PDF page 1513

	R = F_cy(L) / F_ty(LT)
or	F_cy(L) = RF_ty(LT)
similarly	F_cy(LT) = RF_ty(LT)
and	F_cy(ST) = RF_ty(LT)

17. PDF page 1564

D	D²	t	t/D	P_y/10⁴D²	P_y	P_u/10⁴D²	P_u

18. PDF page 1589

Property	Units	Symbol	Recommended ASTM Test Procedures
Modulus of Elasticity
In tension	1000 ksi	E	E 111
In compression	1000 ksi	E_c	E 111
In shear	1000 ksi	G	E 143
Poisson’s Ratio	(Dimensionless)	μ	E 132

19. PDF page 1601

Percent	Test 1		Test 2		Average		Typical
Percent	Stress, ksi σ₁	Strain Departureᵊ in./in. (D₁)	Stress, ksi σ₂	Strain Departureᵊ in./in. (D₂)	Stress, ksi σ_A	Strain Departureᵋ in./in. (D_A)	Stress, ksi σ_T	Strain Departureᵌ in./in. (D_T)	Elastic Strainᵍ in./in. (ε_e)	Total Strainᵒ in./in. (ε_t)
Yield Stress to Ultimate Stress
Proportional Limit (PL)	56.5		58.5		57.5ᵏ		59.6ᵌ	0.0000	0.0058	0.0058
0(TYS)	58.8ᵈ	0.0020	60.9ᵈ	0.0020	59.8	0.0020	62.0ᵌ	0.0020	0.0061	0.0081
20	61.0ᵈ	0.0106	63.0ᵈ	0.0094	62.0	0.0100	64.0ᵌ	0.0100	0.0063	0.0163
40	63.2ᵈ	0.0204	65.2ᵈ	0.0194	64.2	0.0199	66.0ᵌ	0.0200	0.0065	0.0265
60	65.4ᵈ	0.0302	67.4ᵈ	0.0302	66.4	0.0302	68.0ᵌ	0.0303	0.0067	0.0370
80	67.7ᵈ	0.0452	69.5ᵈ	0.0436	68.6	0.0444	70.0ᵌ	0.0446	0.0069	0.0515
95	69.3ᵈ	0.0640	71.1ᵈ	0.0626	70.2	0.0633	71.5ᵌ	0.0636	0.0070	0.0706
100(TUS)	69.9ᵈ	0.0848	71.7ᵈ	0.0838	70.8	0.0843	72.0ᵌ	0.0847	0.0071	0.0918
Ultimate Stress to Fracture Stress (FS)
100(TUS)	69.9ᵉ	0.0848	71.7ᵉ	0.0838	70.8	0.0843	72.0ᵍ	0.0847	0.0071	0.0918
90	69.0ᵉ	0.0962	70.9ᵉ	0.1014	70.0	0.0988	71.1ᵎ	0.0992	0.0070	0.1062
60	66.3ᵉ	0.1058	68.5ᵉ	0.1156	67.4	0.1107	68.5ᵎ	0.1112	0.0067	0.1179
0(FS)	60.9ᵉ	0.1210	63.7ᵉ	0.1378	62.3	0.1294	63.4ᵏ	0.1300 (Elong.)	0.0062	0.1362

20. PDF page 1608

(p)	=	Primary load direction for shear
F_ty(L)	=	Tensile yield stress, longitudinal direction
F_ty(LT)	=	Tensile yield stress, long transverse direction
F_cy(L)	=	Compressive yield stress, longitudinal direction
F_cy(LT)	=	Compressive yield stress, long transverse direction
F_su	=	Shear ultimate stress
F_tu(L)	=	Tensile ultimate stress, longitudinal direction
F_tu(LT)	=	Tensile ultimate stress, long transverse direction.

21. PDF page 1616

Exposure		TUS at 400 °F, ksi
Time, hr	Temp, °F	TUS at 400 °F, ksi
1000	400	80.0
1	500	83.0
10	500	78.0

22. PDF page 1630

Product Forms:	Test Parameters:
Die forging, 10 x 20 inches	Loading - Axial
CEVM	Frequency - 1800 to 2000 cpm
Die forging, 6-1/2 x 20 inches	Temperature - RT
CEVM	Atmosphere - Air
RCS billet, 6 inches CEVM	No. of Heat/Lots:
Forged Bar, 1.25 x 8 inches	6
CEVM
Properties:	Equivalent Stress Equation:
TUS, ksi	Log N_f = 14.8-5.38 log (S_eq-63.8)
274-294	S_eq = S_a + 0.48 S_m
TYS, ksi	Std. Error of Estimate, Log (Life) = 55.7 (1/S_eq)
227-247	Standard Deviation, Log (Life) = 1.037
Temp., °F	R² = 82.0
RT
Specimen Details:
Unnotched	Sample Size:
0.200 - 0.250 inch diameter	104
Surface Condition:	[Caution: The equivalent stress model may provide unrealistic life predictions for stress ratios beyond those represented above.]
Heat treat and finish grind to a surface finish of RMS 63 or better with light grinding parallel to specimen length, stress relieve



References:
2.3.1.4.8(a), (c), (d), (e)

23. PDF page 1651

Material	Material Thickness	Weld Joint Type	Filler Wire Alloy	Heat Treat After Welding	Properties
					F_tu ▷²		F_tu ▷³
					A	B	A	B
6061-T4	Up to 0.30	Sq. Butt	4043	Aged to T6
6061-T4	Above 0.30	Groove	4043	Aged to T6
6061-T4 6061-T6	Up to 0.30	Sq. Butt	4043	As- Welded
6061-T4 6061-T6	Above 0.30	Groove	4043	As- Welded
6061-F	Up to 0.30	Sq. Butt	4043	Sol. Ht and Age to T6
6061-F	Above 0.30	Groove	4043	Sol. Ht and Age to T6