Mechanical Properties of Materials Explained

In the world of sheet metal fabricators, understanding the science behind what are mechanical properties is extremely important. Whether we’re forming, cutting, welding or shaping metal, we must have a deep knowledge of how different materials respond to force and stress. This is essential to ensure durability, performance and safety in the final product.

Selecting the appropriate material involves evaluating its mechanical properties. These are the characteristics that determine how a material reacts when subjected to mechanical loads. These properties help us predict how a component will perform under operational conditions. It also influences everything from cost and efficiency to lifespan and structural integrity.

Our handy guide will discuss:

• what are mechanical properties
• the key mechanical properties of some common metals and alloys
• explain their relevance to a wide range of fabrication and engineering applications

Keep reading for more information!

What are mechanical properties?

Mechanical properties describe how a material responds when external forces are applied to it. This includes properties like tensile strength, elasticity, ductility and toughness (more of that to follow). Unlike physical properties (such as density or melting point) mechanical properties are about how a material performs under load, strain or deformation. Understanding these behaviours is fundamental when designing components expected to endure various stresses. This could be a support bracket within a structure, a sheet formed panel in an automotive application, or a precision cut component in electronics.

On the other hand, physical properties are not influenced by applied forces. This includes density, melting point, thermal conductivity and electrical resistivity. To put it simply, physical properties determine how a material interacts with its environment, while mechanical properties tell us how it will perform when under operational stress.

Key mechanical properties of metals

Here is a detailed overview of the primary mechanical properties relevant to sheet metal fabrication services and metalworking in general.

Hardness

Hardness is the resistance of a material to deformation, scratching or wear. It is also related to how well one metal can cut into another. Hardness is usually tested using Brinell, Rockwell or Vickers methods.

Toughness

Toughness is the ability of a material to absorb energy and resist fracture. It combines strength and ductility and is vital for parts exposed to impact or shock loads.

Elasticity

Highly elastic materials return to their original shape once the force is removed. Metals like steel are highly elastic as they return to their original dimensions after small deformations.

Plasticity

This is the ability of a material to undergo permanent deformation without breaking. It is a vital property for metal forming processes such as bending, forging or rolling.

Malleability

This property enables a material to be deformed under compressive forces into thin sheets. Aluminium and copper are both highly malleable materials.

Stiffness

Stiffness refers to a material’s resistance to elastic deformation under load. A stiffer material bends less under the same force. This is typically measured using the modulus of elasticity (Young’s Modulus).

Ductility

Ductility refers to a material’s capacity to be stretched into a wire or thin form without breaking. It is usually measured by the percentage elongation or reduction in area before fracture. Common ductile metals include copper, aluminium and mild steel.

Resilience

This is a measure of a material’s capacity to absorb energy within its elastic range. Resilient metals are often used for springs and components that experience frequent shock or vibration.

Strength

This is the ability of a material to withstand applied force without failure. This includes tensile strength, compressive strength, and shear strength.

Fatigue

Fatigue is the gradual weakening of a material due to repeated loading and unloading cycles, often leading to failure at stress levels well below the material’s tensile strength. It is a major consideration in rotating machinery and structural components.

Brittleness

Brittle materials fracture without significant deformation. Unlike ductile metals, they do not stretch or compress much before breaking. Cast iron is a classic example.

Machinability

Machinability refers to how easily a metal can be cut, shaped or finished. Metals like brass and aluminium are considered highly machinable, making them suitable for precision engineering.

Creep

Creep occurs when a material slowly deforms under constant stress at elevated temperatures. It is a crucial consideration in high temperature applications such as engines, turbines and boilers.

For more information like this, you can check out our other blog – What is the Strongest Metal?

Applying mechanical properties in sheet metal fabrication

The relevance of these properties becomes clearer when choosing materials for specific fabrication tasks. By carefully selecting a material based on its mechanical properties, sheet metal fabricators can ensure performance, longevity and safety in the final product.

For example:

• Laser cutting services benefit from materials with good machinability and low hardness
• Welding services require materials with appropriate ductility and strength
• Forming or metal folding relies on malleability and plasticity
• High impact components demand toughness and resilience
• Long term load bearing parts need excellent fatigue resistance

Mechanical properties of common metals

Material	Tensile Strength (MPa)	Yield Strength (MPa)	Hardness (HB)	Elastic Modulus (GPa)	Ductility (%)
Mild Steel	400-550	250-350	120-180	200	20-25
Stainless Steel (304)	520-750	210-275	150-200	193	40-50
Aluminium (6061)	240-310	55-276	95	69	12-20
Copper	210-360	70-210	35-110	110	25-45
Brass	300-550	100-200	100-180	100	30-35
Titanium (Grade 2)	345	275	70-100	105	20-30
Cast Iron	200	130	180-240	100	<1
Tool Steel	500-1,200	400-1,000	200-900	210	10-20
Inconel 625	827-1,100	414-758	250-400	207	30-50
Zinc	90-150	50-110	30-50	83	5-10
Nickel	340-620	140-300	100-200	200	40-50
Magnesium Alloy	200-350	100-200	45-90	45	5-10
Bronze	350-700	130-250	60-200	110	15-30
Lead	12-17	5	5	16	>50
Chromium	350-550	250-400	110-160	279	10-20

For a more information like this you may like our other blog – Where Does Metal Come From?

Other types of material properties

Materials exhibit a wide range of other properties in addition to mechanical properties. We’ve listed some of them below.

Thermal properties

Thermal performance is critical in applications that involve high or fluctuating temperatures. For example, in industries such as automotive, aerospace and construction.

Key thermal properties include:

• Thermal conductivity: a measure of how effectively heat flows through the material.
• Specific heat capacity: the amount of energy needed to raise the material’s temperature.
• Boiling and melting points: essential for selecting materials that must endure extreme heat or undergo phase changes

Electrical properties

Electrical properties tell us how materials behave when exposed to electric fields. This includes whether a material conducts or insulates electricity and its ability to resist electrical breakdown. Another consideration is piezoelectricity, which is the capacity of certain materials to produce electric charge under mechanical stress. These properties are vital in electronics, sensors, circuit boards and control systems.

Optical properties

These define how a material interacts with light. It is especially relevant in display technologies, solar panels and lighting systems. Measurements include the amount of light that passes through the material, how light is bent or reflected, absorbance and colour.

Magnetic properties

Magnetic behaviour varies greatly between different metals and involves hysteresis and permeability, which relate to how materials retain and transmit magnetic energy. These are essential in the design of electric motors, transformers and magnetic shielding.

Chemical properties

Chemical reactivity and stability are vital for material selection in harsh or corrosive environments. Key attributes include corrosion resistance and reactivity, as well as pH behaviour and surface energy. This is really important for bonding, plating and coating applications.

Acoustic properties

In applications that require sound management, materials are assessed for sound absorption, reflection and transmission. The speed of sound through the material is also influenced by density and elasticity.

Manufacturing properties

This includes machinability, formability, castability and weldability. This all helps to determine how easily or efficiently a material can be shaped or joined. This often involves fatigue limits and elastic modulus, which affect how materials behave during and after fabrication.

Contact Salamander Fabrications today for your sheet metal fabrication needs! 

Whether you need components for the transportation, energy, construction or manufacturing sectors, the right knowledge of material properties can mean the difference between a reliable part and a costly failure.

With over 50 years of industry expertise, Salamander Fabrications is a trusted name in UK based sheet metal solutions. From laser cutting and CNC folding to powder coating and assembly, we bring precision and quality to every project. 

Our team is on hand to help you select the right material for your application, one that matches your needs in both mechanical performance and cost efficiency. Get in touch today for tailored advice, a quote, or to learn more about how we can support your project.

Visit our contact page, call us on 01484 843599, or email sales@salamanderfabs.com.