AR500 Steel Sheet Metal

AR500 steel: abrasion resistance, cutting methods, and applications

Key things to know about AR500 steel

Top 5 must-know things about AR500

• AR500 is a quenched and tempered abrasion-resistant steel with a Brinell hardness of 470–530 HBW.
• Designed to withstand heavy wear, impact, and repeated stress without deforming.
• SendCutSend laser cuts AR500 with ±0.005″ tolerance.
• Available in multiple thicknesses up to 0.500″, shipped in 2–4 business days.
• Too hard for bending or forming — best used flat, in its as-cut state.

Additional key things to know about AR500

• Much harder and more wear-resistant than mild steel or even AR400.
• Tough to machine or modify once hardened — best to design parts to final shape.
• Welding is possible but requires preheat and special filler metals.
• Commonly used in targets, armor plating, off-road parts, mining, and construction.
• Post-cutting services at SendCutSend include tapping, PEM hardware, dimpling, and powder coating.

What is AR500 steel?

AR500 belongs to the abrasion-resistant (AR) family of steels. The “AR” stands for Abrasion Resistant, and the “500” refers to its nominal hardness on the Brinell scale (470–530 HBW). To achieve this hardness, the steel is quenched and tempered, giving it the ability to take repeated impact and resist surface wear far better than standard steels.

While mild steels are valued for ductility and ease of forming, AR500 is engineered for durability. It’s the go-to material when parts must survive constant abuse, scraping, or impact — such as in armor, mining chutes, or wear liners.

What are the properties of AR500?

AR500 is defined by its balance of hardness and strength. Typical values include:

• Hardness: 470–530 HBW
• Yield strength: ~160 ksi
• Tensile strength: ~200 ksi
• Density: 0.283 lb/in³

That hardness makes it highly resistant to deformation, but it also limits formability. AR500 is not designed to bend or stretch; it is best used in flat profiles that will see direct wear or impact.

Can AR500 be laser cut?

Yes. At SendCutSend, AR500 is cut with industrial fiber lasers, which can handle its hardness with precision.

• Laser cutting vs plasma/oxy-fuel: Plasma and torch cutting can cause significant heat-affected zones (HAZ), leading to edge softening or cracking. Fiber lasers keep the HAZ small and produce much smoother, more consistent edges.
• Tolerances: We hold ±0.005″ across all thicknesses.
• Edge quality: Clean and sharp, with minimal dross.

Because of its toughness, AR500 is not practical to cut with shop tools. Abrasive saws, drills, or hobby-grade cutters wear out quickly and leave inconsistent results.

What edge condition issues are expected with AR500?

Like other steels, AR500 develops a small heat-affected zone during cutting. With plasma or torch methods, this zone can be large enough to soften the material at the edges — compromising its wear resistance.

Fiber laser cutting keeps the HAZ narrow, so edge hardness is preserved much better. At SendCutSend, nitrogen assist gas is used to avoid oxidized edges, leaving AR500 parts ready for finishing or use.

Can AR500 be welded, bent, or formed?

• Bending: Not recommended. AR500’s hardness makes it brittle under sharp forming. Attempts to bend it often result in cracking. If your design requires bent features, a different material such as A36 steel or 5052 aluminum may be a better choice.
• Welding: Possible, but requires special precautions:
  • Preheat the steel to reduce cracking risk.
  • Use low-hydrogen filler metals.
  • Expect hardness loss in the heat-affected zone.

For most applications, AR500 is used flat, in its as-cut condition.

What are typical applications of AR500?

AR500 excels anywhere that wear, impact, or abrasion would quickly destroy softer metals. Common uses include:

• Armor plating (personal, vehicle, or structural).
• Shooting targets (resists pitting and deformation from repeated impact).
• Off-road and heavy equipment (skid plates, wear strips, and protective panels).
• Mining and construction (liners, buckets, chutes, and hoppers).

Its durability makes it indispensable in industries where uptime and reliability are critical.

How does AR500 compare to other AR grades?

• AR400: Slightly softer (400 HBW). Easier to machine and form but less wear-resistant.
• AR500: The sweet spot for impact resistance, balancing hardness with availability.
• AR550/AR600: Even harder, but more difficult to source and process. Typically used in specialty ballistic or industrial applications.

For most projects, AR500 provides the best combination of availability, toughness, and value.

Does AR500 rust?

Yes. Despite its hardness, AR500 is still carbon steel and will rust if exposed to moisture and air. To protect AR500 parts, coatings are recommended:

• Powder coating: Available in-house at SendCutSend, adds a durable, chip-resistant protective layer.
• Paint or primer: Common for targets or equipment exposed outdoors.
• Galvanizing: Rare for AR500 due to its hardness, but possible in some applications.

If corrosion resistance is a priority, a stainless option such as 304 or 316 stainless may be better.

How much does AR500 cost?

AR500 is more expensive than mild steels (like A36) due to its specialized production, but it is often more affordable than stainless steels when cost is compared per unit of performance.

The real value is in longevity: while A36 may wear out quickly in abrasive use, AR500 can last many times longer, reducing replacement costs.

For instant pricing, upload your design to the SendCutSend quote system.

When should you fabricate AR500 yourself vs outsource?

AR500 is notoriously difficult to machine or cut with shop tools. Saw blades, drill bits, and consumables wear out extremely quickly, and plasma or torch methods often ruin edge hardness.

Outsourcing AR500 cutting to SendCutSend provides:

• ±0.005″ precision with laser cutting.
• Minimal HAZ to preserve hardness.
• Optional services like tapping, PEM hardware, and powder coating.
• Parts shipped in 2–4 days.

For most shops and hobbyists, outsourcing saves both time and money compared to fighting with AR500 in-house.

What finishing or post-cutting services can be applied?

Although AR500 is best left flat and unbent, SendCutSend offers several services to make it safer and easier to use:

• Tumbling: Smooths sharp edges for handling safety.
• Powder coating: Adds corrosion resistance and aesthetic options.
• Tapping: Threads holes directly into your parts.
• PEM hardware insertion: Strong, reusable fasteners installed in thin sections.
• Dimple forming: Reinforces holes or creates clearance for flush fasteners.

These services streamline the fabrication process, especially since AR500 is otherwise very tough on tooling.

In review: AR500 

AR500 is built for toughness, making it one of the most durable steels you can work with. Its extreme hardness gives it excellent resistance to wear and impact, making it indispensable for armor, targets, and heavy-duty equipment. While it’s too hard for bending or easy machining, laser cutting at SendCutSend unlocks its potential, providing precise, ready-to-use parts with fast turnaround. Add finishing or post-cutting services, and AR500 becomes not just strong, but production-ready.