Aluminium vs Stainless Steel: What’s the Difference?
When it comes to metal fabrication, two of the most popular materials steel fabricators use are aluminium and stainless steel. In fact, these metals are so popular that they’re found almost everywhere you look.
If you’re trying to choose between aluminium and stainless steel for your fabrication project, it’s important to understand the differences between them – including their properties, applications, and costs.
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What is Aluminium?
Aluminium is a strong yet lightweight metal that is known for being both ductile and malleable. Its versatility makes it a popular choice for many everyday items, from cans and foil to window frames and even aircraft parts. Aluminium can also be anodised or powder coated to provide it with additional properties if desired.
Aluminium Key Properties
Aluminium has many desirable properties, including:
- Lightweight – it’s around a third of the weight of stainless steel, which makes it easier to work with (as it reduces welding distortion) and transport. It also has a better strength-to-weight ratio than stainless steel.
- Malleability – it can be easily formed into a variety of shapes and sizes, from tiny components to large parts.
- Corrosion Resistance – it has a natural oxide layer, which protects it from corrosion so it does not rust. It should be noted, however, that under certain extreme conditions aluminium can corrode. Generally speaking corrosion will not occur when being used in a sheetmetal fabrication environment.
- Versatility – it can be used in a variety of industries and applications (including aerospace, sheetmetal fabrication, decorative panels, automotive parts , and so on).
Aluminium Applications
Look around – chances are you can see something made from aluminium. Some of its common applications include:
- Architecture (window frames, high-rise buildings)
- Electrical storage cabinets
- Decorative panelling
- Council Infrastructure i.e. Rubbish Bins and seating
- Vehicle components i.e. trailer parts
- Marine Industry particularly Aluminium boats
Aluminium Cost
While aluminium is generally the cheaper option, it’s important to note that pricing fluctuates depending on several factors (such as supply and demand and global conditions).
Although it’s the most recyclable material in the world, aluminium processing and refinement are very electricity-intensive (even when dealing with recycled metal) – with the soaring cost of electricity at the moment, this can make aluminium quite expensive.
What is Stainless Steel?
Stainless steel is a popular type of steel (alloyed with chromium) that is known for its corrosion resistance, strength, durability, and ease of maintenance. It’s one of the most popular choices for manufacturing many types of items from kitchen appliances to components for industrial projects. It doesn’t require painting or any other special treatments to enhance its properties.
Stainless Steel Key Properties
Stainless steel has many advantageous properties, including:
- Durability – its high chromium content makes it resistant to heat and wear and tear, which offers it a much longer lifespan than other options.
- Corrosion Resistance – as it’s non-porous, this metal is highly corrosion resistant even when exposed to moisture and salt water. It should be noted, however, that under certain conditions stainless steel can be subject to “tea staining”, a common cosmetic discoloration, not a structural issue, caused by chlorides from salt air, water, or other pollutants damaging the metal’s protective oxide layer. To prevent it, maintain good hygiene, use appropriate stainless steel grades (like 316 for coastal areas), and ensure smooth, clean surfaces.
- Ease of Maintenance – it doesn’t require any special treatment and is very easy to clean, which makes it an ideal choice for sanitary applications (such as public bathrooms).
- Aesthetic Appeal – it offers a modern look, comes in a variety of finishes, and can be polished to a high shine.
Stainless Steel Applications
Stainless steel is equally popular as aluminium and can be found almost anywhere. Some of its common applications include:
- Architecture (bridges, buildings, sculptures)
- Automotive (rail cars, car bodies, engines)
- Food and hospitality (sinks, cutlery, food prep tables)
- Medical (surgical tools and equipment like forceps, surgical implants, and scissors)
Stainless Steel Cost
While stainless steel is typically more expensive than aluminium, it’s important to note that pricing fluctuates depending on several factors (such as supply and demand and global conditions).
Steel is one of the most recycled materials in the world – its magnetic properties make it fairly easy to recover from the waste stream, and its properties don’t change no matter how many times it’s recycled.
So, Which is Better – Aluminium or Stainless Steel?
Both aluminium and stainless steel have their own unique sets of benefits and advantages, which means one may be better suited for some applications over the other. When choosing a metal for your fabrication project, it’s important to keep all of this information in mind so that you can choose the best option.
Still having trouble making a decision? The expert team at Metal-Tech Industries are well-versed in the various applications of aluminium and stainless steel, and we would be more than happy to help you reach a decision based on the unique requirements of your project. Give us a call today.