Stainless steel and aluminum are two of the most popular metals used for manufacturing. Widely used for their versatility and corrosion resistance, aluminum, and stainless steel are staples in the metals industry. To know when it is better to use aluminum vs stainless steel, we must compare factors like their compositions, mechanical properties, and cost.
Main Characteristics of Stainless-Steel vs Aluminum
Stainless Steel
- Contains a minimum of 11% chromium
- Is a ferrous alloy (contains iron)
- Usually magnetic
- High tensile strength
Stainless steel comes in a variety of grades. The grades are classified by a series number and assigned a numerical grade. The numbers classify the grades of steel based on their composition, physical properties, and applications. The most popular grades are 304 stainless steel and 316 stainless steel.
Aluminum
- Non-magnetic
- Low density
- Non-ferrous alloy (doesn’t contain iron)
Due to its low tensile strength, aluminum is commonly alloyed with other metals to give it a number of different superior properties. Some of the most common aluminum alloys are 3003 aluminum and 3004 aluminum.
Aluminum vs Stainless Steel: Which One Do I Use?
Both metals possess properties that are desirable for manufacturing a variety of products. However, the differences in their properties are a key factor when choosing which metal to use.
The Major Advantages of Each Metal
| Aluminum | Stainless Steel |
|---|---|
| -Good Malleability | -High Tensile Strength |
| -High Ductility | -Heat Resistant |
| -Good Conductivity | -Very Durable |
| -Light Weight | -Low Maintenance |
Aluminum vs Stainless Steel: Key Differences
Strength
Stainless steel is heavier and stronger than aluminum. In fact, aluminum is around 1/3 the weight of steel. Even though stainless steel is stronger, aluminum has a much better strength-to-weight ratio than stainless steel.
Conductivity
Steel is a poor conductor of electricity due to its dense protective oxide layer. On the other hand, aluminum is a very good electrical and thermal conductor.
Cost
Aluminum is more costly than stainless steel if you look at the price based on weight. But, if you look at price by volume, Aluminum is more cost-effective because you get more product.
Heat Resistance
When comparing stainless steel vs aluminum, stainless steel has much better resistance to heat with a melting point of 2500 ℉, while aluminum becomes very soft around 400 ℉ with a melting point of 1220 ℉. However, aluminum has the advantage over steel in cold temperatures. As the temperature decreases, the tensile strength of aluminum increases, while steel becomes brittle in low temperatures.
Corrosion Resistance
Aluminum does not rust; however, it does corrode when exposed to salt. Stainless steel is highly corrosion-resistant and does not easily rust. In addition, stainless steel is non-porous which gives it more resistance to corrosion.
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