Stainless Steel Vs Aluminum In Metal Fabrication 

February 3, 2023 6:31 pm Published by Leave your thoughts

Aluminum and stainless steel are two popular metals used in a variety of fabrication applications. They are both regarded for their versatility, durability, and corrosion resistance, among other desirable qualities. Knowing which of these metals would be better suited for a project can be a critical factor in ensuring a successful outcome. Here are a few key differences between the two. 

Corrosion Resistance 

Corrosion is the process that erodes a material’s intrinsic properties, such as strength and ductility, as it is exposed to environmental conditions. It can be caused by moisture, chemicals, and oxidation. Stainless Steel is a common choice for fabrication work due to its superior corrosion resistance. It contains chromium, which provides an added layer of protection that helps prevent corrosion and rusting. It is also non-porous, which makes it less likely to corrode. It can be plated with different metals to increase its durability and corrosion resistance, and it can be powder coated. 

Thermal Conductivity 

One factor to consider when comparing the two is thermal conductivity. This property is important to understand when choosing which metal to use in an application that requires heat transfer. In general, aluminum has a higher thermal conductivity than stainless steel. This makes aluminum a great option for applications that require heating like heat exchangers, car radiators, and air conditioning units. 

Strength And Weight

Generally speaking, stainless steel is stronger than aluminum. This is due to the higher tensile strength (how much force it can withstand). On the other hand, aluminum has a superior strength-to-weight ratio. A component made of aluminum will weigh around one-third the weight of an identical component made of stainless steel. Stainless steel is also easier to weld than aluminum. This can be a huge benefit for many projects that require welding. However, this advantage is limited to certain applications and can be offset by other factors like the cost of labor. 


Cost is a key factor to consider when deciding whether aluminum or stainless steel is right for your project. Understanding the factors that influence pricing will help you select the best option for your needs. Typically, aluminum is less expensive than stainless steel per pound. This is due to the fact that it weighs less to begin with, so you get more material for your money. 


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