Steel versus Aluminum - Weight, Strength, Cost, Malleability Comparison

byAdam Hornbacherof Wenzel Metal SpinningSteel and aluminumare the two most popular materials used in metal spinnings. Each material has a defined and distinct set of characteristics that make it the right or the wrong material for the job. When selecting material for your spun part its important to consider the following: cost, the shape of the spinning, and most importantly the end application.Aluminum vs Steel CostCost and price are always an essential factor to consider when making any product. Theprice of steel and aluminumis continually fluctuating based on global supply and demand, fuel costs and the price and availability of iron and bauxite ore; however steel is generally cheaper (per pound) than aluminum. The cost of raw materials has a direct impact on the price of the finished spinning. There are exceptions, but two identical spinnings (one in aluminum and one in steel) the aluminum part will almost always cost more because of the increase in the raw material price.Strength & Malleability of Steel vs AluminumAluminum is a very desirable metal because it is more malleable and elastic than steel. Aluminum can go places and create shapes that steel cannot and often forming deeper. Especially for parts with deep and straight walls, aluminum is the material of choice. Steel is a very tough and resilient metal but cannot generally be pushed to the same extreme dimensional limits as aluminum without cracking or ripping during the spinning process.Corrosion Resistance of Steel and AluminumWhile malleability is very important for manufacturing, aluminums greatest attribute is that it is corrosion resistant without any further treatment after it is spun. Aluminum doesnt rust. With aluminum there is no paint or coating to wear or scratch off. Steel or carbon steel in the metals world (as opposed to stainless steel) usually needs painted or treated after spinning to protect it from rust and corrosion, especially if the steel part will be at work in a moist, damp or abrasive environment.Weight Differences in Steel and AluminumEven with the possibility of corrosion, steel is harder than aluminum. Most spinnable tempers and alloys of aluminum dent, ding or scratch more easily as compared to steel. Steel is strong and less likely to warp, deform or bend under weight, force or heat. Nevertheless the strength of steels tradeoff is that steel is much heavier /much denser than aluminum. Steel is typically 2.5 times denser than aluminum.The final application of the part will ultimately determine which material the part would be spun from, balancing all the limitations and advantages of each material. On some spinnings its an easy call, while others are a tougher decision. If you or your engineering departments are on the fence with a steel vs. aluminum dilemma, please contact the authority on metal spinnings at Wenzel Metal Spinning, Inc. and we will be happy to provide you with our expert opinion and supporting information. Additional information about steel and aluminum can be found on our materialspage.

Galvanized vs Stainless Steel - Cost, Strength and Weight DifferencesIn the manufacturing industry galvanized commonly refers to galvanized steel. Galvanized steel is regular steel sheets that have been coated in zinc to make them corrosion resistant. Regular steel is made of iron which will rust when exposed to moisture, either in the form of rain or ambient humidity. Over time rust will corrode a steel part to the point of failure. To prevent steel parts from rusting there are two options: Switch to a metal that will not corrode when exposed to water Coat the steel with a physical barrier to prevent water from reacting with the ironAs with most decisions in manufacturing, both of these options are primarily evaluated in terms of cost.Differences between Galvanized Steel, Stainless Steel, and other MetalsOccasionally switching from steel to another metal that does not rust (option A) such as stainless steel or aluminum is not an option simply because of the difference in cost: Economically a substitution doesnt make sense. Aluminum is more expensive than steel, and stainless steel isa lotmore expensive that aluminum. Moreover steel might have certain physical characteristics, such as strength or weight that prohibits a switching for a specific application. The next option is to protect the steel with a physical barrier such as paint or a coating this is what galvanizing does best.Hot Dip Galvanizing (HDP)Galvanizing is a zinc coating applied to sheets of steel through a process called continuous hot-dip, in which steel sheet passes through a bath of molten zinc. The liquid zinc bonds to the iron in the steel forming a protective layer on both sides of the sheet. The steel sheet can then be spun into a finished part because the zinc coating does not flake or peeling off during the metal spinning process. The finished part resists corrosion without any additional or secondary painting or coating, making galvanized spinnings the most economical process for protecting steel from corrosion.byAdam Hornbacherof Wenzel Metal SpinningWenzel is Dedicated to QualityAt Wenzel we take pride in making high quality parts and use only G90 galvanized sheet, meaning there is .90 ounces of zinc coating per square foot or steel sheet. G90 is the best thickness for spinning and the industry standard for coating (ASTM A653). The zinc bonded to the steel forms a crystallite pattern on the surface of the sheet called spangle. We buy galvanized material that has small spangle or is spangle free (crystallite smaller than 1/32 across). For projects with cosmetic applications Wenzel also offers a galvannealed option. Galvannealed steel is very similar to galvanized except that it comes pre-treated with primer making the spun parts very easy to paint or coat, adding color and an extra level of corrosion protection. To learn more about how Wenzels metal spinning techniques, in combination with galvanized steel , resulting in high value and economical parts, pleasecontact us!