Uses of Aluminum

Aluminum is a versatile and widely used metal in manufacturing. For example, in the transportation sector, aluminum is extensively used in the manufacturing of cars, trucks, airplanes, trains, and even ships. It is used in engine components, body panels, wheels (alloyed with magnesium), and frames. Aluminum is also commonly utilized in the construction industry. Its corrosion resistance, strength, and durability make it a popular choice for building structures, including roofs, windows, doors, and facades.

For more information, please visit our website.

Examples of Aluminum Parts and Applications

Aluminum has extensive application across various industries. Some examples of aluminum parts are listed below:

1. Extruded aluminum alloys are used for window and door framing. 
2. Deep-drawn aluminum sheets allow beverage and aerosol cans to be made cost-effectively. 
3. Long-distance and high-voltage conductors rely on aluminum as it has a considerably lower cost than copper for almost the same performance. 
4. Apple and other computer manufacturers use die cast and machined aluminum for PC bodies as it is lightweight and durable.

Advantages and Disadvantages of Aluminum

Aluminum offers a range of advantages that contribute to its widespread use in most areas of product and human environments. These are:

1. Has a low density compared to many other metals, making it an excellent choice for applications in which weight affects performance or efficiency, such as in transportation. 
2. Has a natural ability to resist corrosion. When exposed to air, it forms an impervious and robust oxide layer on its surface, which acts as a protective barrier against further corrosion.
3. Is an excellent conductor of heat and electricity. It has approximately 60% of the electrical conductivity and 50% of the thermal conductivity of copper, at a fraction of the raw material cost.
4. Aluminum alloys have a higher strength-to-weight ratio than steel, making them suitable for a range of structural applications. The material also retains its ductility in heavy use, allowing for structures that are failure-resistant.
5. These alloys offer great ductility and malleability, with moderate weldability, allowing their use in a wide range of manufacturing processes.
6. Is highly recyclable, and its recycling process requires significantly less energy compared to the production of primary aluminum.

Aluminum also has application and performance disadvantages that must be accounted for:

1. Is more expensive than steel, its primary material alternative, for several reasons. The high cost of bauxite processing (in terms of energy required to produce aluminum from ore) can limit the economic practicality of its selection.
2. Its thermal conductivity can be a disadvantage in certain applications, as can its higher coefficient of thermal expansion than steel. Temperature distortion and unwanted thermal transfer in building systems can be significant issues that must be handled with careful design.
3. Exposure to sudden temperature changes or extremely high temperatures can cause the metal to become brittle, losing structural strength and durability. Aluminum engine blocks have been known to fail due to designs that failed to compensate for or prevent damaging temperature fluctuations.
4. Has a relatively low melting point compared to other metals, such as steel or copper. This is a disadvantage in all high-temperature applications.
5. Although aluminum is more corrosion-resistant than many other metals, it can still corrode in some environments, requiring: good design, effective maintenance, and protection in certain applications, such as those exposed to seawater.

Applications of Galvanized Steel and Aluminum

Many applications can be made from either galvanized steel or aluminum, and both metals have specific properties that make them suitable for certain uses. Galvanized steel is a popular choice for applications that require a durable, rust-resistant material. For example, it is commonly used in the construction of automobiles, roofing, and fences. Walkways and stair surfaces are commonly made from aluminum or galvanized steel treadplate, each of which has particular application advantages.

Aluminum benefits from having a low density and high strength-to-weight ratio, making it particularly useful in transportation industries for structures such as aircraft, some ships, and railway cars. Low weight can benefit the making of building components, electrical equipment, and cooking utensils.

Both galvanized steel and aluminum are used extensively in the manufacturing of fan blades. Galvanized aluminum sheet materials are more specifically used in this application due to their lightweight property. However, most HVAC (heating, ventilation, and air conditioning) ducting and fan enclosures are made in galvanized steel sheets for their low cost of materials and high processability.

Choosing Between Galvanized Steel and Aluminum

Choosing between galvanized steel and aluminum depends on various factors such as the application, budget constraints, and environmental considerations.

Material selection must align with a project's primary and secondary requirements, considering factors like strength, corrosion resistance, weight, budget, and aesthetics. Careful design to compensate for a material's weaknesses or better exploit its strengths can alter the material selection in ways that allow better cost or performance.

Galvanized steel outperforms aluminum in strength and durability, making it ideal for applications that require a tougher and more durable material, such as structural components, fences, and outdoor equipment.

Aluminum, on the other hand, is lighter weight but less strong than equivalent sections/gauges of steel but has a higher strength-to-weight ratio. It is more suitable for projects in which weight is a primary driver, like aerospace or transportation, but may not be as robust in heavy-duty applications.

Malleability

Aluminum has a high malleability, which means it can be easily bent, shaped, or formed into various configurations without losing its structural integrity. Galvanized steel is also malleable to a certain extent, but less so than aluminum.

For applications that require extensive shaping, forming, or intricate designs, aluminum is often the easier-to-process choice. However, extreme forming of steel can be performed hot, allowing for increased complexity of shape as a consequence of accepting the increased complexity of the process.

Price

The cost of galvanized steel and aluminum varies widely depending on various factors, including the type, form, thickness, size, and market conditions.

The cost of galvanized steel can range from $0.50 to $1.50 per pound, depending on the specific grade and form. Aluminum prices can range from $1.50 to $3.00 or more per pound for common aluminum alloys, influenced by grade, form, and market conditions.

For accurate pricing information, it's necessary to contact metal suppliers to get an accurate application/volume-specific price for your needs.

Durablility

The relative durability of galvanized steel and aluminum depends heavily on the application and environmental factors.

Galvanized steel is renowned for its durability, particularly in outdoor and (mildly) corrosive environments. It is often used in applications in which long-term durability is a key driver. However, galvanized steel will corrode if the zinc coating is compromised or if it is exposed to unsuitable conditions. Overall, galvanized steel benefits from the properties of steel&#;toughness, ductility, high tensile strength, low fatigue rates, and hardness&#;with the zinc coating compensating for the high environmental susceptibility.

Aluminum is naturally corrosion-resistant due to the formation of a self-healing protective oxide layer on its surface, making it moderately damage-tolerant in terms of corrosion resilience. Aluminum is lightweight making it a suitable choice for applications in which weight and corrosion resistance are essential, such as in aerospace, marine, and outdoor applications. However, it may not be as strong or durable as galvanized steel in some heavy-duty or high-impact applications. In particular, aluminum is more susceptible to fatigue failures and can become embrittled by stress and temperature fluctuations.

Galvanized steel is generally more rust-resistant than aluminum in most non-aggressive environments. The zinc coating on galvanized steel serves as a sacrificial barrier. When it gets scratched or damaged, the surrounding zinc corrodes before the underlying steel, providing a measure of ongoing protection.

Aluminum naturally forms a thin oxide layer on its surface, which protects it from corrosion. While aluminum is highly corrosion-resistant and does not rust in the same way that steel does, it can still corrode in certain specific environments, such as highly acidic or alkaline conditions and in places where mineral deposits can collect.

In typical outdoor environments, in which exposure to moisture is common, galvanized steel's rust resistance tends to be superior to the resistance of aluminum to corrosion, but both will perform well and survive long term. The cost then drives the selection of galvanized steel for applications like fencing, structural components, and outdoor equipment.

In marine environments, aluminum offers some benefit in corrosion performance over galvanized steel, as long-term salt exposure will affect steel considerably more than the self-healing oxide barrier on aluminum, once the zinc begins to erode.

Galvanized steel and aluminum are both popular materials at Xometry. To get your quote, visit our instant quoting engine today.

Goto Kaiyuan to know more.

Disclaimer

The content appearing on this webpage is for informational purposes only. Xometry makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through Xometry&#;s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please refer to our terms and conditions for more information.

Both stainless steel and galvanized steel are strong and durable, but each one has specific advantages, depending on the application. When it comes to galvanized steel vs. stainless steel, you have to understand the difference between the two and consider what type of product you&#;re making and what demands it will face in its environment. From there, the best choice for you will become clear. 

What Is Galvanized Steel vs. Stainless Steel?

Galvanized steel is coated with zinc to protect it from rust, while stainless steel is an alloy made with at least 10% chromium for the same reason: to guard against rust and corrosion. There are several types of stainless steel, each determined by the type and amount of additional materials, like chromium, as well as nickel, titanium, manganese, and/or molybdenum, present in the steel: 

• Austenitic stainless steel

• Ferritic stainless steel

• Long-wearing martensitic steel

• Duplex stainless steel

• Precipitation-hardening stainless steel

Benefits & Drawbacks of Galvanized Steel vs. Stainless Steel

The strengths and weaknesses of each type of steel will help you determine whether it&#;s right for your application:

Galvanized Steel

Galvanized steel is water-resistant, but it does not hold up well under salt water. When compared to stainless steel, it&#;s easier to work with and much less expensive. For many construction applications, galvanized steel is a trusted, economical choice, as long as it won&#;t be in contact with salt water.

However, one drawback is in the welding process: the zinc coating releases toxic fumes that can contribute to flu-like symptoms and discomfort, so it&#;s important for welders to have the proper protective equipment. Because welding removes the zinc in the welding area, that area is subject to corrosion. In many situations, it may be preferable to galvanize the steel after the welding process is complete. 

Stainless Steel

Exceptionally strong and rust-resistant, stainless steel withstands contact with both fresh and salt water&#;but not chlorinated water, which will cause the steel to degrade quickly. It offers more corrosion resistance than galvanized steel, making it a great choice for marine and aerospace applications.

One major drawback is the cost: stainless steel can be about five times more expensive than galvanized steel. It also requires highly skilled welders with exceptional patience and control. Further, stainless steel can weld itself together if two pieces are in contact and the friction rubs through the coating, which could be a concern in certain applications.

Applications of Galvanized Steel vs. Stainless Steel

click to expand

Hinges, gaskets, and fasteners like nuts, bolts, screws, and nails are often made of galvanized steel to withstand extreme weather conditions. In high-moisture environments, like automobile exhaust pipes, marine applications, and the aerospace industry, stainless steel is typically the best choice. 

Choosing between galvanized and stainless steel comes down to your application. For example, galvanized steel is not effective in marine applications. In that situation, stainless steel is essential.

However, in most circumstances, galvanized steel is going to be the more economical option. Materials and labor are both more affordable, and you can still depend on galvanized steel&#;s strength and long service life. 

At Metal Craft Spinning & Stamping, we&#;ve been producing high-quality products for our clients for nearly 60 years. As a fourth-generation family-operated company, we&#;re committed to building long-term, trusted relationships with our clients by providing on-time delivery, a collaborative process, and a personalized approach to every project. Request a quote today, or contact us to learn more about our products and services and whether galvanized steel or stainless steel is best for your project.

For more information, please visit 12 gauge galvanized steel wire.