For example, if strength and durability are the most important attributes for your design, and the shape is not too complex, perhaps a steel alloy is the better option. Whether to choose steel or aluminum for your project will ultimately depend on your project’s characteristics, the forming process, and your budget. Should You Choose Steel or Aluminum for Your Project? Aircraft fuselage, wings, and support structure.

Window and door frames, gutters, and railing.

Architectural and finishing applications, such as side paneling.

Steel reinforcement in concrete structures, such as bridges and parkade.

The following table shows the most common uses of these metals in different industries. When trying to choose between steel and aluminum for your specific project, knowing the common areas of application for each of them could be very helpful. For this purpose, we’ve compared a medium carbon steel and general aluminum alloy. The following table compares specific values for the physical properties of steel and aluminum. However, it is commonly accepted that, pound for pound, carbon steel is generally less expensive than a comparable aluminum alloy. Since the price of both of these metals will fluctuate with the market and the specific alloy, it is hard to say that one will be cheaper than the other in every context. The cost of the material will naturally be a significant factor in which you choose for your project. It’s worth noting that steel can be made highly resistant to corrosion if a minimum of 11% chromium is included in its alloying elements, making it “stainless steel.” Stainless steel, however, is more costly than plain carbon steel, and other physical properties of the steel may be affected. So long as the aluminum isn’t exposed to an environment that causes it to break down, it will continue to provide excellent corrosion resistance. Aluminum, on the other hand, forms a protective oxide layer on its surface that acts as an inert barrier against further oxidation. It rusts easily and will continue to corrode if exposed to the elements. Plain carbon steel has poor corrosion resistance. Thermal ConductivityĪluminum is generally a much better thermal conductor than steel and is often used in applications where heat dissipation or distribution is required, such as in heat sinks. On the other hand, aluminum is relatively easy to form while either cold or hot and is ideally suited for manufacturing processes such as extrusion and rolling. This can be somewhat overcome by heating the steel to very high temperatures, but this adds cost and can compromise other properties. MalleabilityĪnother downside of steel’s high strength is that it is harder to work it into different shapes than aluminum, especially if the shape is complex. For example, a larger aluminum part may offer more strength at a lower weight than the steel alternative. Identifying which metal has the better strength for your application will depend on your design’s flexibility. That said, once the lighter weight of aluminum is factored into the equation, aluminum comes out on top with a superior strength-to-weight ratio. Generally speaking, steel is stronger than aluminum. Strength is often one of the first properties considered when selecting a material, especially in high-stress applications. In fact, for two pieces of equal volume, steel can be as much as three times the weight of aluminum. Steel’s high strength comes at the cost of a much higher density. If you ask someone which metal is lighter, most people will correctly say aluminum. This section compares some of the most important physical characteristics of steel and aluminum. While there are many different steel and aluminum alloys, each with its specific properties, there are some key differences between the two metals.

Should You Choose Steel or Aluminum for Your Project?.

Density of steel