Aluminum vs Steel: Difference and Applications

In the list of metals, the two most primary and commonly adopted metals are steel and aluminum. Both of these are widely used for their excellent properties. Sometimes, in one single application, both can be combined, and sometimes, they are used independently. However, despite being on the list of metals, they do differ.

If you are looking to learn about the comparison between aluminum vs steel, the guide below is for you. So, let's read.

What is Aluminum?

Aluminum alloy is made up of aluminum, followed by some other materials like magnesium, zinc, copper, silicon, and manganese. Aluminum of different grades has these metals created in it using a definite composition.

The presence of copper makes aluminum strength-oriented and resistant to corrosion, and zinc adds durability and hardness. The addition of magnesium to aluminum makes it lightweight yet workable, and silicone makes it capable of casting. Manganese is also added to aluminum alloys to make them corrosion-resistant.

What is Steel?

Steel has a range of carbon between 0.02% and 2.04%. Steel also has various other metals like nickel, manganese, and vanadium, which add to its properties. Chromium added to steel makes it resistant to rust, and nickel also adds to its corrosion resistance. Moreover, carbon enhances its strength, and molybdenum protects it from corrosion.

Difference Between Aluminum and Steel

Aluminum vs Steel: Color

Aluminum is available in dark gray and silver colors and doesn't rust. The steel, on the other hand, has a natural source, which is either rust or black.

Aluminum vs Steel: Density

The density of aluminum is 2.7g/cubic meter, which makes it dense. Steel has a density of 7.8g/cubic meter.

Aluminum vs Steel: Hardness

Aluminum is not as hard as steel. However, it can be hardened using heat treatments.

Aluminum vs Steel: Strength

When compared to aluminum, steel is stronger. The presence of carbon makes it hard. Aluminum is flexible and malleable.

Aluminum vs Steel: Melting Point

The melting point of aluminum is 660°C. Meanwhile, steel has a melting point of 1500°C, which means that aluminum can be melted and cast easily compared to steel.

Aluminum vs Steel: Heat-Conducting Property

Aluminum is a good conductor of heat and is used in heat sinks and also for the cooling systems of cars. Whereas, steel is not a good conductor of heat.

Aluminum vs Steel: Electrical Conductivity

Steel is a poor conductor of electricity and, hence, is not suitable for electronic applications. Whereas aluminum is a good electrical conductor, which makes it suitable for use in electronic applications.

Aluminum vs Steel: Corrosion Resistance

Aluminum has a high corrosion resistance as it is composed of a layer of passivation. However, in case it oxidizes, it can depend on the white patches on the surface. Moreover, if it is exposed to highly alkaline or acidic applications, it can end up corroding.

Steel, on the other hand, has less resistance against corrosion, and when exposed to marine or moisture-oriented environments, it can corrode.

Aluminum vs Steel: Magnetic

Aluminum is a non-magnetic material, whereas steel possesses magnetism.

Aluminum vs Steel: Weldability

Aluminum can be welded but poses some challenges compared to steel. Whereas steel can easily be welded using TIG or MIG welding.

Aluminum vs Steel Recyclability

Aluminum is light in weight, and compared to steel, it doesn't impact the environment. It can be recycled without any issues. However, steel can also be recycled, but only a limited number of times. After that, it will lose its properties.

Aluminum vs Steel: Cost

Aluminum is expensive compared to steel because it is difficult to process compared to steel.

Aluminum vs Steel: What To Consider For Cost-Efficiency

When choosing between aluminum and steel in your projects, some aspects that you must consider for cost efficiency are as follows:

Material Selection

The requirements of the project are considered before choosing between the two materials. You must go with the grade and materials that offer maximum compatibility and low cost so that you can save.

Optimize Volume & Quantity

Purchase the aluminum and steel in a larger volume so that you can take advantage of bulk discounts. It minimizes production cost.

Standard Stock Sizes

Keep a check on the standard stock sizes to analyze if they meet your requirements or not. Standard sizes are cost-effective, and if you can compare them, you will be able to save.

Material Efficiency

Reduce waste and optimize the design of materials so that you can have a cost-effective production. If you use material efficiently, you can cut down on waste.

How to Distinguish Aluminum and Steel?

There are different ways to distinguish between aluminum and steel, and these are as follows:

• Conduct a weight test; steel is a heavy metal, whereas aluminum is light. Checking the weights will help you determine between the two of these materials.
• Aluminum doesn't rust; it only oxidizes, whereas steel rusts. So, looking at the surface also helps analyze if the material is aluminum or steel.
• Steel is stronger than aluminum, and hence, by conducting the hardness test, differentiation is possible.
• The magnet test distinguishes between the two materials because aluminum has no magnetism, whereas steel is magnetic.

Benefits of Aluminum vs Steel

Aluminum

The benefits of aluminum are as follows:

• Aluminum is lighter than steel and is highly recyclable.
• It offers high resistance against corrosion.
• The thermal and electrical conductivity of aluminum is better than that of steel.
• It can be shaped into different designs due to its malleability.
• It is highly reflective and has a low density.

Steel

The benefits of steel are as follows:

• It is affordable.
• Steel is suitable for high-temperature conditions.
• It offers durability and weldability.
• Due to its recyclability, it can offer environmental friendliness.
• It has less weight and more strength.

Applications of Aluminum and Steel

The applications of aluminum and steel are as follows:

Construction Industry

Stainless steel is used for facades, roofing, and cladding as it is highly appealing and strong. Aluminum, on the other hand, is used in the construction industry for doors, curtain walls, and windows. It is lightweight and offers flexibility.

Consumer Goods

Consumer goods of various kinds are manufactured using both materials. However, the use of aluminum is found in such composites where durability is required. Similarly, steel offers an aesthetic appeal.

Automobile Sector

The automobile sector uses steel to make components like exhaust systems and grills. These components require corrosion resistance, strength, and a visual appeal. Aluminum, on the other hand, has a lightweight property, which makes it suitable for various components of automobiles.

Individual Applications of Steel

• The oil and gas industry uses stainless steel due to its temperature and corrosion resistance. Steel is used to make valves, pipes, and fittings.
• The chemical industry requires steel-based heat exchangers and reactors.
• The food and beverage industry requires corrosion resistance and hygienic characteristics, which are present in steel.

Individual Applications of Aluminum

• Packaging Tools are made using aluminum; it is lightweight and formable. Aluminum foil and other packaging materials are used in various applications.
• The electronics industry uses aluminum in making busbars, wires, and transmission lines. It ensures strength and resistance to corrosion.
• Industrial equipment uses aluminum components for its lightweight and strength, and material handling tools, and other machine components are usually aluminum-made.

Conclusion

Aluminum and steel are two materials that go hand in hand in a lot of applications, and, at the same time, they have the ability to stand alone in some applications. So, if you are looking to have components manufactured using aluminum and steel with high accuracy and precision, contact us at DEK.