Aluminum vs. Steel Fabrication: Selecting the Right Material for Your Project

Steel and aluminum are two materials commonly used in industries from aerospace to automotive manufacturing and from construction to electrical components and beyond. They often look similar and are both highly recyclable; however, they aren’t always interchangeable.

There are many grades and alloys of both aluminum and steel; therefore, any comparison between the two will be somewhat general. And of course, the specific application, its design intent, and function in an assembly or structure usually determine the optimal material.

Here, we will explore some properties of aluminum and steel and some significant differences between the two materials.

Aluminum vs. Steel Fabrication

Let’s look at both materials in terms of several key properties: conductivity, malleability/formability, weight, strength, and corrosion resistance, as well as cost.

Conductivity

Conductivity is a measure of how good a conductor a material is, and the higher a material’s conductivity, the lower its resistivity, and vice versa. Thermal and electrical conductivity are important properties for metals. Aluminum is more conductive than steel, making it a good choice when rapid heat dissipation or electrical transfer are needed. Because aluminum is less resistant to heat, it softens at lower temperatures than steel, which limits its use in some applications. Steel has low thermal and electrical conductivity and is well-suited to high-temperature applications or when thermal or electrical insulating properties are needed.

Malleability

Malleability, or plasticity, is how easily a material can be shaped (e.g., drilling, bending) without breaking. Aluminum is very malleable and can be easily cut, folded, and bent. Steel alloys are much harder than aluminum and as a result, they are less malleable. This gives steel materials their high strength but also makes them more difficult to bend, machine, and cut.

Weight

In comparing steel vs aluminum weight, application requirements are critical. Aluminum is about one-third as dense as steel, making it very lightweight. For this reason, it is often used in vehicles and aerospace components to minimize weight and improve fuel efficiency and EV battery life. Steel is far more dense and heavy.

Strength

Which is stronger, aluminum or steel? Aluminum has a high strength-to-weight ratio compared to steel, so it provides structure and strength without the added weight of steel. However, steel, and especially carbon steel, is stronger than aluminum and has a particularly high tensile strength. This makes it a good choice for load-bearing applications, such as in construction.

Corrosion Resistance

Aluminum is highly resistant to corrosion, though it can be susceptible to powdery, white rust when exposed to saltwater or salt spray. Stainless steel is also highly corrosion-resistant because it includes chromium. Carbon steel does not resist corrosion well and usually requires a coating of paint or other material for extra protection.

Cost

Cost is a major consideration when selecting materials. Because it is lighter, transportation costs are often lower for aluminum materials. Steel is heavier and will cost more to transport, though it is generally less expensive to manufacture and is readily available. Of course, supply chain and logistics and global supply and demand cause metal prices to fluctuate over time as well.

Metal Fabrication From Atlantic Tool & Die

When choosing steel versus aluminum alloy materials for a fabrication project, start by defining the critical features or functions the application requires. Then assess those against the properties and considerations discussed here. The team at Atlantic Tool & Die can help with material selection along with stamping, tube manufacturing, assembly, welding, and other fabrication capabilities.

Contact us or request a quote to discuss your next metal fabrication project.

Choosing the Right Metal Fabrication Service For Your Project

Finding a high-quality steel fabrication company to fulfill your project within your specs, budget, and timeline can be challenging. Here are the most important factors to consider when selecting a metal fabrication supplier to support your business.

Things to Consider When Choosing a Metal Fabrication Partner

Experience

In addition to evaluating the metal fabrication company’s general industry experience, it is also important to assess their specific expertise in handling projects like yours. Evaluating the past projects of a steel fabrication business can help you determine if they have the required knowledge, skills, and capabilities to manage your project successfully.

Sufficient Resources

Your fabrication supplier must have enough highly skilled workers to deliver high-quality results. Staff with the proper qualifications and expertise will be able to complete the project on time and as requested to your specifications.

Up-to-Date Equipment

High-quality, efficient fabrication demands continual process improvements and upgrades to equipment and technology. Metal fabrication companies that invest in state-of-the-art equipment are typically more reliable and likely to produce superior results. Ask about the steel fabrication company’s in-house tools and equipment to assess their ability to keep current with the latest industry advancements.

Strong Vendor Relationships

Strong vendor relationships play a vital role in a company’s ability to deliver quality services and products. Metal fabrication companies that closely collaborate with trusted suppliers have more seamless workflows and are more likely to complete your project on time with a steady supply of:

• High-Quality Raw Materials
• Advanced Fabrication Technologies
• Specialized Equipment

Geographical Service Range

Consider the service range and geographical location of prospective steel fabrication partners. Even if you can save on shipping costs by choosing a provider close by, also weigh the potential value offered by other metal fabrication companies if they have better facilities or more experience shipping products and assemblies over longer distances.

Competitive Pricing

Before committing to a single provider, gather multiple comprehensive quotes from different fabrication suppliers. The pricing should align with industry standards and reflect each company’s expertise and quality. Always request detailed estimates that encompass the entirety of the project, eliminating the risk of future hidden costs.

Adequate Facilities

Not all fabrication suppliers are equipped to handle complex projects, so evaluate each facility’s available space, equipment, and resources to accommodate your project’s specific requirements. Choosing a steel fabrication business with adequate facilities contributes to smoother operations and the likelihood of successful project completion.

Certifications and Commitment to Quality

Before committing to a steel fabrication company, verify that they follow industry-standard quality measures and hold all relevant certifications. Learn about their quality assurance, quality control, and inspection processes to see if they can consistently deliver the results you need.

Metal Fabrication Services at Atlantic Tool & Die Co.

As part of our comprehensive metal fabrication services, Atlantic Tool & Die Co. provides value-added assemblies through manual and robotic welding, nut and bolt insertion, riveting, and tapping capabilities across our six world-class manufacturing facilities.

Our experienced team also provides the following specialized services:

• New Tool & Die Construction
• High Volume Metal Stamping
• Tubular Products
• Value Added Engineering
• New Inspection Gauge Construction

Contact us today to learn more about our high-quality metal fabrication services. You can also request a quote with specific requirements for your next project.