Steel versus Aluminum - Weight,

Strength, Cost, Malleability Comparison

by Adam Hornbacher of Wenzel Metal Spinning

Steel and aluminum are 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 Cost

Cost and price are always an essential factor to consider when making any product. The price of steel
and aluminum is 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 Aluminum

Aluminum 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 Aluminum

While 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 Aluminum

Even 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 materials page.

Galvanized vs Stainless Steel - Cost, Strength and Weight Differences

In 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 iron
As with most decisions in manufacturing, both of these options are primarily evaluated in terms of cost.

Differences between Galvanized Steel, Stainless Steel, and other Metals

Occasionally 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 is a lot more 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.
by Adam Hornbacher of Wenzel Metal Spinning

Wenzel is Dedicated to Quality

At 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!