Steel is a popular and widely used in various industries. This material comes in multiple types, which differ in terms of their properties and composition. Stainless steel and aluminized steel are two widely used types in various industries. These two steel types differ from each other in many aspects, sparking a debate about aluminized steel vs stainless steel.
Most people believe stainless is a superior option due to its high chromium content. This chromium makes the material rust-resistant. However, aluminized steel is inexpensive to most manufacturers. This material also offers some unique properties due to its aluminum coating. This article will discuss their differences, helping you choose the right one.
What are Aluminized Steel & Stainless Steel?
Before jumping into differences, let’s first understand the basics of these two steel types.
The aluminized steel is a type of carbon steel that has an additional coating of aluminum material. Some aluminized steel also comes with aluminum-silicon alloy coating. This extra coating is done to steel to make heat and rust resistant to some extent. If the aluminum coating is removed, we will get ordinary steel.
For making aluminized steel, the steel is dipped into a molten solution of aluminum. Due to dipping, molten aluminum comes into contact with the steel surface. It dries and makes a strong coat on the steel surface. Remember, steel alone doesn’t have noticeable heat or rust resistance. The artificial process of enhancing steel properties began in the early 20th century.
Stainless steel is the superior option, containing 10.5% chromium along with carbon and iron. This chromium composition makes this type of steel very strong. Chromium forms a chromium oxide layer when exposed to air. This invisible layer protects the material from rusting and other environmental conditions.
However, stainless steel is in high demand in many industries, including construction. Due to its superior qualities, the price of this material is very high. Interestingly, the stainless steel material is not new and was first developed in the early 1900s. This light, strong, and rust-free material meets modern manufacturing needs.
It is noteworthy that aluminized steel is an alternative to stainless steel. For example, it is inexpensive, lightweight, and resistant to heat and rust. Therefore, it is a suitable option for manufacturers seeking budget-friendly materials. However, its quality and properties are not as effective as you get in stainless material.
Aluminized Steel vs Stainless Steel: Key Differences
As I said earlier, both of these steel types offer unique value propositions. However, some of their properties are also similar, which creates confusion. For example, people think both are rust-resistant, so they are equally good. This is not true, as stainless steel performance and effectiveness are far ahead.
In the section below, we will explore all their key distinctions. This section will help you determine which material (stainless or aluminized steel) is best suited for your needs.
1- Compositions
The aluminized steel is produced through a hot-dipping method. The steel is dipped into molten aluminum or aluminum-silicon alloys. As a result, the aluminum comes on the surface of the steel and creates a coat on it. The base provides strength, and the aluminum coating enhances the corrosion resistance.
If we remove this coating, we will get carbon steel material, which is the core of the product. Remember, this aluminized steel does not contain chromium. Conversely, stainless steel contains 10.5% chromium, along with iron, carbon, nickel, and molybdenum. The 10.5% chromium content is what makes stainless steel very popular.
2- Corrosion Resistance
Both aluminized and stainless steel are resistant to rust. However, when compared head-to-head, stainless steel is more effective in preventing rust. As I mentioned, stainless steel is composed of 10.5% chromium, which confers rust resistance to this material. How? When chromium reacts with oxygen in the air, a layer of chromium oxide forms.
This layer is thin, invisible, durable, and prevents the material from rusting. Moreover, this layer is also scratch-resistant. On the other hand, aluminized steel has an aluminum coating applied to it. Aluminum also makes an aluminum oxide layer when exposed to air. However, this aluminum oxide coating is less durable and offers short-term protection against rust.
Quick Highlight: The aluminum coating initially protects the material. Over time, this coating starts to degrade and deteriorate. Aluminized steel has short rust resistance. Chromium coating is durable, scratch-resistant, and resistant to degradation. It remains in good condition for a long time, ensuring long-term rust resistance in stainless steel material.
3- Strength and Durability
The stainless steel material wins the race when it comes to strength and overall durability. The reason is that this material has a higher nickel proportion (8–10%). This nickel is strong and imparts mechanical strength to this material. As a result, the stainless steel becomes robust, wears resistance, and maintains its structure.
Conversely, aluminized steel contains a negligible amount of nickel. So, it is less intense, and its wear resistance is also compromised. It only depends on aluminum coating for its durability. If this coating degrades, this material becomes prone to rusting and deterioration. Moreover, the better rust resistance of stainless steel makes it even more durable.
Quick Highlight: The parts made with stainless steel can withstand harsh conditions. For example, you can use them in moist conditions. Many parts used in marine conditions are made from this material. Chromium coating makes those parts resist rust. The nickel presence ensures those parts maintain their structural integrity.
4- Heat Resistance
Both aluminized and stainless steel are heat resistant. However, how long they can resist is something that differentiates them. Moreover, they also differ in their extremes of temperature. For example, aluminized steel has aluminum-silicon alloy as a coating. This coat or layer is resistant to heat and can withstand up to 600°C.
On the other hand, stainless steel is a much stronger structure. The presence of nickel makes it robust. It can withstand temperatures of up to 870 degrees Celsius. Moreover, this material performs well when exposed to high temperatures over an extended period. Aluminized steel can resist heat for a shorter duration, making it a less suitable option than stainless steel.
5- Appearance and Aesthetics
Stainless steel is popular due to its excellent physical appearance. Many manufacturers use this material to make decorative products. It has a shiny appearance with a polished feel. From a distance, the parts made with stainless steel look sleek and attractive. Additionally, this material maintains its shine for a long duration.
The aluminized steel is dull and less attractive. You might hear that this material reflects light, but its reflection is not as good as that of stainless steel. It comes with a gray finish, which makes it look bad. Moreover, it is challenging to clean parts made with aluminized steel. However, stainless steel parts are easy to clean, and they maintain their cleanliness for a long time.
6- Magnetic Properties
The aluminized steel has magnetic properties. It sticks to the magnet when placed near it. The reason is that the core of this material consists of carbon steel. This core is highly magnetic. The additional aluminum coating present on the surface of steel is skinny. It cannot affect or suppress the magnetic properties of core carbon steel.
As a result, when aluminized steel goes near a magnet, it sticks with it. On the other hand, stainless steel is non-magnetic and doesn’t stick to a magnet. The magnetic properties of aluminized steel are beneficial in producing various machine parts. Many automated machines utilize magnetic properties to handle materials.
7- Cost & Common Uses
Aluminized steel is an affordable option for everyone. The manufacturers who want cheap parts with some rust resistance prefer this material. It is made of basic steel material with an aluminum-silicon alloy coating. Remember, adding this coating is an easier and less costly process. Therefore, aluminized steel is an affordable option.
On the flip side, stainless steel is a premium material due to its composition. It contains 10.5% chromium, nickel, and other matter, which makes it very strong. However, there is a trade-off between excellent properties and price. The stainless steel is costly and is not suitable for budget-friendly parts and products.
However, this material offers ideal protection against heat, rust, and other environmental conditions. Its visual appeal is also far superior to the aluminized steel. Aluminized steel is a cheaper alternative to stainless steel, offering less effective properties. Here is a table showing the usability and standard application of these two materials:
| Aluminized Steel Applications | Stainless Steel Applications |
| Automotive exhausts and mufflers | Kitchen sinks, cutlery, and cookware |
| Oven walls & baking trays | Food processing and packaging equipment |
| Heat shields and chimneys | Medical instruments and surgical tools |
| Industrial ducting and furnace parts | Marine hardware and outdoor furniture |
| Water heater, furnace housings, and Industrial ducting | Building facades, handrails, and decorative panels |
| Toaster ovens, Dryer drums and HVAC systems | Refrigerators, dishwashers, and washing machines |
Which One Should I Choose, Stainless or Aluminized Steel?
The answer to this question depends on your needs and preferences.
I recommend you choose stainless steel over aluminized steel. This material offers many favorable properties. Those include better rust and heat resistance, along with excellent visual appeal. The aluminized steel is less durable and has lower corrosion resistance. However, you should consider using this material if you have a limited budget.
You should also consider your usage. Are you making parts that will be used at very high temperatures? Are you creating products that withstand salty water conditions? If so, you must choose stainless steel. For parts to be used in less severe conditions, aluminized steel works fine. Their selection of stainless & aluminized steel comes down to your usage and budget.
Frequently Asked Questions
What are the disadvantages of aluminized steel?
Aluminized steel is inexpensive, but it has many downsides. Those include:
- Limited corrosion resistance
- Not suitable for marine parts
- Limited heat resistance of just 600°C
- Their visual appearance is dull and less attractive
- Their aluminum coating is thin and prone to scratching
Is stainless steel better than aluminized steel?
Yes, stainless steel is a superior material to aluminized steel. Its 10.5% chromium content makes it extremely rust-resistant. As well its heat resistance, physical appearance, and overall strength are also better than those of aluminized steel.
Is aluminized steel expensive?
No, aluminized steel is inexpensive and easily affordable to everyone. It comes with an aluminum coating, which is less expensive to apply to steel than other materials. However, its lower cost comes with less rust and heat resistance.
What is the safest steel for cooking?
Stainless steel is the safest material for making cooking parts and utensils. This material is scratch-resistant and doesn’t degrade quickly. Moreover, its heat resistance is also excellent, making it ideal for making cooking parts.
Conclusion
It is noteworthy that both stainless steel and aluminized steel have their upsides and downsides. The stainless steel material is of premium quality, offering excellent features. Parts made with this material will last longer. However, its higher price is a drawback for those who have a tight budget. In such cases, the aluminized steel shines.
This material is very affordable and offers properties similar to those of stainless steel. It provides decent rust and heat resistance, which sets it apart. However, the effectiveness of its rust and heat resistance is not as good as that of stainless steel materials. In my opinion, I would recommend stainless steel. It is costly but offers top-notch performance in the long run.