Aluminized Steel vs. Stainless Steel | Comprehensive Comparison

This is an on-going debate of aluminium vs stainless steel in the industries. It is really an issue whether to choose aluminium for it lightweight or stainless-steel foe its durability and strength. Stainless steel is dominated in applications which require higher corrosion resistance, oxidation resistance and tensile strength. Aluminium is preferred for ease of use and fabrication in complex applications. Still, it is crucial in many aspects and this article will explore these issues in detail.

What is Aluminized Steel?

It is basically aluminum silicon coated steel. aluminized Steel is dip coated in hot solution which ensures strengthening of metallurgical bonds between steel and aluminum coating. This results in a material with unique properties which is neither aluminum nor steel.

ASTM A463 Aluminized Steel

Aluminized steel (ASTM A463) normally exists in two types of classification. Type 1 and Type 2 Aluminized steel. The aluminized coating for both types is the same as galvanized steel on continuous coil coating lines. The difference lies in the composition of coating. Type 1 has a coating of 91% aluminum and 9% silicon. Type 2 has pure aluminized coating.

• T1 25 Aluminized steel

T1 25 aluminum-silicon coated steel with quenched and tempering has a Type 1 coating of aluminum and silicon. It helps to strengthen the metallurgical bonds on steel substrate. The aluminum-silicon coated steel has tight adherence, uniform surface coating on each side of part.

• T1 40 Aluminized steel

T1-40 aluminum-silicon coated steel in quenched and tempering conditions has T 1 coating of aluminum and silicon. strength and ductility increase in the aluminized steel. It is used for construction and other industrial applications.

• 16-gauge aluminized steel

The steel thickness is measured in diminishing fractions like 1/16” or ¼’. The aluminized steel with coating thickness of 1/16” is 16-guage aluminized steel. This material has high strength that it is used to support heavy objects used in building and bridges.

• 20 ga aluminized steel

The 20-gauge aluminized steel has 1/20” thickness. It also has higher strength and malleability. These steels are famous for construction, bridges and for interior decoration.

Common applications

Chromium steel is a good heat-resistant steel, but aluminized steel is a better heat-resistant steel. Its common uses are commercial HVAC units on rooftops, ovens, kitchen ranges, fireplaces, , automotive mufflers, barbecue burner, and the most common is heat exchangers in residential furnaces.

Aluminized Steel vs Stainless steel heat exchanger

Aluminum-silicon coated steel has a better heat transfer rate than stainless steel. The common heat-resistant steel like alloy 321 can be utilized up to 870°C, it also has good thermal conductivity, but aluminum has better conduction, and it is perfect for high quality efficient heat exchangers.

What are the Disadvantages of Aluminized Steel?

Aluminum-silicon coated steel is preferred in most of the factors to stainless steel. but it has some drawbacks. That is, it has less strength and corrosion resistance than chromium steel. It also is much less attractive and has less aesthetic which is not preferred for outdoor or decorative purposes.

Does Aluminized Steel Rust?

No, it does not rust as steel does easily, aluminum has natural corrosion protection barrier and oxidation resistance in the form of oxide layer on its surface. This protects it from corrosion and rust.

Is Aluminized Steel Safe?

Yes, aluminum-silicon coated steel is safe. T1 aluminized steel is mostly utilized in cooking ranges and bakeware. The alumni-silicon coated steel does not rust or is not harmful to get into food.

Is Aluminized Steel Toxic or Safe for Cooking?

Yes, it is safe for cooking. Aluminum-coated steel oxidizes and creates a protection layer between container and food. It is non-toxic and safe for cooking.

Is Aluminized Steel Good for Exhaust Systems?

Yes, it has a good exhaust system and offers a better electrostatic surface. the working temperature can be up to 842 ℃. These exhausts reflect 80% of the heat projected onto them and have good strength to weight ratio.

Aluminized Exhaust Pipe vs Stainless Steel

Aluminized steel exhaust pipes are better than stainless steel because they offer greater electrostatic surface.

Pros and Cons of Stainless-Steel Exhaust

The advantages of stainless-steel exhaust are:

• High corrosion resistance and oxidation resistance
• Better durability and strength
• Appealing aesthetic
• 100% recyclability

The disadvantages of stainless exhaust are:

• Expensive
• Heavy weight
• Difficult to Weld
• Require special tools and skilled labor

Aluminized steel vs 409 Stainless Steel

409 has less corrosion resistance than aluminum-silicon coated steel. but its service life is longer than common aluminized steel exhaust systems. Aluminum-coated steel exhausts are less expensive and have higher strength.

Aluminized Steel vs Stainless Steel Exhaust Sound (Performance and Acoustics)

Both exhausts are identical in structures. Thus, there is no such difference in sound performance and acoustic in both the exhausts

Aluminized Alloy Steel Drum vs Stainless Steel Dryer Drum

aluminum-coated steel has better strength and durability than chromium steel dryer drum. But stainless-steel drums have higher ascetic. Overall aluminized steel is preferred in terms of properties, cost and performance than stainless steel dryer drum than aluminum steel.

Aluminized Alloy vs Stainless Steel in Dryer Drums | Durability Comparison

aluminum-coated steel is long lasting and higher durability than steel. The surface coating and oxidation resistance makes it preferred over painted drums and stainless-steel drums. Also, it is more economical.

Aluminized Steel vs Stainless Steel: Key Differences

Corrosion Resistance

Aluminum-coated steel is good heat-resistant steel, but stainless steel has better corrosion resistance and strength. It is perfect for biomedical applications, surgical tools and for kitchen appliances and sinks.

Is Stainless Steel stronger than Aluminized Steel?

Yes, it is stronger than aluminum-coated steel. It is also aesthetically pleasing than aluminized steel.

Is Aluminized Steel lighter than Stainless Steel?

Yes, it is lighter than chromium steel in normal cases. The weight and physical properties are varied with the grade of stainless steel.

Structural durability and yield strength

Chromium steel has better durability and strength than aluminized steel. It has more resistance than aluminized steel.

Heat Resistance & Thermal Conductivity

Aluminized coating has better heat conduction than stainless steel. chromium steel can be distorted at high temperatures. That is why mostly aluminized steels are preferred for exhaust systems.

Cost Considerations

Aluminized coating is less expensive than stainless steel. Depending on grades, the cost of stainless steel varies but overall, it is more expensive than aluminum-silicon coated steel.

Surface Finish

Aluminized coating has more electrostatic surface. Chromium steel has a fine and smooth surface finish and surface coating. That is why it is preferred for aesthetic and decorative purposes.

Welding Aluminized Steel to Stainless

Aluminum may corrode when oxidized or has an exposure to acidic environments. Stainless steel has no effect on oxidation and acidic environment. At higher welding temperature, aluminum becomes malleable but stainless steel has no effect of higher temperatures without warping.

The welding of aluminized steel can be done with stainless steel by using gas metal arc welding (GMAW).

CNC Machining Aluminized Steel vs Stainless Steel

Aluminized steel and stainless steel both have good CNC machining properties, Aluminized steel is malleable, low rigidity and easy to machine and it has relatively economical CNC machining process. Stainless steel has three times more difficult CNC machining than aluminized steel.

Aluminized Steel vs Carbon Steel

Aluminized steel has better corrosion resistance and oxidation resistance than carbon steel. The aluminum oxide protects it from oxidation, and it is malleable and ductile than carbon steel and easy to process

Aluminized Steel vs Galvanized Steel

Galvanized steel has higher strength than aluminized steel. The requirement of strength varies with the customer and applications but galvanized is heavier than aluminized steel. Also, forging of aluminized steel makes it equally stronger than galvanized steel but it will increase processing cost.

FAQs

What is Better: Aluminized Steel or Stainless Steel?

Stainless steel has higher strength, corrosion resistance, and oxidation resistance, durability and aesthetic than aluminized steel.

Aluminized steel vs Stainless Steel Bakeware

Aluminized steel bakeware has better heat conduction. Stainless steel is a heat-resistant steel that is why aluminized steel is preferred for bakeware.