When you are working on a project that requires sheet metal, it always seems to come down to the question of steel vs. aluminum. Both of these metals are available in sheet form, and each comes in a variety of grades and alloys. To complicate matters further, each grade has different properties that might make it better or worse for a particular application, so choosing a sheet product is no easy task.
Grades of Metal Available in Sheet Form
Sheet aluminum is generally used in Grade 2024-T3, Grade 7075-T6, Grade 5052-H32 and Grade 6061-T6. All of these are corrosion resistant and weldable, with 7075 being the strongest of the group. For steel, Grades 304, 316 and 410 are the most popular, with 316 being the strongest of the group.
Strength
Strength should be a no-brainer—nothing is stronger than steel, right? Well, yes and no. Just about any grade of steel will be stronger than a piece of aluminum of the same size and thickness. Bear in mind, however, that aluminum has a much lower density than steel. It all depends on your application and whether your limiting factor is size or weight to determine which metal provides the most efficiency for the application.
Cost
In general, steel is cheaper than aluminum by about 20 to 30 percent. Of course, most grades of steel are not as resistant to corrosion as aluminum sheet, so steel would need to be replaced more frequently.
Sustainability
Aluminum is generally thought of as the ultimate recyclable material, and this reputation is well-earned. Aluminum is usually 100 percent recyclable. With that being said, steel is no slouch—in fact, steel is the most recycled material on earth. The fact that steel is magnetic actually makes it easier to recycle, too.
Other Factors
Aluminum is easier to shape, mold and bend than steel. Aluminum sheet can be bent easily into just about any desired shape and aluminum can even be extruded to create complicated long and ornate shapes. Most grades of steel, however, can be more easily welded than aluminum and maintain their strength after welding better.
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