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ResourcesMaterialsGalvanized Steel vs. Aluminum: The Key Differences

Galvanized Steel vs. Aluminum: The Key Differences

picture of Kat de Naoum
Written by
Megan Conniff - Xometry Contributor
Updated by
 3 min read
Published December 1, 2023
Updated September 14, 2024

To use galvanized steel or aluminum for your manufacturing needs … that is the question. This article will help you decide.

Galvanizing process. Image Credit: Shutterstock.com/Bogdan Vija

Galvanized steel and aluminum are both manufacturing materials loved and used by Xometry customers, but they have very different properties that manufacturers should be aware of before choosing between the two. Let’s take a look at these two popular metals, their uses, pros and cons, and how Xometry can help you when it comes to using them for your business.

What is Galvanized Steel?

Galvanized steel refers to steel that has been hot-dip coated, electroplated, or mechanically plated—among other methods—with zinc, which protects it against corrosion. This process is called galvanization. Treating the steel in this way provides it with an ionic barrier that will sacrifice itself and prevent the steel from rusting, and that’s why galvanized steel has a long environmental lifespan. Here’s what galvanized steel looks like:

Bent sheet metal part made from galvanized steel.
Bent sheet metal part made from galvanized steel

Due to its durability and corrosion resistance, galvanized steel is used in an impressive number of sectors and applications. Some of these include outdoor equipment (canopies, handrails, street furniture), adding corrosion resistance to parts (nuts, bolts, washers), being used in phone networks and power equipment boxes, and making pipes, and agricultural equipment (gates, barn components, livestock handling equipment).

Pros and Cons

Like with any type of metal, there are pros and cons to think about before using galvanized steel. Here’s the breakdown:

AdvantagesDisadvantages
Advantages
It has a low initial cost and excellent value for money because it can last a long time
Disadvantages
While it’s protected against rust, it’s not fully immune to corrosion. Some aggressive environments, poor design, or minor mechanical damage could cause some corrosive decay
Advantages
Steel can hold its own against environmental factors or mechanical damage during handling, storage, transport, and erection, especially with the added zinc coating
Disadvantages
It can be more expensive than other options like paints or powder coating
Advantages
You can make complex parts and structures with it because it’s malleable, ductile, and weldable, and environmentally stable, thanks to the zinc coating which is the most effective corrosion inhibitor available
Disadvantages
It’s a bit of a diva when it comes to maintenance; if you want it to last a long time, it will need regular tending to
Advantages
-
Disadvantages
It’s not exactly what you would call a lightweight metal

Pros and Cons of Galvanized Steel

What is Aluminum?

Aluminum is another type of metal that’s found in abundance in the earth’s crust (meaning it’s pretty easy to get hold of), though it’s found in the state of metal salts like bauxite, which is a rock deposit that’s rich in aluminum oxide. Aluminum is lightweight when it’s made into its final metallic form. Here’s an example of what it looks like:

A part made from aluminum 6061
A part made from aluminum 6061

Aluminum is very versatile, and so is found pretty much everywhere—from cars, trucks, airplanes, ships, PC bodies, cans, and high-voltage conductors to body panels, wheels (alloyed with magnesium), frames, windows, doors, and roofs, to name a few. Xometry customers use this metal thanks to its many perks, including low density, high strength-to-weight ratio, corrosion resistance, and thermal conductivity. 

Pros and Cons

In the following table, we compare aluminum’s advantages to its disadvantages:

AdvantagesDisadvantages
Advantages
It has a low density and high strength-to-weight ratio, so it’s perfect for situations that require less weight but good performance, like transportation
Disadvantages
It’s more expensive than steel (its main alternative) because it requires a lot of energy to produce
Advantages
It naturally resists corrosion by forming an oxide layer on its surface when exposed to air
Disadvantages
Its thermal conductivity could be a disadvantage in situations where you don’t want temperature distortion and unnecessary thermal transfer
Advantages
It’s a very good heat and electricity conductor (around 60% of the electrical conductivity and 50% of the thermal conductivity of copper, at a fraction of the raw material cost)
Disadvantages
It can become brittle and lose some of its structural strength and durability when exposed to sudden temperature changes or extremely high temperatures
Advantages
It’s ductile, malleable, and somewhat weldable
Disadvantages
Compared to other metals, it has a low melting point which can become an issue in high-temperature applications
Advantages
It’s highly recyclable, and it actually requires less energy to recycle than it does to make
Disadvantages
Although it’s more corrosion-resistant than many other metals, it can still corrode in some environments

Pros and Cons of Aluminum

Galvanized Steel vs. Aluminum

Choosing between these two metals will first require a comprehensive comparison of their properties (don’t worry; we’ve got one below for you). What it will come down to in the end are your exact needs and budget. Sometimes these materials can be used for the same thing, such as walkways, stairs, and fan blades, but most times you’ll find that one will be better than the other at making a particular item. For example, galvanized steel is stronger and more durabile, but it certainly can’t beat aluminum when it comes to light weight and strength-to-weight ratio. Further comparisons can be found in the table below:

PropertiesGalvanized SteelAluminum
Properties
Malleability
Galvanized Steel
Moderately malleable; it can be shaped but is not as flexible as aluminum. It can be formed more easily when it’s heated.
Aluminum
Highly malleable; it’s easy to bend, shape, and form into complex designs without losing its structural integrity
Properties
Price
Galvanized Steel
Approximately $0.50 to $1.50 per pound
Aluminum
Typically $1.50 to $3.00 (sometimes more) per pound
Properties
Durability
Galvanized Steel
It’s very durable, especially in outdoor and somewhat corrosive environments, but it could rust if the zinc coating gets damaged
Aluminum
It’s naturally corrosion-resistant and lightweight, helping it last a long time
Properties
Rust-Resistance
Galvanized Steel
It’s very rust-resistant because of the zinc coating
Aluminum
It doesn’t rust but it could become vulnerable in acidic, alkaline, or salt-heavy areas

Galvanized Steel vs. Aluminum Properties

How Xometry Can Help

Xometry provides a wide range of manufacturing capabilities, including 3D printing, laser cutting, CNC machining, and much more. Both galvanized steel and aluminum are popular among Xometry customers. Want to learn more about either of these metals or request a free no-obligation quote? Reach out to a Xometry representative today.

Disclaimer

The content appearing on this webpage is for informational purposes only. Xometry makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through Xometry’s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please refer to our terms and conditions for more information.

picture of Kat de Naoum
Kat de Naoum
Kat de Naoum is a writer, author, editor, and content specialist from the UK with 20+ years of writing experience. Kat has experience writing for a variety of manufacturing and technical organizations and loves the world of engineering. Alongside writing, Kat was a paralegal for almost 10 years, seven of which were in ship finance. She has written for many publications, both print and online. Kat has a BA in English literature and philosophy, and an MA in creative writing from Kingston University.

Read more articles by Kat de Naoum

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