A Comparison Between Galvanized Steel Vs. Aluminum

Galvanized steel and aluminum products have massive production rates, and manufacturers are raking in billions from producing and supplying these materials. As of 2020, over 1.8 million metric tons of crude steel were produced, and the following year held greener pastures for the aluminum market. 

Research showed that 860,000 metric tons of aluminum were manufactured in the United States, and $11 billion worth of revenue was recorded by a fragment of the market. Keep reading to learn more about the difference between galvanized steel vs. aluminum.

Galvanized Steel Vs. Aluminum: Differences in Chemical Composition

Galvanized steel stands as a form of steel that has undergone a safeguarding process involving zinc aimed at fending off corrosion. This procedure establishes a barrier between the steel and its surroundings, thus diminishing the likelihood of rust and corrosion. The chemical constitution of galvanized steel is primarily made up of iron, carbon, zinc, and other trace elements like silicon, manganese, sulfur, and phosphorus. 

At its core, galvanized steel is a blend of regular carbon steel, which is a fusion of iron and carbon. The carbon quantity ranges between 0.25% to 2.14%, while the exact presence of other elements depends on the specific composition of the base steel. This property of modifying the percentage composition of elements renders galvanized steel more fitting for certain applications, as observed in the discussion of galvanized steel vs aluminum roof.

On the other hand, in aluminum, the major element, making up to 99% composition, is aluminum. Recognized for its silvery-white appearance, aluminum boasts a low density and a high strength-to-weight ratio.

However, there are several aluminum alloys formed through the addition of other elements like copper, magnesium, silicon, zinc, and manganese. The aluminum alloy type determines which elements will be present in it and their composition.

Chemical Composition: Tabular Comparison Between Galvanized Steel vs. Aluminum

The chemical properties of aluminum vs. galvanized steel collectively contribute to their strength, hardness, corrosion resistance, other features, and use in various industries. This table highlights each chemical element in galvanized steel vs. aluminum pipe, tube, sheet, etc., and their value. 

Galvanized Steel vs. Aluminum: Differences in Surface Properties

Galvanized steel possesses distinctive surface properties that make it highly desirable for various applications. These surface properties stem from the zinc coating applied during the galvanizing process and contribute to the steel’s enhanced durability, corrosion resistance, and aesthetic appeal. Here are some key surface properties of galvanized steel:

• Longevity: The robust zinc coating ensures that galvanized steel can endure diverse environmental conditions, including exposure to rain, humidity, saltwater, and harsh chemicals, all without substantial deterioration.
• Self-Healing: Should the zinc coating sustain scratches or damage, the neighboring zinc can provide cathodic protection, aiding in the healing of the affected area through the corrosion process.
• Ease of Inspection: The distinctive spangled pattern on the surface simplifies the assessment of the galvanized coating’s integrity. Any areas exhibiting noticeable changes in appearance might indicate potential damage to the coating.
• Paint Adhesion: The textured surface of galvanized steel, resulting from the zinc coating, facilitates strong adhesion for paints and other coatings. This renders it suitable for endeavors necessitating additional decorative or protective finishes.
• Formability: Despite the presence of the zinc coating, galvanized steel maintains its formability. This permits shaping, bending, and fabrication into diverse forms without compromising its safeguarding attributes. Nevertheless, when comparing galvanized steel wire vs. aluminum, the former proves more resistant to bending.

In contrast, aluminum possesses distinct surface qualities arising from its inherent oxide layer and its interaction with the environment. The ensuing are key surface attributes of aluminum:

• Oxide Layer: When exposed to air, aluminum develops a thin layer of aluminum oxide (Al2O3) on its surface. This oxide layer is a protective barrier, endowing the metal with remarkable corrosion resistance by impeding direct contact between the aluminum and external factors such as moisture and oxygen.
• Non-magnetic: Due to its crystal structure, aluminum is paramagnetic, making it well-suited for scenarios where magnetic interference poses a concern, particularly in sensitive electronic equipment.
• Forming and Machining: Aluminum is soft and malleable, so it is easy to form and bend into various shapes and designs to fit various commercial and industrial applications. In addition, the cutting force required for cutting aluminum is much less than that of galvanized steel, so machining aluminum is more affordable.
• Non-Toxic: Over the years, aluminum has become popular in the food processing industry due to its non-toxic effect on food and its capability to keep food fresh for a long period. Aluminum is both non-toxic and unreactive to food substances, rendering it an excellent choice for applications involving food packaging, cookware, and equipment used in food processing.

Galvanized Steel vs. Aluminum: Differences in Strength

When talking about the strength difference between galvanized steel vs aluminum strength, galvanized steel proceeds aluminum. It is heavier and more sturdy, and its zinc coating gives it the ability to withstand exposure to stress and prolonged pressure.

Even if the galvanized steel’s surface gets scratched or damaged, the material underneath is still strong. On the other hand, aluminum is lighter and more soft than its counterpart (galvanized steel). This feature makes it less suitable for heavy-duty applications and ideal for settings like car manufacturing and aircraft components.

Galvanized Steel vs. Aluminum: Differences in Durability

If you’re gauging how well-galvanized steel vs. aluminum can last under intense pressure, heat, corrosion, strain, and prolonged exposure to other conditions, galvanized steel may come off as the winner in the challenge, especially because of its hot dip coating. Nevertheless, it is important to know that aluminum has features, like corrosion resistance, that can make it last longer than galvanized steel.

Here’s an example: If the zinc layer gets scratched or damaged, the zinc around the scratch protects the steel underneath. This means that the steel stays strong even if it gets a little damaged, the steel stays strong. That’s why galvanized steel is often used in places where it’s exposed to the outdoors or tough industrial settings.

On the other hand, aluminum is tough, too, mostly because of the natural layer that forms on its surface. This layer acts like a shield that stops corrosion from getting to the aluminum. But, the protection for aluminum comes from this layer staying stable and strong, unlike how zinc protects steel by slowly wearing away if there’s damage.

It’s good to remember that while aluminum is resistant to corrosion, some situations, like high levels of acid or a lot of humidity, can still challenge its durability. But most of the time, manufacturers add extra layers or treatments to help aluminum do well, even in these tough conditions.

When you’re picking between galvanized steel vs. aluminum trailers, durability is a big factor. You think about what the thing will be used for and where it’ll be used. Galvanized steel is great for things like outdoor structures, stuff near the water, and heavy machinery. But aluminum is awesome for things that need strength but not heavy, like parts for planes, cars, and fancy architectural details. 

Difference between Aluminium and Galvanized Steel

Galvanized Steel vs. Aluminum: Differences in Weight

The difference between galvanized steel vs aluminum weight mainly comes down to their densities, which affect their weights. Galvanized steel is denser, weighing about 7.85 grams per cubic centimeter, making it heavier than aluminum, with an average density of about 2.70 g/cm3.

The extra weight of the steel itself, along with the zinc coating, adds to its overall mass. This higher density makes galvanized steel a great fit for situations where strength and the overall structure’s toughness are important. Think about things like construction, big projects, and heavy machinery.

So, when comparing the weight of galvanized steel vs. aluminum, it’s noteworthy that both have perks and limitations, depending on the use case. Aluminum’s lightweight quality makes it an excellent choice when it’s super important to keep things light. This is why industries like aerospace, making cars, and transportation love using aluminum.

So, if you’re all about making things strong and stable, galvanized steel’s weight is what you’re looking for. But if you’re more focused on cutting down weight, making things work  well, saving energy, and using less fuel, then aluminum is the way to go for your building or making needs.

Aluminum vs. Galvanized Steel Thermal Properties

Aluminum is a champ in conducting heat. Its higher thermal conductivity means heat doesn’t move as easily through galvanized steel as through aluminum. Because of this, aluminum is like a superstar at transferring heat, which makes it perfect for stuff that involves moving heat around, like heat exchangers, radiators, and electronics.

On the flip side, galvanized steel isn’t as good at letting heat pass through. This can actually be a good thing when you want to keep heat trapped, like in situations where you want to hold onto warmth. But if you’re looking for your setting to require excellent thermal conductivity, opt for aluminum.

Galvanized Steel vs. Aluminum: Differences in Weldability

The weldability of galvanized steel vs. aluminum depends on various factors, including the skill level of the welding professional. While some argue that welding aluminum is more challenging than welding galvanized steel, here are some factors to keep in mind when comparing how easy it is to weld these materials:

• Material Properties: Depending on the alloy, chemical components, impurities, and other factors, aluminum tend to melt quickly than galvanized steel at a melting point of 660.32°C. On the flip side, galvanized steel has a melting point of 1,200°C. For this reason, welders pay close attention to it during the welding process.
• Surface Preparation: When welding aluminum, it is important to properly clean it because it develops a thin layer of oxide on its surface, making the process challenging. As for galvanized steel, the zinc coating creates oxide fumes during the welding process, which can be harmful. 
• Welding Methods: When working with aluminum, the go-to techniques are usually TIG or MIG welding, coupled with the appropriate filler materials and gases. But when it comes to galvanized steel, MIG welding can be employed as well. However, it’s important to handle the zinc fumes carefully to avoid problems such as weld porosity.
• Filler Material: Choosing filler materials that align with aluminum’s properties is essential during every Al welding process to make for a robust weld. On the other hand, when choosing a filler material for galvanized steel, consider the presence of zinc in the joint and its impact on the weld.
• Welding Settings: The settings you use during welding for aluminum and galvanized steel are as important as the expected results. For instance, as a rule of thumb, when welding aluminum using the Gas tungsten arc welding technique, use one amp for every thousandth (0.001) of the material’s thickness.
• Post Weld: Many manufacturers and welding professionals treat aluminum and galvanized steel with distinct after-weld treatments. This final process ensures that the materials have a certain level of protection against corrosion-inducing environments and media.

Galvanized Steel vs. Aluminum: Differences in Aesthetics

With its shiny silver-white color, aluminum has a better aesthetic appeal than galvanized steel. Notwithstanding the metals and the post-weld process employed by the manufacturer, aluminum creates a stylish and contemporary look for its products. On the flip side, galvanized steel has a silver-gray shade, which develops a slightly dull gray, worn-out appearance over time. 

Apart from color, galvanized steel feels a bit rough due to the zinc coating, while aluminum is smoother to the touch and can be given various finishes like brushed or polished. As time passes, galvanized steel forms a patina, adding a vintage or industrial feel. In contrast, aluminum keeps its original color and shine because of the protective oxide layer on its surface.

Beyond their color representation, galvanized steel has a coarse texture due to the element used during the hot-dipping process. On the other hand, aluminum is smoother with its brushed or polished look. Also, galvanized steel develops a patina over a long period, but aluminum maintains its initial color and shine.

Galvanized Steel vs. Aluminum: Differences in Corrosion Resistance

The ability of materials to withstand corrosion is crucial when determining how long they’ll last and how durable they are, especially when they’re exposed to tough conditions or substances that can cause corrosion. 

Galvanized steel gains corrosion resistance through a zinc layer applied to its surface. This zinc layer serves as a kind of sacrificial barrier (galvanic coverage). What that means is if the galvanized steel gets scratched or exposed, the zinc corrodes first, effectively safeguarding the steel underneath.

Conversely, aluminum’s corrosion resistance comes from its natural ability to form a very thin oxide layer when it’s exposed to air. This layer is transparent and actually repairs itself, preventing further oxidation and corrosion. This is because aluminum has a strong affinity for oxygen, creating a robust bond that acts as a shield for the metal.

Corrosion is a major factor for all galvanized steel and aluminum products, including when it comes to comparing aluminum vs. galvanized steel gazebo corrosion resistance. Most people opt for the first, but certain corrosive media can corrupt aluminum’s resistance. So, when selecting between galvanized steel vs aluminum corrosion resistance, the choice depends on the environment in which they’re used. 

Galvanized Steel vs. Aluminum: Differences in Electrical Conductivity

Aluminum is an excellent conductor of electricity, making it suitable for settings where efficient electrical transmission is a must. Some of these locations and applications include industrial areas, electronics, car manufacturing companies, power lines, electrical cables, and other electrically powered environments. 

While aluminum is an excellent electricity conductor, galvanized steel doesn’t conduct electricity as well as aluminum. That is because the zinc cost that adds to its strength, weight, and corrosion resistance adds some defiance to the flow of electric current. For this reason, you can only choose galvanized steel if electrical conductivity is not crucial for your project or work environment. 

Galvanized Steel vs. Aluminum: Differences in Applications

Just like their properties and chemical composition are different, so is their application. Nevertheless, they still share similarities in applications that have been compared side by side, such as in the aluminum vs. galvanized steel hurricane shutters, aluminum flex duct vs. galvanized steel duct, and galvanized steel vs. aluminum gazebo discussion.

While so many comparisons like those mentioned above are flying around, here are other aluminum and galvanized steel applications you should know.

1. Common Applications of Galvanized Steel

Let’s take a look at a real-world scenario that often sparks a debate between aluminum and galvanized steel: aluminum vs. galvanized steel pool. When it comes to pool construction, galvanized steel pools are known for their durability and long lifespan, but they come with a catch—higher cost. 

While they might be a pricey upfront investment, they pay off in the long run. However, the applications of galvanized steel extend well beyond just pools. Here’s where you’ll commonly find it being used:

• Outdoor Structures: Thanks to its protective zinc coating, galvanized steel is a popular choice for outdoor structures like fences, railings, and pergolas. Its exceptional durability and resistance to various corrosion triggers, including water and oxygen, make it perfect for enduring the elements.
• Automotive Parts: Aluminum is the best and most preferred option when comparing aluminum vs. galvanized steel applications in the car manufacturing industry. However, some manufacturers use galvanized steel to produce chassis parts and exhaust systems.
• Construction: For construction needs, like roofing and structure, the choice between aluminum vs. galvanized steel may not be hard. That is because these projects require materials with high strength.
• Water Conduits: Galvanized steel is designed for heavy-duty applications and settings with high corrosive media. While aluminum also has great corrosion resistance, galvanized steel is more saltwater-resistant. Little wonder it’s vast application in water distribution systems. 
• Utility Poles: For sturdy utility poles and electrical transmission towers that can brave outdoor conditions, galvanized steel is the material of choice. However, it’s important to note that these structures aren’t used to transmit electricity, as galvanized steel has lower electrical conductivity than aluminum.
• Marine Equipment: Galvanized steel shines in marine applications due to its ability to withstand the strains of saltwater corrosion and extended stress. It’s utilized in marine components like boat trailers and docks.
• HVAC Ducting: When weighing the pros and cons of galvanized steel vs. aluminum duct applications, galvanized steel often prevails in HVAC systems. Its durability and resistance to environmental factors make it a reliable option for ductwork and ventilation components.
• Industrial Equipment: Galvanized steel is a cornerstone of industrial settings, finding its place in equipment such as storage tanks, platforms, and conveyors, where resistance to corrosion is paramount.
• Agricultural Machinery: The robustness of galvanized steel suits it well for use in agricultural machinery and equipment, withstanding the stresses and elements that come with prolonged exposure.
• Safety Barriers: Another notable application of galvanized steel is in safety barriers and rails along highways and construction sites. It offers protection while holding up against various weather conditions.

2. Applications of Aluminum

Aluminum is a highly versatile metal with various industry applications. When comparing galvanized steel vs. aluminum fence, galvanized steel vs. aluminum mailbox, or other aluminum products, you’ll find that it is a preferred choice for many constructors and individuals. Besides that, here are some of the most common use cases of aluminum:

• Aerospace: In the aerospace sector, aluminum takes the lead over galvanized steel, largely due to its lightweight composition. It’s a well-known fact that galvanized steel is heavier compared to aluminum, which is why it finds limited use in aerospace applications. Aluminum’s strength, however, makes it a go-to material for crafting aircraft frames and various components.
• Electrical Wiring: With its impressive electrical conductivity, a feature that galvanized steel lacks, aluminum finds its place in electrical wiring and power transmission lines. Its efficiency in conducting electricity makes it a preferred choice for these purposes.
• Automotive Panels: Aluminum serves a unique purpose in the automotive sector for body panels. Unlike galvanized steel, aluminum is utilized to reduce weight and enhance fuel efficiency while still maintaining the structural integrity of the vehicle.
• Packaging: When it comes to food processing, industries look for metals or steel materials that are non-toxic to avoid food poisoning and early spoilage, and aluminum has been a reliable companion over the years. Its lightweight nature and non-toxicity make it a preferred choice over galvanized steel in this industry. 
• Electronics: Galvanized steel is suitable for heavy-duty applications and harsh weather use, but electrical projects are a nearly no-go area for this material. So, instead of the heavy steel, industries requiring smooth electric passing opt for aluminum which is an excellent conductor of electricity.
• Architectural Design: Aside from their excellent corrosion resistance and electrical conductance, aluminum also has a better visual appeal than galvanized steel, making it suitable for various architectural designs and settings, including fences, facades, and roofing systems.
• Cookware: Since aluminum is an excellent conductor of heat, cookware made from it is highly efficient for heating. So, manufacturers make pots and nonstick pans from anodized aluminum, kettles, and other cookware.
• Bicycles: Unlike galvanized steel, which is heavy and stiff, aluminum’s lightweight nature allows for easy bending, rolling, and maneuverability. These properties are a great fit for applications requiring easy movement and cycling, hence its use in bicycle production. .
• Solar Panels: The solar panel industry is booming, with a market value exceeding $25 billion in the United States alone, thanks to the installation of about 3 million solar panels. Since their energy source is the sun, these panels are installed directly under sunlight, which would’ve been a problem if not for the use of aluminum to maintain their lifespan even under exposure to various weather conditions.

3. Aluminum Vs. Galvanized Steel Gutters (Galvanized Steel Gutters Vs. Aluminum)

When comparing galvanized steel vs aluminum rust, the first parameter to consider is their rust resistance. They are both corrosion-resistant, but aluminum is much more resistant than galvanized steel. Aluminum is also lightweight and easy to paint to your desired color, so if you need a versatile gutter material to last you more than 30 years, opt for aluminum gutters.

4. Galvanized Steel Vs. Aluminum Fenders

For fenders, galvanized steel is less likely to crack or bend under pressure than aluminum. However, aluminum fenders have longer lifespans and are more lightweight than galvanized steel fenders. Additionally, aluminum fenders require little to no maintenance or early replacements, unlike galvanized steel fenders.

5. Galvanized Steel Vs. Aluminum Flashing

In terms of what material makes a better flashing between galvanized steel vs. aluminum, there’s hardly a clear winner because both materials exhibit great durability, weldability, and formadability. However, since galvanized steel flashings are heavier than ones made from aluminum, they are much more resistant to intense stress and heavy pressure impacts.

6. Galvanized Steel Vs. Aluminum Horse Trailers

Galvanized steel horse trailers are more rigid, stronger, heat slowly, and are cheaper than aluminum steel horse trailers. However, aluminum horse trailers, though more expensive, are more durable, offer a smoother ride experience, and ensure easy replaceability and low long-term maintenance.

7. Galvanized Steel Vs. Aluminum Pipe

Galvanized steel pipes are naturally designed for high temperature and pressure use. This is why they are widely used in chemical industries, water lines, and sewer plumbing. On the flip side, aluminum pipes are used in industrial buildings, Guerney systems, and processing plants. Unlike aluminum, galvanized steel pipes will need replacement after 25 years since they don’t have a long lifespan like aluminum pipes.

8. Galvanized Steel Vs. Aluminum Road Gates

When choosing between galvanized steel and aluminum road gates, your requirement is the most important consideration. If you want a pricier, long-lasting, lightweight gate with excellent corrosion resistance, you should opt for aluminum road gates. However, if you’re on a slim budget and need a stronger gate, the galvanized steel gate is ideal.

9. G0alvanized Steel Vs. Aluminum Shutters

Galvanized steel shutters are one of the most inexpensive shutters you can find in the market. They are not only cheap, but they beat aluminum shutters hands down in terms of protection and strength. However, issues may arise if you’re installing them yourself. The weight will require additional manpower. On the flip side, aluminum gutters last longer and are more visually appealing than galvanized steel shutters. 

10. Galvanized Steel Vs. Aluminum Vent

Aluminum has a higher thermal conductivity level than galvanized steel, so it is preferred in vent systems since it is lightweight and performs better than galvanized steel. While galvanized steel is also employed in vent systems, it only boasts strength, durability, weight, and lower upfront costs.

11. Galvanized Steel Vs. Aluminum Duct

When comparing galvanized steel vs. aluminum duct, the major upside for galvanized steel is its design and configuration for heavy-duty applications. However, galvanized steel is more prone to oxidation and corrosion than aluminum. On the flip side, aluminum ducts are durable, have long lifespans, are lightweight, and are extremely resistant to various corrosive media.

12. Galvanized Steel Vs. Aluminum Fence

As discussed earlier, aluminum offers better aesthetic appeal than galvanized steel. It has a smooth and shiny surface and can be repainted to your desired color. This property makes it a preferred option for home fencing and other settings. However, for certain applications, strength and weight are crucial, and that is where galvanized steel fence steps in since it is stronger and heavier than aluminum.

Galvanized Steel Vs. Aluminum: Differences in Cost

In terms of aluminum vs. galvanized steel cost, galvanized steel has a less expensive upfront cost than aluminum due to several factors. First, galvanized steel undergoes a process of coating it with a layer of zinc to prevent corrosion. This additional processing requirement contributes to its long-term value over aluminum, making it a cost-efficient option in the galvanized steel vs. aluminum cost argument. 

However, additional expenses, such as the material’s weight, may affect the cost of aluminum vs. galvanized steel. As pointed out earlier, galvanized steel is heavier than aluminum, increasing labor costs during installation. On the other hand, aluminum comes with a higher upfront cost than galvanized steel.

While aluminum’s extraction and refining processes might affect its place when comparing the cost of galvanized steel vs. aluminum, its benefits, such as being lightweight and naturally corrosion-resistant, make it an attractive option for various industries. So, when searching for the best for your project using the galvanized steel vs aluminum price as a determinant, it is advisable to consider your budget and project needs.

Galvanized Steel vs. Aluminum: Differences in Maintenance

Over the years, galvanized steel has demanded more upkeep than aluminum, partly because of its coarse and porous surface, among other reasons. It’s prone to rust and corrosion, particularly in settings with high humidity, chemical exposure, or regular scraping, despite having a protective zinc coating.

On the flip side, aluminum boasts inherent corrosion resistance thanks to the thin oxide layer that naturally forms on its surface. This layer acts as a shield against extensive rusting. Consequently, aluminum requires less maintenance compared to galvanized steel. Periodic cleaning to remove dirt and debris is usually enough to keep its surfaces in good shape and performing well.

Galvanized Steel vs. Aluminum: Differences in Recyclability and Environmental Impact

Opting for aluminum over galvanized steel carries a greener advantage, driven by its higher recyclability rate and reduced environmental impact. Aluminum is fully recyclable, and the recycling process demands less energy than its initial raw material extraction. This translates to fewer greenhouse gas emissions and lower energy consumption.

onversely, recycling galvanized steel, though possible to a certain extent, involves a more intricate process. The zinc coating adds complexity, necessitating the removal of this layer before effective steel recycling can occur. This extra step increases energy usage and could lead to heightened environmental costs.

Furthermore, aluminum’s lightweight nature contributes to lower emissions during transportation and lower energy consumption over its entire lifecycle. Its built-in corrosion resistance diminishes the need for protective coatings or frequent maintenance, further curbing its overall environmental impact.

Galvanized Steel vs. Aluminum: Tabular Difference in ASTM Specification

The table below highlights the ASTM International (American Society for Testing and Materials) specification of various aluminum vs. galvanized steel products.

Galvanized Steel vs. Aluminum: Which One Should You Choose?

The choice between aluminum vs. galvanized steel hinges on the needs of your industry and environmental considerations. Each material offers its own unique advantages. Galvanized steel is known for its robustness, cost-effectiveness, weightiness, and suitability for scenarios involving high humidity and corrosive elements.

On the other hand, aluminum brings its lightweight nature, ability to endure various stresses and weather extremes, corrosion resistance, and environmental sustainability perks to the table. When choosing, it’s essential to weigh the factors that hold the most significance for your specific project. This way, you can select the material that best aligns with your objectives and priorities.

Conclusion

Whether you manufacture cars or need galvanized steel and aluminum materials for marine settings, hospital, and industrial purposes, KDM is the top original equipment manufacturer of all electrical and electronic components. They have a team of engineers and welders working hand-in-hand to offer you the best products that suit your construction needs.

With decades of successful service deliveries and tons of certifications, including UL, NEMA, ISO, and REACH, you will surely get the best value for your money. Contact KDM today for personalized sheet metal bending, laser cutting, welding, or finishing solutions for your project.