Table of Contents
Pros and Cons of Major Metals
Steel
- Pros: High strength, widely available, cost-effective, weldable
- Cons: Heavy, prone to corrosion unless treated
Aluminum
- Pros: Lightweight, corrosion-resistant, easy to machine
- Cons: Softer, lower strength than steel, more expensive
Copper
- Pros: Excellent electrical and thermal conductivity, corrosion-resistant
- Cons: Expensive, softer and harder to machine than aluminum
Stainless Steel
- Pros: Corrosion-resistant, strong, aesthetic finish
- Cons: Heavier and costlier than mild steel, harder to machine
Brass
- Pros: Corrosion-resistant, decorative finish, good machinability
- Cons: Higher cost, not as strong as steel
Comparison: Cost, Strength, Weight, Corrosion, Machinability
| Metal | Cost | Strength | Weight | Corrosion Resistance | Machinability |
|---|---|---|---|---|---|
| Steel | Low | High | High | Low (unless treated) | Moderate |
| Aluminum | Moderate | Medium | Low | High | High |
| Copper | High | Low | Medium | High | Low |
| Stainless Steel | High | High | High | High | Low |
| Brass | High | Medium | Medium | High | High |
Application Examples
- Steel: Structural frames, heavy machinery, automotive parts
- Aluminum: Aerospace components, lightweight enclosures, marine parts
- Copper: Electrical connectors, heat exchangers, plumbing systems
- Stainless Steel: Food processing equipment, medical tools, architectural trim
- Brass: Decorative fixtures, musical instruments, valve components
Sourcing and Availability Tips
- Check regional supply trends—some metals may have longer lead times.
- Work with certified suppliers to ensure consistent quality.
- Ask about mill certifications and traceability, especially for regulated industries.
- Consider metal availability when planning prototypes vs. mass production.
Final Decision Guide / Cheat Sheet
- Need strength and low cost? → Choose steel
- Need light weight and corrosion resistance? → Go with aluminum
- Need conductivity? → Use copper
- Need rust resistance and strength? → Pick stainless steel
- Need aesthetic finish and easy machining? → Try brass
Choosing the right metal starts with knowing your priorities—performance, cost, appearance, or ease of fabrication. Use this guide to match the material to your job, and you’ll avoid headaches down the line.
