Contact us

Blogs  | Weiye Aluminum
Location:Home - blog

Why Are Aluminum Extrusions Better Than Stainless Steel?

weiye 0

Aluminum is a highly versatile metal, and engineering designers can use it for various applications. Additionally, its benefits to steel are hard to beat. For instance, Aluminum is strong, lightweight, and corrosion resistant. Additionally, it makes formable structures.

Also, Aluminum is easily recyclable, making it environmentally friendly and attractive. Finally, the metal is resilient, reshapes after impact, and flexes under loads.

Aluminum’s unique properties make it a better choice for design engineers than steel. For instance, manufacturers can make aluminum extrusions in different colors, shapes, and physical properties fitting various requirements. Aluminum is more flexible than stainless steel, making it a better option.

Extruded profiles made from stainless steel are the better solution for projects requiring high levels of corrosion resistance. However, aluminum extrusions are easier to design, and manufacturers can work them to fit individual purposes. Steel extrusions require rework or additional machining to fit complex applications.

Read on to discover why you should use aluminum extrusions over stainless steel and where to get the best aluminum extrusions.

Reasons why aluminum extrusions are better than stainless steel




Most people know that aluminum is lightweight. However, they don’t know that it’s lighter than steel by two-thirds, which is why automotive and aerospace engineers use it when making cars and planes. The metal’s lightweight nature makes it perfect for customers since it lowers operational costs.

Despite its lightweight nature, the metal has a strength of 35000 psi. Plus, manufacturers can apply specific forging skills to create aluminum extrusions as strong as steel. This is quite beneficial for users since they’ll get dependable aluminum extrusions at a less costly price than steel.

Unlimited geometries


Aluminum extrusions have extraordinary design flexibilities. For instance, manufacturers can extrude extremely complex designs, allowing engineers to place materials where needed to create structures with optimum strength. Doing this helps minimize fabrication costs than would have been the case with steel.

Many tube designs manufacturers produce that can’t be produced with steel. Those that can be produced using steel require complex processes and cost more. Thus, aluminum extrusions provide a better option than steel and are more efficient, making aluminum the better alternative.

Unique properties


You can form extruded metal products to create varying shapes that serve different purposes. Aluminum’s unique properties make it easier to work with than steel. For instance, it’s easier to shape extruded aluminum products than steel products because You can easily bend the aluminum.

For example, aluminum extrusions made for bike wheel customers bend easily, allowing users to bend the material and roll it into hoops for bike rims. Satellite cooling customers can make complex compound bends when making their heat pipe cooling systems. Finally, customers of disposable medical devices choose tempers allowing surgeons to bend the extrusions as needed during operations.

Colors and coatings


Manufacturers can anodize extruded aluminum to enhance its appearance, extend its life, and improve wear resistance. The metal’s coating is clear, and manufacturers can combine it with organic dyes to meet user demands.

Additionally, manufacturers can treat the extrusions with chemical conversion coating, minimizing oxidation. This process is specific to many aerospace applications. Chem film and anodization processes are bio-compatible and are used when manufacturing disposable medical devices.

Low tooling costs


Extrusion dies are more inexpensive than other types of tooling. For instance, die costs for extruded .350” diameter rods costs $500. The cost for .500” OD by .400” ID tubes is $1300. Some of the most exotic dies are for thin, multi-hollow wall designs, costing over $3500. The dies are the exception, and lead times may vary between 2 to 4 weeks for tool production.

Aluminum extrusions cost less than steel.


Aluminum extrusions are more cost-effective than stainless steel tubes by up to 70%. Additionally, there are several examples of machine parts that manufacturers have redesigned using extrusions, reducing the costs by 30 to 40 %. This makes aluminum extrusions the go-to alternative for users that find steel too expensive to work with.

Corrosion resistant


Aluminum is less corrosive than steel. The metal resists corrosion without the need for any additional forms of treatment after extrusion. Additionally, the metal requires less maintenance over time.

Aluminum doesn’t rust and doesn’t need any coating to prevent corrosion. You could paint steel to prevent rusting; however, the coating may scratch or wear off, exposing the metal to corrosion.

Aluminum metal reacts with atmospheric air to form aluminum oxide. The compound forms an outer layer preventing the metal from further corrosion. Additionally, manufacturers can enhance the metal further by providing a variety of finishes like painting, polishing, media blasting, brushed finish, powder coating, anodizing, or chemical wash techniques.



Steel is less ductile and malleable than aluminum, which can withstand high tensile stress before it fails. Thus, manufacturers have an easy time making extrusions, and they are perfect for heavy structures that can break steel.

They don't require machining.


There are lots of custom and standard machining services available with 80/20. However, they aren't required with aluminum as they are with steel. Working with steel extrusions requires metal machining, which involves drilling and cutting to remove imperfections and shape the final product as desired.


Steel extrusions are good for projects that demand heat resistance and superior strength. Conversely, Aluminum extrusions are great for projects requiring versatility and cost-effectiveness. However, the metal you choose to work with depends on your project and desired results.

Conclusion - Why Are Aluminum Extrusions Better Than Stainless Steel


Aluminum extrusions are 100 % non-toxic and recyclable. We also have various finishing options, are highly reflective, and are resilient. We also have high thermal and electrical conductivity. We can make intricate shapes with aluminum profiles for construction buildings, various industry and furniture, etc. The aluminum profiles and fabrications are non-magnetic, non-sparking, virtually seamless, and non-combustible. 

We produce the best and most reliable aluminum extrusions. Our company was founded in 1992, has unrivaled industry experience, and produces large-scale aluminum extrusions. We have great customer service and distribute our orders overseas. Get in touch with us through our contact page and make your order today!