A Handy Guide to Aluminum Fabrication (Updated for 2024)

Aluminum is about 1/3 the weight of steel.

So, you’re probably asking yourself, “should I be using aluminum on my next project?” Before doing that, here are nine facts that could influence your decision.

One of  the most common questions about aluminum relates to strength: "Is aluminum stronger than steel?" Aluminum is about 1/3 the weight of steel. However, aluminum does have a very strong strength-to-weight ratio. This means it is very strong in proportion to its total weight. For you, that can lead to energy savings in your application. 

Feature Characteristic Benefit Light Weight 1/3 weight of steel Weight savings Corrosion resistant Aluminum combines with oxygen to form a tough film which protects the metal Low maintenance, long life, and a consistently good appearance High strength-to-weight ratio Very strong in proportion to its total weight Energy and labor savings High electrical conductivity Copper is rated higher but is three times as heavy Substantial savings High thermal conductivity or heat transfer Conducts heat effectively, good for radiator or cookware Less metal is used to make more product Low magnetic, low sparking Difficulty in sparking; used in electronic equipment Safety Low heat radiating Does not radiate heat effectively, good solution for moving hot liquid gases Safety High heat and light reflectivity Will reflect 80% of the heat and light striking it. Ideal for heat shielding and lighting Safety and cost savings Excellent machinability Suited for high-speed machining Produce more parts per hour/pound/unit of energy Malleable and ductile Pliable material that can be easily drawn, formed, and worked Allows for an unlimited range of applications

Aluminum does not rust, but ...  

You may be asking, "Does aluminum rust?" Aluminum does not rust, but it does corrode. Aluminum combines with oxygen to form a tough film which protects the metal. For you, that means low maintenance, a longer life, and a consistently good appearance for application. 

Aluminum is difficult to spark! 

Another common question is, "Is aluminum magnetic?" Overall, aluminum is a low magnetic, low sparking metal. This helps when it is used in electronic equipment because it is difficult to spark. 

Aluminum features high electrical conductivity. 

While copper is rated higher in terms of electrical conductivity, it is about three times as heavy. That means aluminum offers you substantial savings in this category. 

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According to The Aluminum Association, a roof that is properly coated with aluminum can reflect up to 95% of solar energy that strikes them. This can dramatically improve energy efficiency. 

Aluminum likes to cook.  

Aluminum is an ideal material for radiators or cookware. This is due to the fact that aluminum features high thermal conductivity (heat transfer), which means aluminum conducts heat effectively.
However, while aluminum conducts heat effectively, it has a low rate of heat radiation. That makes aluminum a good material for applications that move hot liquid gases. 

Aluminum likes to reflect.

Aluminum will reflect 80% of the heat and light striking it. This makes it an ideal material for heat shielding and lighting. 

Aluminum has a need for speed!

Aluminum features excellent machinability, which makes it suitable for high-speed machining. For you, that means the ability to produce more parts per hour, per pound, and per unit of energy. 

Aluminum isn't toxic 

Aluminum is not known to have toxic effects, which makes it a good choice for things like food and beverage containers. 

Aluminum and plasma don't play well together. 

When cutting aluminum, it is best to use a either a saw, shear, or laser. It is not advisable to use plasma, because when aluminum combines with water it can produce a build-up of hydrogen gas bubbles, which could be ignited by the plasma laser. In fact, there are many tips about which metals to use with which cutting methods, according to our fabrication experts. 

You will notice that when ordering aluminum online, Ryerson only provides the option to saw, shear, or laser cut the product. 

Knowing all of this, you may be asking yourself one last question: How much is aluminum per pound? The answer to that question tends to fluctuate daily. Luckily Ryerson has a resource to help you keep track of the pricing trend of aluminum.

For more information, please visit Aluminium 8000 Series.