Compare Sheet Metal Materials

Aluminum 5052 is a widely used alloy across common part applications made from sheet metal. This popular choice provides superior corrosion resistance, making it ideal for parts exposed to harsh environments. 5052 has a high modulus of elasticity, lending it to formability and weldability, allowing for unique shapes to be created out of the flat sheet. This material is versatile due to high strength, its lightweight nature, and aesthetic characteristics.

Aluminum 6061 is also known as “structural aluminum.” 6061 is alloyed with silicon which provides higher strength capabilities than an alloy such as Aluminum 5052. 6061 has a lower modulus of elasticity compared to other options, making it less formable and weldable than 5052, but it maintains similar lightweight characteristics. The alloy composition of 6061 is designed to prioritize strength over aesthetics.

Brass C260 is primarily composed of copper and zinc, giving it the golden-yellow color for which it is known. Mechanically, Brass has corrosion-resistant and formable qualities similar to Aluminum 5052. Brass is heavier than aluminum, making it well suited for aesthetic or decorative applications.

Copper 101 (C101) is known as oxygen free electronic or OFE Copper. It is primarily chosen when material impurities are undesired and electrical conductivity is crucial. It offers strong corrosion resistance and formable qualities but is more costly than oxygenated Copper 110. C101 is typically used for applications where exceptional conductivity is favored over cost savings.

Copper 110 (C110) is the oxygenated relative of Copper 101. Containing only a small amount of oxygen, C110 is more widely used for practical applications such as heat exchangers, wiring, and plumbing components. C110 is more readily available and is a lower cost copper option without trading off the formability characteristics of C101. While a strong electrical conductor and corrosion resistor, C110 contains impurities in the form of oxygen which can’t stand up to the purity of C101.

Low Carbon Steel 1008 is a mainstay material option in sheet metal fabrication. Containing less than .30% carbon, 1008 is formable, not prone to cracking, and its minimal carbon content provides weldability without the brittleness of a high carbon option. 1008 comes uncoated from the mill and is susceptible to corrosion, however it readily accepts coatings and finishings (such as zinc or powder coat) for protection.

Cold-Rolled Galvanized steel arrives from the mill with a zinc coating which prevents corrosion and provides its distinctive shiny, spangled appearance. This unique surface appearance makes it more challenging for other finishes, like powder coating to adhere to the metal without additional material preparation. This material lacks weldability due to fumes from its zinc coating, however galvanized is easily formed in the press brake.

Cold-Rolled Galvannealed steel differs from galvanized due to receiving heat treatment and annealing after a zinc coating is applied. This additional process transforms the zinc coating to a zinc-iron alloy, providing corrosion resistance and low shine. The difference in surface finish appearance allows for better paint adhesion, however similar issues remain in terms of weldability. Both pre-plated steels offer strong formability characteristics.

Stainless Steel 304 comes in two varieties, 2B and #4. These identifiers refer to the surface finish applied at the mill, but the underlying material is the same. 2B has a low shine appearance, whereas #4 has a brushed aesthetic from a mechanical polishing process. 2B typically costs less than #4, however both are formable and weldable. Of note, welding 304-#4 can remove the desirable brushed finish. 304 provides only adequate corrosion resistance and is particularly risky in high-chloride environments such as saltwater or coastal regions.

Stainless Steel 316 is similar to 304 but is instead alloyed with molybdenum. This feature enhances its corrosion resistance, especially in high-chloride marine environments. 316 has similar strength characteristics to 304 and is equally formable and weldable. Thanks to the addition of molybdenum, 316 is versatile, but comes at a higher cost than 304.