Aluminum vs Stainless Steel Wire Mesh: What Works Best?

29 Apr.,2024

 

Aluminum vs Stainless Steel Wire Mesh: What Works Best?

 

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In the early 1800s, chemist Sir Humphry Davy discovered that a piece of wire cloth could help the functionality of miners' safety lamps. This increased the demand for woven wire mesh and projected the wire mesh industry.

During the initial years, wire mesh was woven using materials like brass, which was relatively inexpensive compared to alloys like stainless steel. But as time went on, we saw a changing of the guard, and stainless steel became the more affordable and widely used alloy used to weave wire mesh.

But just because it is widely used doesn't necessarily mean it's the right choice for you. To achieve the best result, you must understand how stainless steel compares to other alloys, such as aluminum.

W.S. Tyler has been a respected entity within the wire mesh industry for over 140 years. We take pride in educating those interested in wire mesh on everything they need to know to create optimized solutions tailored to their needs.

With that, we wrote this article to help you better understand the differences between aluminum and stainless steel wire mesh. You will learn:

  • What aluminum is

  • The benefits of using aluminum wire mesh

  • What stainless steel is

  • The benefits of using stainless steel wire mesh

  • Which of the two alloys makes sense for you

 

What Is Aluminum?

Much like nickel wire mesh, aluminum is an alloy that naturally exists within the periodic table of elements. It is known to bind with other chemicals easily; thus, aluminum in its pure is not seen naturally despite being one of the most prominent elements on the planet.

When using aluminum to weave wire mesh, W.S. Tyler will use one of three variants: 1100 aluminum (pure), alclad 5056, and 5056 aluminum.

 

What Are the Benefits of Using Aluminum Wire Mesh?

One of the most widely known benefits associated with aluminum is the fact it is lightweight. This is particularly true compared to other, more widely used alloys like stainless steel.

This can help reduce the stress inflicted on and throughout your machinery.

Aluminum also has the ability to create a protective layer of aluminum oxide when subjected to oxygen. This, in turn, helps aluminum resist various forms of corrosion.

Wire mesh woven from aluminum will also deliver better heat conductivity than stainless steel. To that end, aluminum features properties that make it a great electrical conductor.

Along with being lightweight, aluminum is widely known for its malleability. This allows aluminum wire mesh to be formed in customized components with ease.

 

What Is Stainless Steel?

Stainless steel is a steel alloy that meets the required carbon composition threshold while also containing chromium. The chromium within all stainless steel alloy does not generally exist in steel by itself.

Instead, it is incorporated on a molecular level when steel is in a molten state.

With properties experimentally calculated over the course of several decades, stainless steel is one of the most widely used alloys used to weave wire mesh. That said, W.S. Tyler will typically use a 300 series or 400 series stainless steel to weave wire mesh.

 

300 Series Stainless Steel Alloys:

  • 304

  • 309

  • 310

  • 316

  • 317

  • 318

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  • 321

  • 330

  • 347

 

400 Series Stainless Steel Alloys:

  • 430

  • 446

 

With a handful of different stainless steel variants to choose from, it should be noted that 304 and 316 are the most widely used.

 

What Are the Benefits of Stainless Steel Wire Mesh?

As stated above, all stainless steel contains chromium. Not only does this allow the alloy to be categorized as stainless, but it also makes it highly resistant to corrosion.

This includes corrosion from various alkaline and acidic substances present during industrial applications.

Stainless steel also has the capability to withstand high-heat conditions. It can maintain its performance when subjected to extreme heat as it combats oxidation.

But possibly the most critical property of stainless steel, compared to aluminum, is its durability. Whether subjected to high-impact situations or variations in temperature, the individual wires of stainless steel wire mesh will maintain their integrity for much longer than nickel.

 

What Alloy Should I Use?

The alloy you use to weave your wire mesh is critical to its performance and longevity. This is why it is critical that you choose the right one.

As it is a fairly soft alloy, aluminum is typically reserved for applications that value a corrosion-resistant mesh that is lightweight over strength. But if durability is essential to the success of your operation, stainless steel may be the better choice.

That said, stainless steel's high threshold for heat can make welding difficult if a low-carbon stainless steel is not used.

Weave Your Wire Mesh With the Right Alloy

While stainless steel is the most widely used alloy used to weave wire mesh, it's not always the right choice. Sometimes applications call for specific requirements, and alloys, such as aluminum, must be used to accommodate these requirements.

Now, if your application will subject your wire mesh to high-impact, corrosive conditions, the durability of stainless steel may perform best. But if your application can benefit from a lightweight wire mesh without sacrificing corrosion-resistant capabilities, you can consider using an aluminum alloy.

But, as stated above, the needs of your process dictate what alloy you use to weave your wire mesh. For this reason, you should understand how each alloy available to you fits within your process and industry.

Having helped engineers, system operators, and everyone in between navigate the wire mesh industry for over 140 years, W.S. Tyler strives to ensure your wire mesh solutions produce efficient results you can proudly stand behind.

To learn more about the other alloys you can use to fabricate your wire mesh solutions, read the following article:

304 Stainless Steel Benefits & Applications I Wire Mesh & ...

304 stainless steel is a stainless steel alloy with excellent formability, drawing, and machining characteristics. It's a popular material choice for a wide variety of wire mesh products, metal sheeting, and other fabrications. With exceptional corrosion resistance, high strength, and low weight 304 SS wire meshes and sheets are suitable for broad-ranging applications and use cases. With over half a century in the steel industry, Marlin Steel is committed to providing excellent 304 stainless steel mesh and sheet products for our clients.

Common Industrial Applications of 304 SS Wire Mesh and Sheet

304 SS wire meshes and sheets are a reliable, versatile material that can handle a wide variety of tasks and applications throughout consumer, commercial, and industrial markets. Some popular applications of our wire mesh and sheet products are:

  • Filtration applications, including liquid filtration, particle sieving, petroleum refining, and chemical processing
  • Production of security screens, baskets, and decorations.

Some of the industries we serve include:

  • Aerospace
  • Architecture
  • Chemical
  • Food production and processing
  • Mining
  • Petroleum
  • Pharmaceuticals

Benefits of 304 Stainless Steel

Stainless steel alloys are versatile materials that resist corrosion from exposure to chemicals and moisture. Every stainless steel alloy has a unique mix of favorable characteristics and strengths. The key properties of 304 stainless steel include the following:

  • Durability: 304 stainless steel is a strong, durable metal that can resist mechanical and chemical damage.
  • Chemical Resistance: This alloy resists corrosion and oxidation, making it a good choice for filters and other products that will come into contact with water and chemicals. It has a relatively low carbon content, further reducing its vulnerability to corrosion. It can even withstand saltwater and oxidizing acids.
  • Workability: 304 SS is very formable, easy to fabricate and shape, and simple to clean without causing damage. It can be safely sanitized through different methods such as steam cleaning and dry vapor cleaning.
  • Strength and Mechanical Resistance: 304 SS is well-regarded for impact resistance and ability to perform well and retain its physical characteristics in low-temperature environments.
  • Nonferrous Properties: 304 stainless steel is not magnetic.

 

Common Uses for 304 Stainless Steel Wire Mesh and Sheets

304 SS wire meshes and sheets are popular materials for use in the production of a wide array of goods. At Marlin Steel, we fabricate meshes and sheets used to produce the following goods:

304 Stainless Steel Wire Mesh Products

  • Architectural and decorative trims
  • Chemical handling equipment
  • Equipment for commercial textile dyeing operations
  • Food processing and handling equipment, such as sieves
  • Oil refinery still tubes
  • Parts for household appliances, such as filters, traps, and cages
  • Steam piping parts and components
  • And more

 

304 Stainless Steel Sheet Products

  • Automobile components
  • Chemical containers for commercial and industrial use
  • Dyeing equipment for textiles and more
  • Food processing equipment
  • Heat exchanger parts
  • Hollowware such as saucepans and sinks
  • Machinery parts for general industrial applications
  • Water filtration devices

Contact Marlin Steel for Premium Wire and Steel Products

Marlin Steel is a leading provider of high-quality stainless steel and wire products of all types, such as wire meshes, racks, sheets, and standard and custom wire baskets. For over 50 years, we have provided Fortune 500 companies and international brands with custom-engineered products. Today we fabricate custom products from 304 SS, 316 SS, 330 SS, 1008 Grade Steel, 1010 Plain Steel, and Inconel. Our company is ISO 9001:2015 certified as part of our commitment to product quality assurance and excellent customer service throughout every stage of production.

We also offer a wide range of finishing processes and treatments, wire forming, sheet metal fabrication, machining, and welding services as a one-stop-shop for custom metal and wire goods. Contact us today to learn more about our capabilities. 

For more information, please visit Stainless Steel Security Mesh.