How to Choose the Right Material
Selecting the right material is a crucial decision that affects the strength, durability, and cost of your project. Each material has unique properties and ideal applications.
Material Properties Comparison
| Property | Steel S235 | Aluminium 5754 | Stainless Steel 304 |
|---|---|---|---|
| Density | 7850 kg/m³ | 2660 kg/m³ | 8000 kg/m³ |
| Tensile Strength | 360-510 MPa | 190-240 MPa | 515-720 MPa |
| Corrosion Resistance | Low (needs protection) | High | Very high |
| Thermal Conductivity | 50 W/(m·K) | 130 W/(m·K) | 16 W/(m·K) |
| Weldability | Very good | Good | Good |
| Relative Cost | € | €€ | €€€ |
Steel S235 - Versatile Choice
When to use Steel S235: load-bearing structures, industrial enclosures, mechanical components, welded projects, budget solutions.
Advantages: lowest price, high mechanical strength, excellent weldability, widely available, easy machining.
Disadvantages: requires corrosion protection, heavy, rusts in humid environments.
Aluminium 5754 - Lightweight and Resistant
When to use Aluminium: mobile applications, radiators, humid environments, aesthetic projects, food industry.
Advantages: very light, naturally corrosion-resistant, excellent thermal/electrical conductivity, no painting needed, easy anodizing.
Disadvantages: lower strength (needs thicker sections), higher price than steel, welding requires special equipment.
Stainless Steel 304 - Premium Durability
When to use Stainless Steel: food and medical industry, chemical environments, exterior architecture, hygienic requirements.
Advantages: highest corrosion resistance, excellent strength, aesthetic appearance, easy cleaning, heat-resistant, fully recyclable.
Disadvantages: highest price, harder to machine, low thermal conductivity.
Price Comparison
Cost per 1m² sheet (2mm thick, 2025 estimates):
- Steel S235: ~140 PLN/m²
- Aluminium 5754: ~150 PLN/m² (+7%)
- Stainless Steel 304: ~320 PLN/m² (+130%)
Decision Guide
Ask yourself:
- Exposure to corrosion? No → Steel S235; Yes, humid → Aluminium or Stainless Steel; Yes, chemical → Stainless Steel 304
- Weight matters? No → Steel S235; Yes → Aluminium 5754
- High strength required? Yes → Steel S235 or Stainless Steel 304; Moderate → Aluminium (thicker sections)
- Budget? Low → Steel S235; Medium → Aluminium 5754; No limits → Stainless Steel 304
Typical Applications by Industry
- Automotive: Aluminium (light body panels, radiators)
- Construction: Steel S235 (structural frames, supports)
- Food: Stainless Steel 304 (tanks, tables, production lines)
- Electronics: Aluminium (enclosures, radiators)
- General Industry: Steel S235 (versatile applications)
Summary
Material choice depends on your project's specific requirements. Steel S235 is a safe option for most industrial uses. Aluminium 5754 is ideal where low weight and corrosion resistance matter. Stainless Steel 304 offers premium durability for demanding applications.