Choosing the Right Material for Your Project

Overview of Materials

Some metals are more popular than others, but each construction metal offers its own unique benefits and drawbacks. The following profiles offer a starting point for selecting an appropriate material for your project, though you’ll want to consult with an expert throughout the design process.

Cold Rolled Steel

Cold rolled steel is produced using a different process than hot rolled steel, resulting in different and extremely versatile properties. One advantage of the process is that it produces closer tolerances and more exact dimensions because the product undergoes more extensive shaping before cooling. It is available in high strength grades that can tolerate high loads, making it suitable for heavy-wear automotive, industrial, and construction applications. However, as an extremely versatile material with good drawability, cold rolled steel is also suitable for smaller applications, including consumer goods and furniture. Hudson’s cold rolled steels 1008-1010 are cost-effective for any of these uses.

Stainless Steel

Stainless steel is one of the most desirable construction materials, offering resistance to extreme temperatures and corrosion along with superior strength. On top of having these functional physical properties, stainless steel is also easy to work with and results in an aesthetically pleasing finish. This material is typical of the automotive, chemical, and food and beverage industries, and we offer Hudson Technologies grades 304L, 316L, 347, and 350 to suit the needs of these industrial clients. These 300 Series stainless steels are composed of 16–26% chromium and up to 35% nickel.

Aluminum

Aluminum is a low-cost, sustainable option that still offers corrosion resistance, durability, malleability, and ductility. Aluminum is commonly incorporated into alloys to increase its versatility and strength, but even on its own, aluminum is a staple of the pharmaceutical, food and beverage, automotive, electronic, and construction industries. It is used for everything from medical instruments to cooking utensils and aircraft components. Hudson’s aluminum offerings include 1100-0, 3003-0, 5052-0, and 6061-0.

Copper

Copper is another metal that offers superior resistance qualities, including to corrosive chemicals and water. In addition to this advantage, it is also formable, ductile, and malleable, enabling diverse applications across the electronics, construction, aerospace, and automotive industries. In these contexts, copper functions in solar units, air conditioners, transformers, motors, and cables, among other things. Copper also has well-documented antimicrobial properties that can be advantageous in the food and beverage and medical industries.

Brass

Like copper, brass resists corrosion from chemicals and water, and it has a similarly attractive finish, making it desirable when aesthetics are a concern. As an alloy of zinc and copper, the characteristics of brass will vary with the ratio of its constituents. Brass 70/30 and 85/15 (yellow cartridge and red brass, respectively), are solderable and drawable, meaning that they are excellent candidates for plates and solders. Other alloys may be chosen for different applications, depending on the desired features. The most common uses are for bearings, fasteners, valves, and electronics throughout multiple industries.

Hastelloy

A less common choice, hastelloy is nonetheless valuable for certain applications. The alloy consists of varying combinations of molybdenum, chromium, and nickel, and offers a number of beneficial physical characteristics. It is highly drawable and resistant to heat and chemicals, including acid catalysts and halides, making it ideal for certain chemical and processing environments.

Monel

Monel consists of nickel-cobalt alloys that grant it reliable strength and resistance to both corrosion and extreme temperatures. However, monel is quite expensive, so it is only preferable when other metals won’t suffice. This generally translates to more rigorous operating conditions such as those experienced in chemical processing or the oil and gas industries. Monel is also notably used in the marine industry as a key component of valves, wiring, and piping.

Titanium

Titanium is slightly heavier than aluminum but offers similar strength and corrosion resistance. Its key advantage is its reliable strength-to-weight ratio, which makes it extremely popular for military, architectural, and aerospace applications. Such uses include landing gear components, fasteners and springs, tubing, and similar structures. Titanium also boasts complete biocompatibility, meaning that it is inert and resistant to corrosion from bodily fluids. Predictably, this makes titanium extremely valuable for medical applications. Titanium alloy grades 1, 2, 5, 7, 9, 11 and 23 are available from Hudson Technologies.

Kovar

Kovar represents another metal with an important niche in the medical industry. A low-expansion, vacuum-melted alloy of iron, nickel, and cobalt, Kovar finds its way into laser and X-ray tubes, radiation devices, and hermetic seals. The alloy is also useful for deep drawing applications due to its consistent quality and drawability.

Hy-Mu 80

An alloy of nickel, iron, and molybdenum, Hy-Mu 80’s chief draw is its electromagnetic resistance. Because of this unique property, Hy-Mu 80 is often chosen as a shielding material to insulate sensitive electronics. This application is important in the aerospace, medical, and military industries to protect electronics, transformer cores, toroids, and other critical devices.

Cupronickel 715

Cupronickel 715 is an alloy consisting mainly of copper and nickel, though it is often reinforced with manganese and iron. Its advantageous properties include ductility, drawability, and high resistance to corrosion in seawater. The latter characteristic predictably makes cupronickel 715 an ideal choice for marine and fishing applications, including propellers, hulls, and crankshafts. It is also commonly used for coin and medal minting as well as for varied applications in the aerospace, electrical, and chemical industries.

Nickel Silver Alloy 2

Comprised of nickel, copper, and zinc, nickel silver alloys are beneficial for electronic applications like lead wires, battery casings, heating coils, and fuel cells. These uses are possible primarily because of nickel silver alloys’ ability to resist electrical stimulation while still offering conductivity and corrosion resistance. Nickel silver alloys are also highly machinable and malleable, enabling intricate structures like those used in fasteners, jewelry, and musical instrument components.

Haynes 242

Haynes 242 is a unique alloy consisting of nickel, molybdenum, and chromium, the combination of which grants properties like oxidation resistance and low thermal expansion. Because Haynes 242 is so durable under harsh temperature conditions, it is commonly used in the aerospace industry for components like containment and seal rings, pumps, and rocket nozzles.

17-7 PH

Despite its unwieldy name, 17-7 Precipitation-Hardening Stainless Steel is commonly requested for many industrial applications thanks to its superior hardness and strength. 17-7 PH is corrosion resistant, easily formable, and resistant to fatigue and deformation. This set of advantages makes the alloy useful in chemical processing equipment, power boilers, and durable fasteners and springs, especially in the aerospace, oil, and chemical processing industries.

Inconel

Hudson Technologies offers grades 625 and 718 of Inconel, a nickel-based alloy that offers corrosion and heat resistance and beneficial drawing properties. Its durability and resistance make it suitable for products like propeller blades and rotors, pressure vessels, and heat exchanger tubing. Common industries for Inconel, then, include not only the aerospace industry but also electronics, medical, chemical, automotive, and marine manufacturing.

Steel in its various types is a vital component of the United States economy. As of January 2020, domestic steel production was at 1,928,000 tons — making steel one of the most widely consumed domestic manufacturing products. From buildings to medical equipment and vehicles, the world literally runs on steel products. But not all steel materials are made alike.

There are multiple steel types and alloys that each have unique properties — making them each suited to specific production goals. Some steels are sturdy and heavy, while other steels are ductile and versatile.

Frequently, our customers approach us regarding the best type of steel for their application. We put together this quick guide to help you navigate the language of steel. Of course, you may still have questions regarding the application. Feel free to reach out to us with any unique property needs so that we can help you find the right steel and manufacturer for your needs.

Carbon Steel

Technically, carbon steel is a metal alloy that contains both iron and carbon. But in the manufacturing industry, carbon steel is often defined in multiple ways. Both of the following constitutes a “carbon steel” in the metals market.

• Steel that contains up to 2% carbon
• Steel that does not contain any standard amounts of elements that would classify it as an “alloy steel” (e.g., cobalt, nickel, tungsten, molybdenum, titanium, zirconium, vanadium, chromium, etc.)

You may also notice the term “carbon steel” applied to steels with less than 0.4% copper or steels that have certain magnesium to copper contents, though those definitions are contested across industries. For the purposes of this, we’re talking about the first two definitions.

There are three ways that carbon steel is classified — low, medium, and high

Low Carbon Steel

Low carbon steel (or “mild carbon steel” or “plain carbon steel”) refers to carbon steels that have up to 0.30% carbon content. This is, by far, the most common type of steel on the metals market. There are a few reasons for this. For starters, low carbon steel is relatively inexpensive. Also, since the carbon content is lower than medium and high steels, low carbon steel is easy to form and is perfect for applications where tensile strength isn’t an immediate issue, such as structural beams.

Another benefit of low carbon steel is that its properties can be improved relatively easily by adding additional elements, such as magnesium. Low carbon steel is also an ideal choice for carburizing, which improves case hardness without impacting ductility or toughness.

What are some common uses for low carbon steel?

• Structural components
• Machinery
• Pipes
• Domestic appliances
• Automobile components
• Surgical instruments
• Medical equipment
• Wires
• Bolts
• Stampings
• etc.

Core properties of low carbon steel:

• Low cost
• Low hardness
• Mild strength
• High machinability
• Very high toughness
• High ductility
• High weldability

Medium Carbon Steel

Medium carbon steel refers to carbon steels that have between 0.31% and 0.60% carbon content and between 0.31% and 1.60% magnesium. One of the biggest benefits of medium carbon steel is its strength. However, that comes with some tradeoffs. Medium carbon steel has low ductility and toughness — making it more difficult to form and weld.

What are some common uses for medium carbon steel?

• Machinery parts
• Pressure structures
• Cranks
• Gears
• Railway tracks

Core properties of medium carbon steel:

• Low hardenability
• Medium ductility
• Average toughness
• Medium strength
• Medium weldability
• Average machinability

High Carbon Steel

High carbon steel refers to carbon steels that have between 0.61% and 1.50% carbon content and between 0.31 and 0.90 magnesium. When it comes to hardness and toughness, high carbon steel is the carbon steel of choice. However, this comes at a tradeoff. It’s very difficult to weld, cut, or form high carbon steel.

What are some common uses for high carbon steel?

• Railways
• Bars
• Spring steel
• Plates
• etc.

Core properties of high carbon steel:

• Low hardenability
• Low ductility
• Reduced weldability
• Low machinability
• High toughness
• High strength

Stainless Steel

While carbon steel is typically defined by its carbon content, stainless steel is defined by its 10.5% minimum chromium content. Like carbon steel, stainless steel also contains carbon and iron, but the extra chromium is the key that gives it its unique properties. One of the biggest benefits of stainless steel is that it protects the steel for oxidization — which degrades metals over time. Stainless steel is also identified by its sheen, a property provided by the chromium. You will often see stainless steel utilized in cookware, knives, and medical equipment.

Like carbon steel, there are various types of stainless steel, each with a unique market price and properties.

Austenitic Alloys

Stainless steel austenitic alloys are, by far, the most common types of stainless steel metals on the market. They resist oxidation, provide a unique look, and are non-magnetic (though they can become magnetic in certain circumstances).

There are two common austenitic alloy grades:

• Grade 304
• Grade 316

Grades of austenitic alloys also include 301, 302, 303, 309, and 321.

Ferritic Alloys

Stainless steel ferritic alloys are another semi-common stainless steel alloy. Unlike austenitic alloys, they are magnetic — lending them to applications where magnetism is necessary. These are typically the cheapest stainless steel alloys due to their relatively low nickel content.

There are two common ferritic alloy grades:

• Grade 430
• Grade 434

Martensitic Alloys

Stainless steel martensitic alloys are the least common stainless steel alloy. These alloys have incredible hardiness and toughness, but they have poor oxidation properties, making them only suited for applications that require incredible hardiness.

There is one common martensitic alloy grade:

• Grade 420

Alloy Steels

The widest and most diverse range of steel alloys is “alloy steels.” These are made by combining carbon steel with various alloying elements to provide unique properties to each steel. There is an incredibly wide range of alloy steels, but some of the most common include:

• Chromium
• Cobalt
• Molybdenum
• Nickel
• Tungsten
• Vanadium

Due to the incredible variety of alloy steels, you can create steels with almost every possible property using alloy elements. That being said, some of these steels are relatively expensive.

Tooling Steels

The final steel group is tooling steels. These are steels used for tooling activities such as drilling. Commonly made up of molybdenum, vanadium, tungsten, and cobalt, tooling steels are heat-resistant, durable, and strong.

There are 6 grades of tool steel:

• Air-hardening
• Water-hardening
• D-type
• Hot-working
• Shock-resisting types
• Oil-hardening

Do You Need Steel?

Staub Manufacturing offers services using most of the steels listed above. If your company needs best-fit steel parts to manufacture high-quality products, contact us. We’re American ISO 9001:2105 certified manufacturers who are ready to help you deliver superior fabricated steel products.