Steel vs. Aluminum vs. Brass Metal Sheets: A Comparison!

Metal Sheets have been part of the manufacturing industry for years. Their next-level fabrication support nurtures many real-life applications. Different types of metal sheets are available and vary in their material. Among those, steel vs. aluminum vs. brass metal sheets are top-rated.

 

Each of these materials has unique properties. So, their sheets also offer unique perks when used in the manufacturing process. Are you looking to select the right plate for your project? Knowing their differences will help you a lot. So, don’t walk away, as much mind-opening information is coming your way!

 

Overview of Aluminum, Brass, and Steel Metal Sheets

Metal sheets are produced by rolling a material through a series of rollers. Their thickness ranges between 0.2 mm and 6 mm. Metal sheets can be made from different materials, such as aluminum, brass, steel, etc. 

 

The metal sheets of steel are rigid but inexpensive. Aluminum sheets are lightweight, decent in strength, and show optimal corrosion resistance. Brass sheets are expensive, have less corrosion resistance, and are fragile. I consider aluminum sheets to be a superior option among the three.

 

Keep in mind that each of these materials has unique characteristics. It means that the sheets made with them also have distinctive properties. Manufacturers use different materials to achieve sheets for various purposes. For example, when lightweight sheets are needed, they use aluminum.

 

Similarly, the usage of steel makes the metal sheets cheap and inexpensive. But it has some drawbacks as it is super hard. Machining this material is not straightforward. So, what kind of metal sheet would you choose? Brass, Aluminum, or Steel? I am sure that you’ll be super confused! 

 

Let me give you another eye-opener. The selection of metal sheets controls the quality of the product! Imagine you choose a sheet for the car’s roof. However, the sheet is not corrosion-resistant. How would your car roofing offer optimal performance when you remain outside in the rainy season?

 

I said earlier that understanding the materials used to make them is crucial. Once you know their properties, life gets easier. You’ll be able to select the suitable plate sheet for different projects. I will explain the differences between these metal sheets in the section below. 

 

Differences Between Steel, Aluminum, and Brass Metal Sheets

Let’s explore the key differences among these sheets that make them fit different needs. Remember, the major difference lies in the manufacturing material.

 

1- Weight

 

Aluminum metal sheets are very lightweight. Their usage is typical when manufacturers aim to keep the weight low. On the flip side, steel is the heaviest material, so steel metal sheets are the heaviest. 

 

The brass material is neither too light nor very heavy. It lies between aluminum and steel. Keep in mind that different alloys of these materials are available. The weight of those can vary. However, you’ll generally see aluminum as the lightest and steel as the heaviest.

 

So, aluminum is the best choice for lightweight metal sheets. Such metal sheets are suitable for making aerospace parts and components. However, steel sheets are ideal when you need a combination of both heavyweight and excellent strength.

 

2- Grades of Materials

 

As I said earlier, each of these materials has different grades. Each of those grades differs from parent material in terms of characteristics. When choosing the metal sheet, you should not forget to select the suitable grades of the materials. Some popular grades of aluminum are as follows:

 

• 1100-H14 Aluminum
• 3003-H14 Aluminum
• 5052-H32 Aluminum
• 6061-T6 aluminum

 

The properties of the 1100-H14 aluminum grade will be different from 3003-H14 aluminum. So, the sheet of these material grades will also differ in their properties. During selection, you should be proactive in deciding the correct grade of material for your project.

 

3- Strength

 

The strength of a metal sheet is a crucial factor you should always count on. The steel metal sheets of steel are the strongest. They have exceptional high tensile strength of up to 2,500 MPa. So they can comfortably bear the stress without breaking. 

 

Due to their high strength, steel sheets are helpful in the construction industry. Aluminum sheets come second regarding tensile strength. They can bear the maximum stress of around 700 MPa. As I said earlier, aluminum is a lightweight material. If you need a sheet that is lightweight but has optimal strength, aluminum sheets are suitable.

 

Brass is the weakest of these three metal sheets. It breaks when you apply even a tiny amount of stress (greater than 500 MPa). The question is: Which metal sheet should you use? If strength is a priority, go with steel. However, choosing aluminum metal sheets would be wise if you want a strong but lightweight sheet.

 

4- Workability and Machinability

 

As I said earlier, stress is a rigid material. So, the sheets made of this material are also very robust and rugged to the machine. Their workability requires high-end and powerful machines. Therefore, using this material to produce products can be super costly.

 

On the flip side, aluminum and brass are not very hard, so their workability is easy. But who wins if we compare aluminum and brass metal sheets? Brass has low tensile strength, so breaking and machining would be easy. You won’t need any expensive equipment for cutting it.

 

Due to this, the manufacturer uses brass sheets to make decorative pieces. Keep in mind that aluminum sheets are more popular than brass ones. The reason is that they are lighter than brass. However, brass is a good material for making different small products from metal sheets.

 

Quick Tip: Both aluminum and brass sheets offer optimal machinability. You won’t find any issues while cutting or working on them. Brass is super easy to cut, and aluminum is slightly more rigid than brass. However, manufacturers consider aluminum as good as brass in terms of machinability.

 

5- Corrosion Resistance & Durability

 

All these materials are excellent in terms of corrosion resistance. However, stainless steel (a type of steel) should be the priority. This material has around 10% chromium, which forms a chromium oxide layer when in contact with oxygen.

 

The formation of this layer is convenient in protecting the sheet from corrosion. However, carbon steel, also a type of steel, is unsuitable for corrosion resistance. Both aluminum and brass offer decent rust protection. But they don’t compete with the performance you get with stainless steel sheets.

 

The aluminum also makes an aluminum oxide layer. This protects the material from further rusting. However, it is not as effective as that of the chromium oxide layer. Therefore, I highly recommend you use a stainless steel sheet for harsh conditions. Both aluminum and brass are optimal for outdoor conditions but not harsh ones.

 

Quick Highlight: Stainless steel sheets are expensive but ideally durable. They belong to the premium category of metals. More than 10% chromium makes them unique, and this material offers exceptional resistance against rust.

 

6- Cost & Affordability

 

Steel (typically carbon steel) is very cost-effective. However, I don’t like the carbon steel as it does not offer any noticeable corrosion resistance. Stainless offers ideal resistance but is very expensive, making the sheet premium. The aluminum sheets are also affordable as their prices are lower than stainless steel.

 

Brass is a very costly material, and you won’t see it used in sheets. Steel and aluminum sheets are generally the most common. Brass sheets are considered premium, and they are used for making artwork or enhancing the aesthetic look of something.

 

The question is, which of these materials are valuable to money? I consider stainless and aluminum sheets worth the investment. The reason is that these materials are durable, strong, and corrosion-resistant. I don’t recommend using brass as it is fragile and won’t fit your needs.

 

Head-to-Head Comparison of Aluminum, Brass & Steel Sheets

In the section above, I compared all these three materials together. But I just mentioned their differentiating factors. I know those will give you their overview, but not comprehensive insight. Therefore, I am going to compare these metal sheets individually to help you understand their distinctions. The purpose is to teach their differences in a way you remember when making a buying decision.

 

• Steel vs. Aluminum

 

In the section above, you’ve learned which one is better. But let’s have a more dedicated view of these two metal sheets. Remember, steel and aluminum sheets have comparable applications in our daily lives. While deciding between these two, consider the following properties:

 

• The strength of both materials
• Availability of features for the given products
• Shape-changing capabilities 
• Easy metal working

 

Aluminum is a soft metal with lightweight properties. That means you can deploy aluminum sheets in all applications requiring lightweight yet good strength. Moreover, the surface finish is also next-level, enhancing the beauty of your products. Therefore, aluminum is a good choice for consumer goods compared to steel.

 

Steel is a hard metal owing to its elegant strength of molecules. The addition of chromium makes it rust-resistant as well. Steel is the primary choice for all durable applications, such as aerospace products. But remember, it has a higher weight than aluminum sheets.

 

We have made a table to help you better understand the differences between both metals.

 

Property	Steel	Aluminum
Composition	Iron with carbon (up to 2.1%)	Pure aluminum. Sometimes, its alloys with copper, magnesium, silicon, manganese, and zinc
Density	~7.85 g/cm³	~2.70 g/cm³
Strength	High tensile strength	Lower tensile strength
Corrosion Resistance.	Varies: stainless steel is highly resistant, and carbon steel can rust.	Naturally, it forms a protective oxide layer; it is highly resistant and can be anodized for extra protection.
Magnetic Properties	Often magnetic	Non-magnetic
Thermal Conductivity	Lower than aluminum	Higher than steel
Electrical Conductivity	Lower than aluminum	Higher than steel
Machinability	More difficult to machine and form	Easier to machine and form
Weight	Heavier; higher density	Lighter; lower density
Cost	Cost-effective for structural applications	Expensive per unit weight
Common Applications	Construction, automotive, infrastructure, industrial equipment	Aerospace, automotive, consumer goods, construction

• Steel vs. Brass

 

Are you stuck between steel and brass sheets and confused about which to choose? Worry not! As I said earlier, steel is strong, but brass is less rigid and ideal for machinability. Steel and brass sheets have very different applications, uses, and features.

 

For example, a stainless steel sheet is a hard metal with a high strength. Therefore, it can be used in applications where hardness and durability are the first choice. Moreover, its corrosion resistance features stand it out compared to brass.

 

On the other hand, brass is less rigid than steel. Exposure to the external environment can tarnish its look, but don’t worry; it has some good features. Brass’s malleability is beyond words. You can use it for many applications, molding its shapes to required angles and better materials. 

 

Its excellent look and external lushness push its applications from durable to decorative. That means brass must be your first station if you are looking for decorative products. Here is a quick table showing their difference:

 

Property	Steel	Brass
Composition	Iron with carbon (up to 2.1%) and other alloys sometimes.	Copper and zinc
Density	~7.85 g/cm³	~8.4-8.7 g/cm³
Strength	High tensile strength	Moderate strength
Corrosion Resistance	Varies: stainless steel is highly resistant, and carbon steel can rust.	Good corrosion resistance.
Magnetic Properties	Often magnetic	Non-magnetic
Thermal Conductivity	Lower than brass	Higher thermal Conductivity
Electrical Conductivity	Lower than brass	Higher Electrical Conductivity
Machinability	More difficult to machine	Easier to machine and form
Weight	Heavier	Lighter
Cost	Cost-effective	Expensive
Aesthetic Qualities	Functionality can be finished for aesthetic purposes.	An attractive gold-like appearance.
Common Applications	Construction, automotive, infrastructure, industrial equipment	Plumbing, electrical components, musical instruments, decorative items

• Aluminum vs. Brass

 

Both aluminum and brass sheets are similar to some extent. They both offer machinability and are not as hard as steel. However, they still have some differences. 

 

Aluminum sheets are famous for their high strength and lightweight. The decent corrosion resistance makes it a preferred choice for projects that need lightweight but strong parts. Moreover, aluminum is a cost-effective material compared to a similar range of brass materials.

 

Brass is undoubtedly an excellent material for glamor and surface finish. However, it is less corrosion-resistant than aluminum. Exposure to the external environment can tarnish the surface appearance of brass sheets. The result is a black layering of material on their surface, causing a diminished glow.

Property	Aluminum	Brass
Composition	Pure aluminum or aluminum alloys	Copper and zinc
Density	~2.70 g/cm³	~8.4-8.7 g/cm³
Strength	Lower tensile strength	Moderate strength
Corrosion Resistance	Naturally, it forms a protective oxide layer; it is highly resistant and can be anodized for extra protection.	Good corrosion resistance.
Machinability	Easier to machine and form	Excellent machinability
Weight	Lightweight	Heavier
Cost	Less expensive than Brass	Expensive
Aesthetic Qualities	Silvery appearance can be anodized for color	An attractive gold-like appearance
Common Applications	Aerospace, automotive, consumer goods, construction	Plumbing, electrical components, musical instruments, decorative items

 

Which is the Best: Steel, Aluminum, or Brass sheet metal?

 

Steel sheets are strong but less flexible in terms of machinability. Brass sheets are costly, less durable, and very heavy. Aluminum sheets are ideal and the best option. They are lightweight, machinable, inexpensive, and optimally strong. 

 

That’s my opinion, but your selection process should not rely on my one answer. Keep in mind that different materials have different results! First, you have to decide on the following factors before you dive into the right decision.

 

• What is your goal? Is it strength or external glamor?
• Do you need a hard or soft material?
• What applications do you aim to manufacture with the material?
• Do you need to develop decorative pieces?

 

Deciding on all such purposes can result in an easy selection. For example, steel is a peerless choice if you need a durable aerospace product. It not only offers a high tensile strength but also increases durability. The long life in continuous stress conditions saves you costs in the long run.

 

If you have decorative applications, there are two choices available to you.

 

• Brass
• Aluminum 

 

Aluminum has good corrosion resistance and offers excellent decoration, but it is not as good as brass. Moreover, if you choose brass, you will face the challenges of corrosion and heavy weight. However, the strength of brass is another pro!

 

You can only rely on one factor to decide between the metal sheets. Instead, conduct a comprehensive review of features to explore the right metal option. Examining chemical and physical properties and setting goals in advance is better.

 

Conclusion 

 

Selection of a suitable metal sheet can sometimes take time and effort. But assess your needs and be realistic about the demands. Bring in the metal that matters most to you according to price and purpose. We at AIXI Hardware supply its consumers with flawless CNC machining opportunities. Our efforts allow you to access various applications in a single go. Our 100% precise machining ensures the high-quality shaping of your steel or aluminum sheets. Check it out now!