Aluminum vs Stainless Steel Wire Mesh: What Works Best?

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 enhance the functionality of miners' safety lamps. This increased the demand for woven wire mesh and propelled the wire mesh industry forward.

Initially, wire mesh was woven using materials like brass, which was relatively inexpensive compared to alloys like stainless steel. But over time, stainless steel became more affordable and widely used in weaving wire mesh.

However, widely used doesn't necessarily mean it's the best choice for you. To achieve optimal results, it's crucial to 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.

This article aims 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 form 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 of aluminum is its lightweight nature, especially compared to other widely used alloys like stainless steel. This quality can reduce the stress inflicted on your machinery.

Aluminum can also create a protective layer of aluminum oxide when exposed to oxygen, helping it resist various forms of corrosion. Additionally, aluminum wire mesh offers better heat conductivity than stainless steel and features properties making it an excellent electrical conductor.

Along with being lightweight, aluminum is known for its malleability, allowing aluminum wire mesh to be easily formed into customized components.

What Is Stainless Steel?

Stainless steel is a steel alloy that meets the required carbon composition threshold while also containing chromium. Chromium 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 calculated over several decades, stainless steel is one of the most widely used alloys for weaving wire mesh. W.S. Tyler usually employs 300 series or 400 series stainless steel to weave wire mesh.

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300 Series Stainless Steel Alloys:

• 304
• 309
• 310
• 316
• 317
• 318
• 321
• 330
• 347

400 Series Stainless Steel Alloys:

• 430
• 446

With various stainless steel variants to choose from, it's noteworthy that 304 and 316 are the most widely used.

What Are the Benefits of Stainless Steel Wire Mesh?

As previously mentioned, all stainless steel contains chromium. This makes the alloy highly resistant to corrosion, including corrosion from various alkaline and acidic substances present during industrial applications.

Stainless steel can also withstand high-heat conditions, maintaining its performance under extreme heat and oxidation. But possibly the most critical property of stainless steel, compared to aluminum, is its durability. Whether subjected to high-impact situations or temperature variations, the individual wires of stainless steel wire mesh will retain their integrity for much longer.

What Alloy Should I Use?

The alloy you use to weave your wire mesh is crucial to its performance and longevity. Therefore, it’s essential to make the right choice.

As a relatively soft alloy, aluminum is typically used in applications that prioritize a lightweight, corrosion-resistant mesh over strength. However, if durability is critical to your operation, stainless steel might be a better option.

Keep in mind, though, that the high threshold for heat in stainless steel can make welding challenging if low-carbon stainless steel isn't used.

Weave Your Wire Mesh With the Right Alloy

While stainless steel is the most widely used alloy for weaving wire mesh, it isn’t always the right choice. Some applications have specific requirements that necessitate using alloys like aluminum.

If your application will subject your wire mesh to high-impact, corrosive conditions, the durability of stainless steel might be the best option. However, if a lightweight wire mesh with corrosion-resistant capabilities suits your application better, consider using an aluminum alloy.

Ultimately, the needs of your process will dictate which alloy to use. Therefore, you should understand how each available alloy fits within your process and industry.

Having assisted engineers, system operators, and others in 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 other alloys you can use to fabricate your wire mesh solutions, read the following article:

If you are looking for more details, kindly visit stainless steel square wire mesh.