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Aluminum Welding Vs Steel Welding – Which Material Is Stronger?

image of a welder welding a metal pipe with his mask on.

If you are about to start a welding project and you are not sure whether you should choose steel or aluminum, understanding the differences in application and strength between each material can help you take your decision. The reality is that both types of welds are widely used, but often in different situations as they come with their own advantages and drawbacks. This blog aims to not only show you which material provides the strongest weld, but also explain the differences between each type of welding.

Aluminum Welding

Aluminum is a very popular welding material and, even though it can be difficult for beginners, it can bring you significant advantages depending on the nature of your project. Let’s look at what aluminum welds have to offer:




Aluminum provides a superior strength-to-weight ratio which gives the possibility of having a strong, yet light weld. It is often used in projects where weight plays a significant role, such as those from the automobile and aerospace industry.


Hight Conductivity


Another reason for why many people choose aluminum over steel is its high conductivity capabilities. If the transfer of heat or electricity is a priority in your project, aluminum would likely be a smarter choice.




The fact that aluminum can resist corrosion effectively makes this material a popular choice in a wide range of situations. For those who are not necessarily looking for pure strength, but searching for a rust resistant welding solution, aluminum is an option to consider.


Drawbacks of Aluminum:


Aluminum can be difficult to work with. It usually requires professionals with extensive experience in welding who are able to deal with a material that has a much lower melting point than steel. Moreover, it is not as versatile as steel as it is usually suitable for low-temperatures situations only.


Steel Welding


In most cases, steel is used in welding projects that require strength and durability, such as automotive parts, industrial equipment, rack systems, plumbing parts, and others. Some of the advantages steel offers in comparison to aluminum are:


High Strength


In terms of load-bearing capacity and pure strength, steel is more advantageous. Since the material can withstand high levels of temperature variation and strong impacts, it is commonly chosen in projects where robustness is a priority.


Easier to Weld


In contrast with aluminum, steel is relatively easy to weld. It has a higher melting point which gives the welder more control over the welding process, which minimizes mistakes. 


Drawbacks of Steel


Since steel doesn’t provide the same conductivity capabilities that aluminum does, it is not recommended for projects where electricity or heat transfer is intended. Additionally, it is a much heavier material which can be a disadvantage in many applications.


Which Material is Stronger?


If you are going to prioritize strength in your welding project, using steel is probably the best choice. The material is not only able to endure vibrations and stronger impacts, but it also has a higher melting point which makes it more resistant to heat and temperature variations. However, it is worth remembering that aluminum provides high rust resistance, which can provide you with more durability depending on the purpose of your weld.


Welding Services in Drayton Valley and Edmonton


If you are looking for steel or aluminum welding solutions in Edmonton or Drayton Valley, we have got you covered. At Advantage Manufacturing Ltd we offer a wide range of custom manufacturing services for multiple applications. Our experienced team is CWP approved and can efficiently help you with any project your might have. Don’t hesitate to give us a call and let us find the ideal welding solution for you.


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