Published by Worthy Hardware at April 15, 2025

Sheet Metal Materials Types and Selection Guide

As a seasoned expert in metal fabrication, I often encounter the challenge of selecting the perfect sheet metal for various applications. The choice of material can drastically influence both the functionality and longevity of the final product. Many of my clients come to me overwhelmed by the options and unsure of where to begin. That's why I've crafted this guide—to demystify the process and help you make informed decisions based on your specific needs.

In this guide, I will walk you through the primary types of sheet metal materials used in the industry today. From aluminum to brass, each material offers unique benefits and limitations. Understanding these differences is key to selecting the right material for your project, whether it's for construction, automotive, electronics, or decorative purposes.

Maintaining your interest, I'll delve deeper into each material, explaining their properties, common uses, and why they might be the right—or wrong—choice for your next project.

Sheet Metal Aluminum Material

1. 1100 Aluminum: This grade is almost pure aluminum with 99% composition, prized for its ductility and softness. It's ideal for applications requiring extensive forming, such as deep drawing and spinning. It's also excellent for welding but offers lower strength.
2. 3003 Aluminum: As the most commonly used aluminum alloy, 3003 is alloyed with manganese, enhancing its strength by about 20% over 1100 and improving its corrosion resistance. It's versatile, easy to work with, and perfect for uses in roofing, siding, and other architectural forms.
3. 5052 Aluminum: This alloy includes magnesium and offers higher strength and excellent corrosion resistance, especially against saltwater, making it ideal for marine applications like tanks and streetlights.
4. 5083 Aluminum: Known for its exceptional strength and toughness, 5083 is highly resistant to corrosion and is used in marine and automotive applications. It's particularly suitable for welding and remains strong even after forming, making it a top choice for cryogenic containers, pressure vessels, and architectural projects.
5. 6060 Aluminum: This medium strength alloy is often used for applications that require good aesthetic finish and corrosion resistance. It is easier to extrude, especially into complex shapes, making it ideal for frames, railings, and furniture.
6. 6061 Aluminum: This is a precipitation-hardened aluminum alloy containing magnesium and silicon. It's renowned for its versatility, good corrosion resistance, and high strength, which make it suitable for automotive parts, bridges, and aerospace components.
7. 7075 Aluminum: One of the strongest aluminum alloys available, 7075 is commonly used in aerospace and military applications where its strength-to-density ratio is critical. However, its corrosion resistance is lower, which often necessitates additional cladding layers.

Sheet Metal Stainless Steel Material

304 Stainless Steel: Often considered the standard "18/8" stainless steel, this grade contains 18% chromium and 8% nickel. It is the most widely used stainless steel because of its excellent corrosion resistance and value. 304 is highly versatile and can be used in everything from kitchen equipment to automotive parts and architectural trim.
316 Stainless Steel: This grade includes an addition of molybdenum (usually 2% to 3%) to increase corrosion resistance, particularly against chlorides and marine environments. It's stronger at high temperatures than 304 and is often used in marine applications, chemical processing equipment, and in pharmaceutical and food processing.
430 Stainless Steel: A ferritic stainless steel, 430 contains higher chromium and no nickel, making it less expensive than 304 but also less corrosion-resistant. It is magnetic and has good ductility and thermal conductivity. This grade is often used in automotive trim, interior architecture, and household appliances.
410 Stainless Steel: This is a martensitic stainless steel that contains lower chromium and no nickel, offering good wear resistance but less corrosion resistance. It is strong, can be hardened through heat treatment, and is typically used in applications requiring high strength and moderate corrosion resistance, such as fasteners, valves, and turbine parts.
321 Stainless Steel: Alloyed with titanium, 321 stainless steel is similar to 304 but with better high-temperature strength and resistance to intergranular corrosion. It’s often used in aerospace applications, exhaust systems, and thermal oxidizers.
2205 Duplex Stainless Steel: Known for its high strength, 2205 duplex stainless steel combines many of the beneficial properties of ferritic and austenitic steels. Because it has higher chromium and molybdenum content, it offers superior corrosion resistance and strength. It is used in environments that are aggressive, such as in pulp and paper manufacturing, chemical processing, and seawater equipment.

Sheet Metal Steel Material

S235 Steel: This is a structural steel grade with good weldability and high strength, typically used in construction and heavy engineering. It's a common choice for structural components such as beams, frames, and platforms due to its robustness and ductility.
C45 Steel: A medium carbon steel, C45 is known for its strength and hardness after quenching and tempering. It is commonly used for mechanical engineering applications such as gears, bolts, and studs. C45 has excellent machinability and responds well to heat treatment.
DC01 Steel: This grade is a cold-rolled steel offering high strength and good formability. It is primarily used in forming applications such as automotive parts, electrical appliances, and various types of panels.
S355 Steel: An advanced structural steel, S355 provides high-strength and is commonly used in heavy-duty environments like construction, bridge building, and components where high strength is required. It also shows good weldability with all common welding techniques.
A36 Steel: Widely used in the construction industry for structural purposes such as building frames. A36 is a low carbon steel, which ensures good strength and weldability with a lower cost compared to higher grades of steel.
SS400 Steel: SS400 is a structural quality carbon steel that is used in a broad range of general construction and industrial applications. It offers excellent weldability and forms ability, making it a frequent choice for general structural purposes.
AR400 Steel: Known for its abrasion resistance, AR400 is a high-carbon alloy steel used in applications involving wear and impact, such as mining equipment, dump truck bodies, and conveying systems.
Corten Steel: Also known as weathering steel, Corten has increased resistance to atmospheric corrosion compared to other steels. It is typically used in outdoor structural applications, such as bridge and building facades or art sculptures, where appearance and longevity are both important.

Sheet Metal Brass Material

C26000 Brass (Cartridge Brass): This is perhaps the most popular grade of brass sheet metal, containing about 70% copper and 30% zinc. It offers excellent ductility and strength, making it ideal for deep drawing, such as in the manufacture of ammunition casings, hence the name. It's also used extensively in musical instruments and architectural applications.
C28000 Brass (Muntz Metal): Known for its distinctive yellow color, C28000 contains a slightly higher percentage of zinc than C26000, which gives it good strength and rigidity. This makes it suitable for applications in the marine industry and for architectural structures where higher strength is required.
C22000 Brass (Commercial Bronze): Despite its name, this alloy actually contains no tin but has a higher copper content (around 90% copper and 10% zinc). It offers excellent corrosion resistance and is typically used in hardware, architectural applications, and decorative elements where a more golden appearance is desirable.
C23000 Brass (Red Brass): With about 85% copper and 15% zinc, C23000 is known for its rich, reddish color and good corrosion resistance. It is commonly used in plumbing, hardware, and some ornamental applications.
C36000 Brass (Free-Cutting Brass): This grade is the most machinable of all brasses due to its lead content, which makes it easy to cut and form into complex shapes with minimal tool wear. It's widely used for precision components such as gears, fittings, and valves where detailed machining is required.
C46400 Naval Brass: This alloy includes a small amount of tin to improve its corrosion resistance, particularly in seawater. This makes it ideal for marine hardware, propeller shafts, and other naval applications.

Sheet Metal Copper Material

C11000 Copper (Electrolytic Tough Pitch Copper): This is the most widely used grade of copper for sheet metal, offering excellent conductivity and ductility. C11000 is primarily used in electrical applications, such as wiring and electrical components, but it is also popular in architectural features for its aesthetic qualities.
C10100 Copper (Oxygen-Free Electronic Copper): Known for its very high purity and superior conductivity, C10100 is mostly used in applications requiring high conductivity with minimal oxygen content, like electronic conductors and semiconductor bases. It's also preferred for its excellent ductility and corrosion resistance.
C10200 Copper (Oxygen-Free Copper): Similar to C10100 but with slightly different characteristics due to the manufacturing process, C10200 is also used in applications that require high conductivity and corrosion resistance. It's ideal for vacuum electronic devices and glass-to-metal seals.
C12200 Copper (Phosphorus-Deoxidized Copper): This grade has a low residual phosphorus content, which gives it good corrosion resistance and makes it suitable for plumbing, heating, and cooling applications. It’s also used in gas lines and hydraulic systems, where resistance to corrosion is essential.
C14500 Copper (Tellurium Copper): Alloyed with a small amount of tellurium, this copper grade is known for its exceptional machinability without compromising conductivity. It's frequently used for electrical connectors and components where precise machining is required.
C18200 Copper (Chromium Copper): This grade is known for its high strength and conductivity, making it suitable for spot welding electrodes, high-strength cable connectors, and other applications where durability and conductivity are critical.

Sheet Metal Galvanized Steel Material

Hot-Dip Galvanized Steel: This is the most common form of galvanizing. The steel is submerged in a bath of molten zinc, which coats the steel completely, providing robust protection against corrosion. It's widely used in outdoor applications such as roofing, fencing, and street furniture.
Electrogalvanized Steel: Here, the zinc coating is applied using an electrochemical process. The result is a smooth and uniform finish that is slightly thinner than the hot-dip zinc layer but provides an excellent surface for painting. This type is often used in automotive parts, appliances, and other indoor uses where aesthetics are important.
Galvannealed Steel: In this process, steel is first galvanized with zinc and then heated to an extent that the zinc and steel layers combine to form zinc-iron alloy layers. The finish is matte and paint-ready, making it suitable for use in construction where paint adhesion and corrosion resistance are necessary.

Common Grades of Galvanized Steel

G90 Galvanized Steel: This grade specifies the zinc coating thickness, offering a good balance of durability and cost-effectiveness. It’s a common choice for general outdoor structural applications.
G60 Galvanized Steel: Less expensive than G90, this grade has a thinner zinc coating and is suitable for less severe environments but still offers significant corrosion resistance.
G30 Galvanized Steel: This grade has the lightest coating, making it less durable than G90 or G60 but suitable for interior applications or environments with minimal exposure to corrosives.

Processing Techniques used in Sheet Metal

Cutting Techniques

Shearing: This method involves cutting sheet metal with straight blades. It’s used for cutting large sheets into smaller, more manageable pieces before further processing.
Laser Cutting: Utilizes a high-powered laser beam to melt, burn, or vaporize the metal, offering high precision and the ability to cut complex shapes. Ideal for detailed and intricate designs.
Waterjet Cutting: Involves using a high-pressure jet of water, often mixed with an abrasive substance, to cut materials without introducing heat, which prevents material distortion and is suitable for metals sensitive to high temperatures.
Plasma Cutting: Uses a plasma torch to cut through electrically conductive materials by means of an accelerated jet of hot plasma. It is particularly useful for thick sheet metals.

Forming Techniques

Bending: One of the most common fabrication processes, it involves deforming the metal along a straight axis. Hydraulic press brakes are typically used to achieve precise bends.
Stamping: This process includes a variety of operations such as punching, embossing, bending, and coining. It is used to form specific shapes from a metal sheet.
Roll Forming: Involves continuously bending a long strip of sheet metal (typically coiled steel) into a desired cross-section. The strip passes through sets of rolls mounted on consecutive stands, each performing an incremental part of the bend until the desired cross-section profile is obtained.
Deep Drawing: A form of stamping where the depth of the drawn part exceeds its diameter. This method is used for creating components like pots, cups, sinks, and panels.

Joining Techniques

Welding: The process of joining two pieces of metal together using various forms of heat. Common methods include TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas) welding.
Riveting: Joins pieces of metal by driving a metal pin or bolt through them. It’s a sturdy alternative to welding that does not require melting the base materials.
Adhesive Bonding: Involves using a chemical adhesive to bond metal parts. This method is useful for creating bonds that are aesthetically pleasing without the heat effects of welding.
Mechanical Fastening: This includes the use of various fasteners like screws, nuts, and bolts to join pieces together, allowing for easy assembly and disassembly.

Finishing Techniques

Painting: Applying a coat of paint not only improves the appearance of the metal but also offers additional corrosion resistance.
Powder Coating: A dry finishing process that provides a high-quality, durable finish. A free-flowing powder is applied and then cured under heat to form a hard coating.
Plating: Involves coating the sheet metal with another metal to provide enhanced corrosion resistance, increased solderability, or to reduce friction.
Anodizing: An electrochemical process that converts the metal surface into a durable, corrosion-resistant, anodic oxide finish. This is commonly used for aluminum.

Selecting the Right Sheet Metal Material Factors

1. Mechanical Properties

Strength: Consider tensile and yield strength based on the part's application. Structural and load-bearing parts typically require high-strength materials like stainless steel or carbon steel.
Hardness: Impacts wear resistance and machinability.
Ductility and Formability: Essential for complex shapes or parts requiring deep drawing or bending (e.g., aluminum 1100 or brass C260).

2. Corrosion Resistance

For outdoor or marine environments, materials like 316 stainless steel, 5052 aluminum, or galvanized steel are preferred.
For indoor or dry environments, a lower-resistance material like C45 carbon steel may be acceptable and more cost-effective.

3. Weight Requirements

Aluminum and magnesium alloys offer excellent strength-to-weight ratios and are commonly used in aerospace and transportation industries.
Steel is heavier but provides superior strength and impact resistance, ideal for structural applications.

4. Thermal and Electrical Conductivity

Copper (C11000, C10200) and brass (C36000) are best for electrical applications due to their excellent conductivity.
Consider thermal expansion and heat resistance in high-temperature environments.

5. Weldability and Machinability

Some materials are easier to weld or machine than others.
For example, C36000 brass and C14500 tellurium copper are excellent for machining.
304 stainless steel and 5052 aluminum are generally good for welding.

6. Surface Finish and Aesthetics

If the visual appeal is critical (e.g., in architectural or decorative applications), brass, copper, or anodized aluminum offer premium appearances.
Surface finishing options like polishing, painting, or powder coating should also be considered.

7. Environmental and Chemical Exposure

For exposure to chemicals, saltwater, or industrial environments, choose materials with higher corrosion resistance like 316 stainless steel or 5083 aluminum.
For applications in food or pharmaceutical industries, materials must meet hygiene standards—304/316 stainless steel is the standard.

8. Cost and Availability

Budget constraints are always a factor. Lower-cost materials like galvanized steel or C235 carbon steel can be good choices if performance requirements allow.
Also, consider lead time and material availability in your region.

Conclusion

Selecting the right sheet metal material is essential to ensure your product meets performance, durability, and cost expectations. Whether you need aluminum, stainless steel, or specialized alloys, the right choice makes all the difference. Contact us today for expert advice and customized sheet metal solutions tailored to your project needs.

FAQ

Q1: What is the most corrosion-resistant sheet metal material?
A: 316 stainless steel and 5083 aluminum are among the top choices for corrosion resistance, especially in marine or chemical environments.

Q2: Which sheet metal is best for electrical conductivity?
A: Copper (C11000 or C10100) offers the highest electrical conductivity, making it ideal for electrical components.

Q3: Can galvanized steel be welded?
A: Yes, but it requires special precautions like ventilation and cleanup to handle the zinc coating safely.

Q4: What’s the difference between hot-dip and electro-galvanized steel?
A: Hot-dip offers thicker, more rugged protection, while electro-galvanized provides a smoother finish ideal for painting.

Q5: Which material is best for lightweight applications?
A: Aluminum, particularly grades like 5052 and 6061, is excellent for lightweight and high-strength applications.