When metals are exposed to high temperatures, almost all alloys and metals oxidize and corrode. However, the rate at which corrosion affects the metal mainly depends by the temperature and environment in which it is being used in.

High temperature corrosion is quite common in various industrial facilities, such as manufacturing plants, gas turbines and jet engines, etc. Therefore, it is important for the businesses to look for ways in which they can reduce this corrosion and increase the lifespan of their industrial machinery.

In this article, we will be comparing two of the most common ways in which businesses prevent corrosion, i.e. aluminizing steel or using stainless steel.


Aluminizing steel is a process through which steel is dipped into molten aluminum with a small percentage of silicon, to make a metallurgical bond between the aluminum alloy and the steel.  When the steel is removed from the molten aluminum, it is allowed to air dry to make the bond stronger.

This process creates three layers in the finished product. This includes the steel core—which is the innermost layer—with aluminum in the middle and oxidized aluminum as the outermost layer. The oxidized layer protects the inner layers from corrosion and erosion.


Stainless steel is iron containing a small percentage of chromium, usually 10.5%. The percentage of chromium may vary and used alongside various other metals, like nickel, silicon, titanium, molybdenum nitrogen, manganese, copper and carbon. This is why there are more than 50 varieties of stainless steel available today.

The steel with the highest percentage of chromium is the one that has the most corrosion-resistant qualities.  Making stainless steel is far more complex as compared to aluminized steel and requires ten different processes.


Here are some ways in which aluminized steel is different from stainless steel:


Stainless steel is usually very shiny and mainly used for items that need a great deal of aesthetics, such as jewelry and molding on cars. It is also used extensively in construction projects, especially for door and window handles.

Aluminized steel on the other hand is not as shiny as stainless steel, which is why it is more suitable for industrial settings.


Since aluminized steel is a coating, it has extensive applications in the industrial as compared to stainless steel. Aluminum coatings are used in gas plants, furnace components, furnace tubes, etc. to protect the industrial equipment from corrosion.

Aluminized steel is also a cost-effective option for protecting the industrial equipment from corrosion, which is why it is a popular option in various industries.

If you want to increase the life of your heavy-machinery while also guaranteeing the safety of your clients, we would love to help! VaporKote has more than 30 years of experience in the industry and is known far and wide for its quality boronizing and aluminizing services.

Get in touch with us to learn more about how you can increase the life of your equipment!

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