For engineering projects, corrosion-resistant metals are highly effective at preventing rust and degradation, helping engineers preserve the structural integrity of materials for long periods.
These metals resist rust and oxidation and perform well in challenging circumstances. This reduces damage caused by water, chemicals, or extremely unfavorable weather.
Moreover, they require less maintenance and last longer, for decades. This makes them the most reasonably priced alternative on the market. Let’s discuss how to choose the right one.
What Are Corrosion Resistant Metals?
Stainless Steel(Galvanized)
Corrosion-resistant metals avert rust, oxidation, and chemical damage. They form a protective layer that prevents excessive environmental wear.
Moreover, these metals are compatible with wet environments, salt water, and acidic regions.
The most common metals are stainless steel, titanium, and aluminum alloys. Manufacturers may apply artificial coatings for extra protection and strength. The right option depends on the corrosive conditions a metal is exposed to.
These metals are used for industrial sectors like marine, aerospace, and construction due to their durability and high strength.
What is Corrosion Resistant Alloy? How Does It Differ from Regular Metals?
Corrosion-resistant alloys (CRAs) are a combination of metals designed to resist oxidation and rust, in chemical, and high-temperature environments.
Elements like chromium, nickel, and molybdenum increase the alloy’s ability to form a protective oxide layer. This prevents corrosion and damage in damp, acidic, and high-temperature conditions.
Generally, carbon steels and other simple metals lack protective elements. So they are prone to rust, corrosion, and wear and tear. CRAs reverse corrosion and apply a protective shield, a stable oxide layer. This prevents further corrosion.
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The Most Corrosion Resistant Metals: Top Choices for Harsh Environments
Here are some of the most popular metals and corrosion-resistance alloys;
Aluminum
Aluminum Parts
Aluminum is widely used in several industries. Mostly, aluminum grades are light with non-magnetic and electric conductivity. These features make it useful in cookware, electronic boxes, and structural parts of buildings.
In addition, aluminum alloys 6061-T651 are known for their strength and quick machining ability. In aerospace industries, 7075-T651 is frequently used due to its high mechanical performance. For working with metal sheets, 5052-H32 is preferred because of its good formability. AlSi10Mg is used in 3D printing because of its toughness.
Aluminum alloys, including aluminum-magnesium alloys, naturally form a protective oxide layer. This enhances their corrosion resistance. In addition, polishing, painting, and Hard Coat Anodizing increase its protection against wear.
Titanium
Titanium Machined Part
Titanium is used in aerospace, medical implants, and power generation equipment. It is strong and light and offers high corrosion resistance. It has a superior strength-to-weight ratio compared to aluminum.
The Ti-6Al-4V alloy is extensively known in engineering as a “workhorse alloy.” It is commonly used for CNC machining applications. While it is used in some 3D printing applications, its use in traditional machining remains predominant. Saltwater, along with harsh chemicals, can damage most metals. However, titanium is resistant to such a hostile environment.
Stainless Steel
Stainless Steel Parts
Stainless steel is not susceptible to corrosion due to the presence of a chromium oxide layer. A variety of Stainless Steel Machining grades are available, each with an additional set of properties.
For example, grade 303 stainless steel has higher machinability but lower corrosion resistance. With a balance of great characteristics, grade 304 serves as a suitable general-purpose alloy.
Marine and chemical industries benefit from grade 316 as it contains added molybdenum, making it more suitable for these purposes.
In addition, low-carbon stainless steels like 304L and 316L are easier to weld. Stain-resistant 17-4 PH aerospace-grade steel is known for its exceptional hardness and durability, which makes it ideal for gas turbines and petrochemical applications.
Cobalt Chrome
Chrome-Plated Product
Cobalt chrome is stronger and more wear-resistant than stainless steel. Its biocompatibility makes it suitable for use in medical implants, dental prostheses, and joint replacements. Besides, its natural protection against corrosion makes it favorable for high-temperature industrial applications such as furnace liners and engine parts.
Co28Cr6Mo cobalt chrome alloy is widely used for 3D printing. It is capable of resisting extreme conditions while still retaining its strength and durability.
Inconel
Inconel Polished Parts
Inconel is known for its superb heat and corrosion resistance properties. It’s a nickel-based superalloy and can withstand extreme temperatures of up to 1,300°F (700°C). Therefore, it is a perfect fit for use in aerospace, gas turbines, and chemical processing.
Inconel 718 is a precipitation-hardened nickel-based superalloy. It contains a combination of nickel, chromium, molybdenum, and niobium. These alloys intensify their high-temperature strength and corrosion resistance. However, it poses difficulties for conventional machining, DMLS 3D printing makes it easier to sinter Inconel 718 directly through a laser.
Brass
Brass Threaded Machined Parts
Brass is an alloy that contains copper and zinc. It has good machinability and resists corrosion, which makes it ideal for use in parts like plumbing fixtures, electrical components, bearings, etc.
Free-cutting brass (C360) contains lead traces. So, it is easier to machine and best for mass production runs. Meanwhile, C260 cartridge brass is optimal for deep drawing processes, specifically for making casings for bullets.
In addition, Brass is often used in mechanical components of electronics due to its machinability, but copper is preferred for electrical and thermal conductivity. This makes it a reasonable choice in precision machining and engineering.
Copper
Copper Machined Product
As you know, copper is the best conductor of electricity and heat. It is commonly used in wires, heat exchangers, and EMI shields. The two primary grades, C101 and C110, provide better corrosion resistance and are more formable in comparison.
Copper has antimicrobial properties. Therefore, it is usable in the medical and sanitary field. However, copper is relatively hard to machine compared to brass, but it is still a necessary material for engineering and electronics.
Prolean Tech facility offers 50+ metals and alloys for CNC machining services with a range of quality Metal Surface Finishing options. You can choose the right metal that meets your parts/products’ physical & mechanical characteristics.
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Applications of Corrosion Resistant Metals in Industries: Where They Are Used
Corrosion resistant metals are widely used in marine construction, food processing equipment, and aerospace parts. For example;
Marine Applications
Heavy Duty Machined Components
For marine purposes, materials must withstand continuous attack from salt water, high humidity, and varying temperature changes.
Stainless steels, particularly 316L and duplex stainless steel, are ideal corrosion-resistant materials. These are intensively used in shipbuilding, offshore oil platforms, and underwater pipelines.
Moreover, these alloys enable outstanding performance in hull structures, propeller shafts, and marine fasteners and components. This leads to reduced maintenance and service costs over time.
Food Processing Equipment
Spare Parts For Food Processing Equipment
Food equipment must be resistant to acidic and oily substances and frequently cleaned in a sanitary manner that does not destroy machinery. Stainless steel is the preeminent material of choice because of its hygienic qualities, resistance to corrosion, ease of cleaning, and durability. Mixing tanks, conveyor systems, and cutting surfaces are often made from stainless steel.
Nickel alloys are used for high-temperature oxidizing environments such as industrial ovens and heat exchangers, owing to outstanding resistance to oxidation.
Aerospace Parts
Aerospace Screw Machined Part
In aerospace, products need to perform well at freezing heights and the blazing heat of supersonic speeds.
Aerospace uses nickel-based alloys for turbine blades, exhaust systems, and engine casings because of their strength, fatigue resistance, and oxidation stability.
In addition, copper alloys are used for cryogenic fuel lines and electrical wiring due to their high conductivity and durability.
How Prolean Tech CNC Machining Metal Services Help in Shaping Corrosion Resistant Metals
Prolean Tech’s CNC Machining Services
Prolean Tech specializes in CNC machining service for stainless steel, nickel alloys, titanium, and copper alloys. Thanks to our cutting-edge technology, we can manufacture high-quality, durable parts that do not corrode and can be relied upon to function effectively even in extreme environments.
Are you in need of durable parts? Look no further as we expertly deliver CNC machining for top corrosion-resistant metals. To get components built for durability, reach out to us today!
FAQ’s
Q1: What metals are most corrosion resistant?
The most corrosion resistant metals are the advanced alloys, such as titanium, aluminum, copper, and stainless steel (316 and duplex grades), as well as top-tier Hastelloy and Inconel alloys. These metals can withstand moisture, oxidation, extreme chemicals, and high thermal conditions.
Q2: How do corrosion resistant alloys differ from other metals?
Corrosion-resistant alloys (CRAs) are different because they include chromium, nickel, and molybdenum protective oxide layers. Such metals do not rust, oxidize, or chemically react, which makes them optimum for hostile environments.
Q3: How does corrosion proof steel perform in harsh environments?
316 and duplex stainless steel are members of corrosion-proof steels. These perform best in rough environments because of their high ratio of chromium and molybdenum. They resist harsh seawater, chemicals, and high-temperature peers. Therefore, these prevent pitting and crevices from attacking corrosion.
Q4: Can corrosion resistant metals be used for CNC machining?
Stainless steel, titanium, and aluminum parts are quite effective for CNC machining. Unlike other metals, they do not lose their strength, are very resistant to wear, and maintain durability in harsh, moist chemical conditions.
Q5: What are the most commonly used corrosion resistant alloys in machining?
316 stainless steel and 17-4 PH grade steel are normally used corrosion resistant alloys for machining. Besides, titanium grade 5, Inconel 625 and 718, and Hastelloy C-276 are also used in machining. These provide high-strength chemical durability and are resistant to corrosion.
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