Aluminum is the lightweight, cost-effective, and easier-to-machine option for most applications. Stainless steel offers superior strength, temperature resistance, and corrosion performance for demanding environments but at higher weight and machining cost.
| Property | Aluminum 6061-T6 | Stainless Steel 304 |
|---|---|---|
| Tensile Strength | 310 MPa (45 ksi) | 515 MPa (75 ksi) |
| Yield Strength | 276 MPa (40 ksi) | 205 MPa (30 ksi) |
| Hardness | 95 HB (Brinell) | 201 HB |
| Density | 2.70 g/cm³ | 8.00 g/cm³ |
| Machinability Rating | 90/100 | 45/100 |
| Thermal Conductivity | 167 W/m·K | 16.2 W/m·K |
| Melting Point | 582–652 °C | 1,400–1,450 °C |
| Tolerance | ±0.005 mm | ±0.01 mm |
| Property | Aluminum 6061-T6 | Stainless Steel 304 | Winner |
|---|---|---|---|
| Weight (Density) | 2.70 g/cm³ | 8.00 g/cm³ | Aluminum |
| Tensile Strength | 310 MPa | 515 MPa | Stainless |
| Machinability | 90/100 | 45/100 | Aluminum |
| Corrosion Resistance | Good | Excellent | Stainless |
| Thermal Conductivity | 167 W/m·K | 16 W/m·K | Aluminum |
| Machining Cost | Low | High (2-3x) | Aluminum |
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