Evaluating the Cost Effectiveness of Corrosion Resistant Metals

Automation Technology8 mins readWed, Mar 22, 2023
Corrosion resistant metals, aluminum, cooper, galvanized steel

When it comes to the cost of manufacturing products, materials matter. Corrosion-resistant metals can be a more expensive investment upfront, but their attractive properties like durability and longevity may save money in the long run. This blog post will explore the cost-effectiveness of metals with corrosion resistance, with a focus on business applications. 

What is cost-effectiveness in the context of corrosion-resistant metals? 

Cost-effectiveness has been an important factor in early manufacturing processes when selecting materials and surfaces.


As technology advanced, research on corrosion-proof metals has allowed manufacturers to optimize the material choices for specific product use cases and sustainability goals. 

This cost-effectiveness allows for a reduction in the costs associated with production, all while increasing the efficiency of the products and the manufacturing processes. With careful selection, metals that exhibit corrosion resistance can play a crucial role. By choosing the appropriate material, manufacturers can prevent many issues that may lead to faulty product repairs caused by the corrosive effects of used metals.

Factors that contribute to the cost-effectiveness 

Wear-resistance steel plates and stainless steel are the two main types of metals used in industrial processes, often as a cost-effective option. The cost-effectiveness of these metals depends on several factors, including their mechanical properties such as corrosion and wear resistance, their thermal properties such as heat resistance, strength, and rigidity, and their chemical resistance to acids and alkalis. 

Wear-resistant steel plates can be especially beneficial for cost optimization due to their long-term durability over multiple cycles. Additionally, metal products made with stainless steel are both economical and sustainable solutions, since this metal is highly resistant to environmental conditions. 

Different types of corrosion-resistant metals 

Metals used in products and manufacturing processes must be able to withstand harsh environments to ensure long-term performance, and sustainability. 

Metal corrosion comparison, corrosion-resistant metal versus regular metals

Some common choices for corrosion-resistant alloys and metals that can be utilized for a variety of applications are:

  • Stainless steel,
  • aluminum,
  • copper, 
  • bronze, 
  • brass, 
  • galvanized steel

Stainless Steel

A durable choice: Stainless steel does not corrode as quickly as many other metals do and has excellent durability. 


Lightweight corrosion-resistant metal: Aluminum resists corrosion in most environments where other metals might suffer damage. 


Copper alloys are a good choice for various applications due to their natural corrosion resistance, which results from a protective oxide layer that forms on the surface when exposed to air or water. This natural process enables copper alloy materials to withstand high temperatures and maintain their integrity, making them an ideal choice for various applications.


High-strength: Bronze is mainly an alloy of copper with tin or zinc which makes it corrosion-resistant while also having high-strength characteristics. 

Door nobs and ornaments made of bronze


Brass is another alloy consisting of copper and zinc which makes it versatile and highly durable and widely used in engineering components where resistance to liquids such as water or oils is needed. 

Galvanized Steel

Lastly, galvanized steel is coated with a protective layer of zinc which prevents oxidation and rusting even if the metal is scratched since zinc corrodes more slowly than steel.

Comparison of the cost-effectiveness of each type of metal

Rusted parts and elements, cogs and wheels

Protective coating applications are a critical part of manufacturing processes, helping to increase the performance and lifespan of products. Metals possess different properties that make them suitable for particular purposes. For example, aluminum is lightweight and has corrosion resistance, while steel is stronger and more durable. 

Galvanized steel has excellent rust protection but is prone to scratching. Copper is an efficient conductor but it can be expensive and prone to tarnishing. Bronze and brass are decorative but can be easily scratched or dented. 

For instance, when selecting metals for Protective Coating Applications both sustainability and life cycle costs need to be taken into account.  Ultimately, weighing up these components will help ensure cost efficiency when making material selections in both commercial as well as industrial contexts. 

When and where to use each type of metal 

Stainless steel: A corrosion-resistant metal, is a widely preferred material for numerous everyday items like cutlery, kitchen sinks, and household appliances. This popular choice owes its strength, durability, and resistance to rust and corrosion to the presence of a thin chromium oxide layer. Both austenitic stainless steel and martensitic stainless steel, which are distinct categories of stainless steel, offer reliable performance and longevity due to their inherent corrosion-resistant properties

Common Applications of Aluminum: Aluminium is a lighter metal than stainless steel but has similar properties. It's often used for construction materials, window frames, and automotive components. 

Galvanized Steel in Outdoor Structures: Galvanized steel is coated with a layer of zinc to protect it from corrosion and rust. It's typically used for outdoor structures such as fences, railings, and roofing. 

Copper's Role in Wiring and Piping: Copper is an excellent conductor of heat and electricity, making it suitable for wiring and piping applications. 

Decorative Applications of Bronze and Brass: Bronze and brass are both alloys made up of copper combined with other metals. They're popular for decorative items such as door handles, doorknobs, and fixtures. 

Door nobs and ornaments made of bronze

Selecting the right metal

When selecting the right type of metal for a project, stainless steel, aluminum metal, copper, bronze, brass, and galvanized steel all have their respective advantages. Stainless steel is ideal for projects that require corrosion resistance and durability. Keep in mind that, galvanic corrosion and pitting corrosion can compromise martensitic stainless steel and other corrosion-resistant metal alloys, including copper alloys, particularly when exposed to sulfuric acid, oxygen, or high temperatures

Aluminum metal is lightweight yet strong and offers ductility when worked with in manufacturing processes or products. Copper and bronze are softer metals often used in applications requiring electrical conductivity. Brass is considered easy to machine due to its low-temperature melting point; it's also known for being highly resistant to corrosion.  Galvanized steel can provide extra protection against corrosion when exposed to water or chemical solutions. 

Ferritic stainless steels and martensitic stainless steels, as iron-based alloys, exhibit exceptional corrosion resistance, making them highly suitable for various applications, especially in environments with high temperatures. These metals' galvanic and pitting corrosion resistance is further enhanced by the addition of trace elements such as nickel. The alloying process results in the formation of self-healing oxide layers, which protect the material from different corrosion types and ensure longevity and durability.

Corrosion-resistant metals offer excellent mechanical properties, including high tensile strength and compatibility with the human body. In addition, heat treatment of these metals allows for further strengthening by introducing other elements to improve their performance. These qualities make these metals highly desirable in the aerospace industry, and petrochemical applications. 

They are commonly used in CNC machining and CNC milling processes, where precision and durability are crucial. Their resistance to corrosive substances like hydrochloric acid makes them ideal for use in demanding environments, ensuring the reliability and longevity of components and structures.

Stainless steel various parts, screws and fittings

What type of metal is used in parcel lockers? 

Parcel lockers are typically made from strong and durable metal materials such as stainless steel, galvanized steel, and aluminum. Stainless steel is the most commonly used metal for parcel lockers because it has excellent corrosion resistance and can withstand harsh weather conditions without rusting or corroding. 

High quality metal sheet being cut inside a parcel locker manufacturing company

Galvanized steel is also a popular material for parcel lockers since it is more affordable than stainless steel and also corrosion resistant. Aluminum is another option for parcel lockers as it offers excellent durability, strength, and lightweight properties. All of these metals are commonly used in the construction of parcel lockers to ensure maximum protection and security of delivered items. 

Long-term benefits of quality materials in parcel lockers

Using quality materials for parcel lockers is cost-effective in the long run. Quality materials such as solid stainless steel and galvanized steel are less likely to rust or corrode, resulting in a longer life span of the parcel locker system

Industrial robot working on a parcel locker inside a parcel locker company

This can translate into fewer maintenance costs over time due to fewer repairs or replacements needed. Additionally, these types of materials are more secure than other less reliable alternatives, reducing the risk of potential theft or vandalism. 

With a well-designed and built parcel locker system, businesses can save money in the long run on repairs or replacements while also keeping their deliveries safe. Furthermore, quality materials provide extra durability even in extreme weather conditions, making them ideal for outdoor use. 


For instance, stainless steel is an excellent choice for applications that need corrosion resistance, while aluminum offers lightweight and durability, while copper and brass are also very useful in electrical applications due to their conductivity and heat capacity. With careful selection of the right metal, businesses can enjoy cost-effective solutions with maximum efficiency and performance that will last for years. 

Using these metals allows for energy savings through improved heat transfer capabilities and better thermal conductivity. Knowing which metal is best suited to a particular application like parcel locker manufacturing can help businesses maximize their success with minimal cost and effort. In the end, selecting the best metals for a given task can result in more reliable, cost-effective, and durable results that will provide long-term value. 

Other factors such as sustainability, processing costs, and manufacturing efficiency should also be considered. If you need help finding the right corrosion-resistant metal for your parcel locker project, please don't hesitate to call or email us. We would be happy to assist you in making the best decision for your needs.