How to Find the Right Metals for Your Project

Selecting the correct metal can be the difference between a part or assembly working perfectly for its entire lifespan and failing on its first use. Metals vary greatly in terms of strength, corrosion resistance, and workability, adding many variables to your decision.

In this article, we’ll take a look at some of the things to consider when selecting the correct material for your project.

Key Properties:

Metals differ greatly in their mechanical properties; for instance, a high-strength steel can be anywhere from 3 to 5 times stronger than Copper.

However, while steel is a conductor of heat and electricity, copper is far more conductive, making it a better choice for something like electrical connectors.

Other properties to consider, in addition to strength, are ductility, hardness, and density.

• Ductility: the ability for a material to deform without breaking. Useful for parts needed to move and flex without cracking. It is also an important factor in various manufacturing processes
• Hardness: the degree to which a material resists abrasion and indentation. Brass wears easily, for instance, whereas cast iron does not. In an application that involves abrasive material processing, a harder material is best
• Density: the link between density and strength is crucial. Some metals, while very dense, have a low strength-to-weight ratio. Aluminium is approximately twice as strong as steel per lb, but it weighs about 60% less per volume.

Corrosion Resistance

Almost everyone is familiar with rust; it’s what happens when the iron in steel reacts with oxygen in its environment. The speed at which a part corrodes is linked to the type of environment it’s in and how well it’s protected.

Stainless steels, aluminium, and most other non-ferrous metals are not susceptible to the traditional form of corrosion, but they almost always cost more to source and manufacture than steel.

Steel can be protected by painting or galvanising, but these add cost, time, and complexity, often adding maintenance costs in the long term. In certain applications, a surface coating is not suitable, such as when used in food manufacturing.

Cost

Cost is always a big factor in engineering, and it should be considered not only when buying raw materials but when specifying manufacturing methods and tolerances, too.

In general, steel is the most affordable metal; it is used in vast quantities, so tonnage prices are far lower than those of stainless steel, aluminium, or other non-ferrous metals.

However, bearing in mind the previously discussed topic of corrosion, it is not always the most cost-effective solution to select the cheapest material.

For instance, a coastal structure made from painted steel may last 40 years, but it may need repainting every 5 years. A stainless steel structure is likely to cost twice as much but will be virtually maintenance free.

Cost of the most commonly used metals:

Below is a rough tonnage price for common metals in the USA in 2026:

These figures are approximate and will vary greatly depending on current policy, demand, and supply levels.

Manufacturability

In order to use the metals to serve a purpose, they will need to be manufactured in some way. This may simply be cutting and drilling holes, or it may involve bending/forming, welding, and machining.

While most metals have specific grades tailored to specific manufacturing processes, it’s generally a good idea to consider the complete production process before selecting a metal.

This is important for not only feasibility issues but also cost. For instance, it usually costs more to machine a part from a very hard metal such as titanium than it does from regular mild steel.

The same considerations need to be given for other fabrication methods, such as bending, welding, and drilling, as well as coating processes such as anodising and galvanising.

Sourcing metals online vs locally

Unless you are considering a highly specialist alloy, the chances are you will have plenty of choice when it comes to material sourcing. There are a few considerations that can improve project spend and lead time.

• Availability and lead time: A purveyor that gives accurate predictions of lead time and keeps stock levels up to date will cause fewer delays. Modern companies that keep electronic inventory are generally better in this regard.
• Price: national companies, with multiple branches, are likely to get better wholesale prices than smaller, local-only outfits
• Minimum order quantity: if you are just starting, in the prototyping phase, or only have a small project on the go, traditional suppliers may be reluctant to help you out.
• Cutting service: receiving your material cut to length and ready to use can be a great help to productivity and speed.

Choose Metals Supermarkets

Thankfully, Metals Supermarkets ticks all of the above boxes, allowing you to easily browse, purchase, and track your items online while receiving great service and material cut to length.

Find your nearest store, or browse the range here.