Stainless Steel vs. Carbon Steel

Steel is everywhere, but anyone who has worked with the metal knows it is by no means a one-size-fits-all product. When considering various steel types and grades, it is critical to choose the type best suited to your project’s environmental and structural demands. This post explores the key qualities and differences of stainless steel vs. carbon steel, which are the two most common types of steel.

Carbon steel and stainless steel share the same main two ingredients: iron and carbon. Alloy content is the main difference between the two and is what gives each their distinct physical properties.

Carbon steel can contain small amounts of alloys, such as chromium, molybdenum, nickel, manganese, or silicon. However, these elements will combine to be less than 10.5% of the steel’s makeup. Meanwhile, stainless steel must contain at least 10.5% chromium or more.

Which is better, carbon steel or stainless steel?

Let’s take a closer look at each to compare and contrast their compositions, top qualities, and capabilities.

Carbon Steel

Carbon steel has a carbon content of up to 2.5%. Most other types of steel contain a relatively low carbon content—typically about 0.05-0.3%.

The most significant advantage of carbon steel’s higher carbon content is its increased strength. It also provides for improved heat distribution and malleability.

Under the larger umbrella of carbon steel, there are low-, medium- and high-carbon varieties. A higher carbon content increases hardness and makes steel good at resisting abrasion and retaining its shape. However, when placed under extreme levels of tensile stress, it is likelier that high-carbon steels will crack rather than bend. Lower-carbon steels will deform under intense pressure instead of breaking. That flexibility makes low-carbon steel easier to weld and handle across manufacturing processes.

Stainless Steel

Stainless steel earns its name by being highly resistant to any staining caused by corrosion.

A chromium content of at least 10.5% is why, and the higher the chromium content, the higher the resistance and overall strength. Stainless steel’s carbon content is less than 1.2%, but chromium is an invaluable and critical ingredient. It does not rust when exposed to moisture and reacts with oxygen to form a passive chromium oxide layer of corrosion protection.

Stainless steel’s oxidation resistance continues even at high temperatures, allowing it to effectively retain its strength under extreme heat better than alternatives such as galvanized steel or aluminum. At the other end of the thermometer, stainless steel is also standard in cryogenic applications as it remains strong and impact-resistant without becoming brittle at very low temperatures.

Is Carbon Steel Stronger Than Stainless Steel?

Carbon steels tend to be stronger, more durable, and less flexible than stainless steels. However, stainless steel has critical protection against rust and corrosion and is much more visually appealing.

Although it is typically stronger and more durable than stainless steel, carbon steel is susceptible to rust and corrosion upon exposure to a damp or humid environment. Even a tiny amount of moisture, including water vapor in the air, can cause carbon steel to rust.

Carbon steels with very low amounts of carbon may not match the tensile strengths of some stainless steels due to the presence of other alloying elements in some grades increasing their strength. However, carbon steels with at least 0.3% carbon content are more readily heat-treated.

When to Use Carbon Steel vs. Stainless Steel

Taking full advantage of its key weatherproof properties, stainless steel is best in any setting involving a wet environment or outdoor exposure to nature’s elements.

With its excellent resistance to corrosion and the ability to withstand extreme temperatures, stainless steel is widely used in cookware, appliances, and throughout the food service and beverage industries. It’s also often utilized in medical devices, healthcare facilities, and other applications where the metal’s aesthetic appeal or corrosion resistance is required. With many desirable qualities, manufacturers have discovered many uses for stainless steel in the technology, agriculture, and architectural construction industries.

The most significant benefit of carbon steel is its strength and durability, and it is a critical component of most major construction, engineering, and manufacturing projects. It is the metal of choice for building frames, bridges, and large structural components such as beams, tubes, or rolled sheets. Carbon steel is ideal for tools needing a heavy-duty cutting edge, and it is also common in automotive components or anywhere high strength and toughness are required.

Although different grades of the metals will carry varying costs, adding various alloying elements contributes to stainless steels being more expensive than carbon steels. If the metal will be hidden from sight or not subject to a corrosive environment, carbon steel will likely be a better and more economical option.

Make the Right Choice: Work with Westfield Steel

Each unique project’s needs, demands, and specifications will determine which type of steel is best suited for the job. With decades of experience and unique expertise in the best and most appropriate uses across diverse applications, Westfield Steel can help you find the perfect type of carbon or stainless steel.

Whether your projects or products require rust resistance or increased hardness and lower weight are top priorities, contact our full-service experts today for guidance to find the perfect carbon steel or stainless steel solutions.