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In the fields of manufacturing and construction, we like aluminum for its lightweight and corrosion-resistant properties, which ensure it does not rust. However, when it comes to fastening aluminum, you have to be careful about this one issue called “corrosion,” especially galvanic corrosion. As a fastener specialist with 15 years of experience, I’ve seen firsthand how the wrong choice of fasteners can lead to significant issues down the line.
Today, I am going to share with you the top five fasteners I use with aluminum to get rid of the trouble.
1. Coated Steel Fasteners
Why Coated Steel?
Coated steel fasteners are an excellent choice when working with aluminum. The protective coatings, often zinc or other similar materials, create a barrier that prevents direct contact between the steel and aluminum, significantly reducing the risk of galvanic corrosion.
Key Benefits:
- Cost-effective: Zinc-coated steel is relatively inexpensive.
- Durable: The coating extends the lifespan of the fastener.
- Versatile: Suitable for a variety of applications.
However, not all coatings are created equal. Look for high-quality coatings that provide comprehensive coverage to ensure optimal protection.
2. Electroplated (Galvanized) Steel Fasteners
The Electroplating Advantage
Electroplated steel fasteners, especially those galvanized with zinc, are a step up from regular coated fasteners. The electroplating process ensures a more uniform and robust layer of protection against corrosion.
Key Benefits:
- Enhanced Corrosion Resistance: The electroplating process provides superior protection.
- Cost-Effective: Generally cheaper than stainless steel options.
- Wide Availability: Easy to find and replace if needed.
These fasteners are widely used in environments where exposure to moisture and other corrosive elements is common, making them a reliable choice for aluminum applications.
3. Aluminum Fasteners
Keeping it Consistent
Using aluminum fasteners with aluminum components is a straightforward way to eliminate the risk of galvanic corrosion entirely. This is because identical metals do not cause galvanic reactions.
Key Benefits:
- No Galvanic Corrosion: Perfect material match eliminates corrosion risks.
- Lightweight: Keeps the overall structure light.
- Aesthetic Match: Ensures uniform appearance.
However, aluminum fasteners may not provide the same level of strength as steel fasteners, especially for heavy-duty applications. They are ideal for applications where weight and corrosion resistance are more critical than sheer strength.
4. Non-Metal Fasteners
A Unique Solution
Non-metal fasteners, such as high-strength plastic or composite fasteners, are excellent alternatives for reducing metal-to-metal corrosion. These fasteners are especially useful in less heavy-duty applications where the need for high strength is not paramount.
Key Benefits:
- Zero Corrosion: No metal means no risk of galvanic corrosion.
- Lightweight: Significantly lighter than metal fasteners.
- Chemical Resistance: Often resistant to a wide range of chemicals.
These fasteners can be used in a variety of environments and are particularly useful in situations where the materials being joined are also non-metallic.
5. Stainless Steel Fasteners
A Popular Choice with Precautions
Stainless steel fasteners are commonly used with aluminum, especially in industries like solar energy, where both materials are prevalent. While there is a potential for galvanic corrosion, this can be mitigated with proper precautions.
Key Benefits:
- High Strength: Provides excellent tensile strength for robust applications.
- Corrosion Resistance: Stainless steel is highly resistant to rust and corrosion.
- Versatile: Suitable for many different environments and applications.
In any environment where corrosion is a concern, we recommend using an anti-seize compound or a plastic washer between the stainless steel fasteners and the aluminum. This simple step can add many years to the life of your assembly.
How to choose the right fastener without-corroding?
When selecting fasteners for aluminum, it’s essential to consider the specific application, environmental conditions, and required strength. For critical applications, especially those exposed to harsh or marine environments, additional precautions like coatings or sealants might be necessary.
Practical Tips:
- Consult Galvanic Corrosion Charts: These charts can help you choose materials that are compatible and minimize the risk of corrosion.
- Use Insulators: Plastic washers and anti-seize compounds can help prevent direct metal-to-metal contact.
- Regular Maintenance: Regular inspection and maintenance can help catch and address corrosion early.
In conclusion, understanding which fasteners to use with aluminum is key to preventing corrosion and making your projects last. You could choose from coated steel, electroplated steel, aluminum, non-metal, or stainless steel fasteners to hold your projects together and be confident that you’re not going to have a galvanic corrosion problem.
Conclusion
Selecting the right fasteners for aluminum involves understanding the risks of galvanic corrosion and choosing materials that minimize these risks. Coated steel, electroplated steel, aluminum, non-metal, and stainless steel fasteners each offer unique benefits suited to different applications. Proper selection and maintenance are key to long-lasting, corrosion-free assemblies.
That’s it! By following these guidelines, you can ensure your aluminum projects remain strong and corrosion-free for years to come. If you have any questions or need further advice, feel free to reach out to us at Shanghai Hengrui Industry Co., Ltd.
