Exhaust Material: Aluminized Steel

What is Aluminized Steel?

Aluminized steel is mild steel coated with an aluminum-silicon alloy. The silicon helps the aluminum bond to the steel, creating a protective layer that resists corrosion.

How to Identify Aluminized Steel

Aluminized steel has a light gray color and may appear shiny compared to mild steel, though it is not as reflective as stainless steel or chrome. It remains magnetic and can be checked with a magnet.

Outside Diameter Capabilities:3125” (7.938mm) – 5.000” (127mm)

Gauge Capabilities:028″ (.711mm) – .120″ (3.048mm)

Length Capabilitie:1.25″ – 240.00″

Shape Capabilities:D-shape, Double-D, Round, Square, Rectangle, Oval, and Specialty Shapes

End Conditions:Haven Cut, Mill Cut, Saw Cut, Brushed Deburred, End facing, and Chamfering

Finishing:Re-metallizing, ID/OD scarfing to remove extruded weld bead

Pros and Cons of Aluminized Steel

Pros:

• Cost-Effective: Aluminized steel is more affordable than stainless steel, yet more expensive than mild steel.
• Easy to Work With: It is easier to handle and fabricate compared to stainless steel.
• Corrosion Resistance: The aluminum coating protects the steel from rusting.

Cons:

• Vulnerability to Damage: Scratches or damage to the coating expose the steel, making it susceptible to rust, especially in areas that experience wear, such as curbs or rock impacts. Welded joints are also prone to rust.
• Internal Rust: Aluminized steel exhaust systems can rust from the inside out. Moisture collects inside the exhaust system, especially during short trips when the exhaust doesn’t get hot enough to evaporate the moisture, leading to internal rusting.

Lifespan of Aluminized Steel

The lifespan of aluminized steel varies by climate:

• Moderate Climates: Typically lasts 3-5 years on a daily driver.
• Dry Climates: Can last 8 years or longer due to reduced moisture exposure.

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