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Are you curious about what metals don’t rust? Whether you’re a DIY enthusiast, engineer, or architect, rust resistance is a hot topic in the world of metalwork. Especially in Britain’s famously unpredictable weather! Knowing which metals can stand up to rain, salt, and the test of time is key to building long-lasting, low-maintenance structures, gadgets, and artworks.

We’ve been working in the world of sheet metal fabricators for over 50 years now, so we know a thing or two about metal! From gleaming stainless steel to lightweight aluminium, the world offers a host of metals that shrug off rust and corrosion, each with unique advantages. In this guide, we’ll explain the difference between rust and corrosion, explore why certain metals hold up better than others, and showcase the top 10 rust-proof metals.

What causes metal to rust?

Rust is a specific form of corrosion and is a form of iron oxide. It is the enemy of iron and its alloys, like steel. The science is simple – when iron meets oxygen and moisture, a chemical reaction forms iron oxide, better known as rust. This familiar orange, brown layer is more than unsightly, it also expands as it forms. This puts stress on metal structures, making them brittle and exposing them to the risk of failure.

What makes rust especially challenging in the UK is our climate. We have plenty of rain, high humidity, and coastal salt, all of which accelerate rust formation. And if sulphur dioxide or carbon dioxide are present (in city air or industrial settings) the process is even quicker.

Rust is also permeable. That means even once the surface has rusted, water and air can keep seeping in, allowing the corrosion to fester deeper into the metal. For engineers, homeowners, and fabricators, preventing rust is all about careful material choice and protection.

The difference between rust and corrosion 

Although the terms are sometimes used interchangeably, there’s a crucial distinction between rust and corrosion. Corrosion is the broad term for the gradual destruction of metals due to chemical reactions. Any metal can corrode, though some do so much more readily than others.

Rust, on the other hand, is specific to iron and iron-based alloys. This can weaken anything iron from old garden gates to the Cliff Bridge. Other metals, like aluminium or copper, may tarnish or form their own oxides, but these layers are usually much more stable and protective, rather than destructive.

Top 10 metals that don’t rust

So, what metals don’t rust? Below, we reveal the top ten, detailing why they resist rust, where they’re used, and their key properties.

What makes these metals resistant to rust?

The main secret behind what metals don’t rust comes down to chemistry. Metals like stainless steel, aluminium, and titanium form a thin, invisible oxide layer that acts as a barrier. This protects the rest of the metal beneath from air and moisture.

For others, like copper and bronze, a natural patina forms on the surface. This is a green or brown coating that’s not only attractive, but also keeps out further corrosion. Meanwhile, metals like gold and platinum simply don’t react with air or water, making them impervious to rust.

Galvanised steel takes another route. By coating steel in zinc, it gets a protective shield. Even if scratched, the zinc corrodes first, sacrificing itself to protect the steel underneath. This process is known as ‘cathodic protection.’

When to choose rust resistant metals

The choice of what metals don’t rust should be guided by your project’s needs.

• Outdoor structures: Opt for stainless steel, aluminium, or bronze for railings, sculptures, or signage.
• Marine applications: Bronze and titanium excel in saltwater environments, while galvanised steel offers cost-effective protection for short-term uses.
• Medical and food use: Stainless steel and titanium are biocompatible and easy to sterilise.
• Aesthetic projects: Copper, brass, and bronze provide rich, lasting colours and patinas.
• Electronics: Gold and nickel are invaluable for reliable, rust-free connections.

5 metals that are prone to rust or corrosion

Now we’ve highlighted our top 10 list for what metals don’t rust, let’s take a quick look at some that are on the opposite side of the scale.

1. Iron: Pure iron rusts very quickly when exposed to air and water, forming iron oxide (rust). This is commonly found in structural beams, old pipes, and cast iron items.
2. Carbon steel: An alloy of iron and carbon with little or no protective alloying elements. This is widely used in construction and manufacturing, but will rust rapidly if not coated or protected.
3. Cast iron: Another iron and carbon alloy, even more brittle than steel, and highly susceptible to rusting if left unprotected. Used for manhole covers, old cookware, and some pipes.
4. Low alloy steel: This steel has only minor additions of other elements like manganese or nickel. This offers little corrosion resistance compared to stainless steel. This can be found in bridges, frames, and machinery parts.
5. Wrought iron: Malleable iron with a very low carbon content, historically used for gates and fences. Although it has some natural corrosion resistance compared to pure iron, it still rusts easily if exposed to the elements.

How to prevent rust

• Pick rust resistant metals: Opt for stainless steel, aluminium, titanium, and other metals from our top 10 list, especially for outdoor or marine applications.
• Apply protective coatings: Paint, powder coating, oil, or specialised sealants can prevent moisture from reaching metal surfaces.
• Use galvanised or plated finishes: Galvanising coats steel in zinc, while other metals can be nickel or chrome plated for extra protection.
• Keep metals clean and dry: Regular cleaning removes corrosive salts, acids, and pollutants.
• Consider cathodic protection: Especially in marine or underground settings, sacrificial anodes made from zinc or magnesium help protect key metalwork.
• Environmental control: For valuable metalwork (like classic cars or art), use dehumidifiers, climate control, or silica gel packs to minimise moisture exposure.

How to prevent corrosion 

• Choose corrosion free metals: Aluminium and stainless steel are both versatile and eco-friendly choices for a range of environments.
• Laser treatment: Advanced laser technology can create a non-crystalline surface, increasing resistance to corrosion.
• Non-metallic coatings: Grease, carbon fibre, plastics, paint, and oil create effective moisture barriers.
• Specialist anti-corrosion coatings: Modern products provide strong, UV-resistant layers that don’t chalk, fade, or require multiple coats.
• Use drying agents: Keep equipment and storage areas free from dampness and check regularly for leaks.
• Regular maintenance: Inspect and maintain all metal items, addressing any damage to coatings immediately.

Contact Salamander Fabrications for your metal protection needs today!

If you would like any more information on how to ensure your metal projects are protected from the elements, please give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

We’re also happy to talk you through any of our services, including our:

• Welding services
• Metal folding services
• Sheet metal fabrication services
• CAD design services
• Electro mechanical assembly services

If you liked reading this blog then you may like to check out our other post – How to Cut Metal: 10 Techniques to Know.

By Embryo

What is a pure metal in comparison to an alloy metal? Also, ever wondered what the full list of pure metals actually is? You’ve come to the right place for the answer! We like to think of ourselves as more than just a sheet metal company, with over 50 years of industry experience, we believe we know everything there is to know about metal!

So we’ve brought you this handy guide to discuss what a pure metal is, the difference between pure and alloy metals, and a table of pure metals with their associated features and properties. Keep reading for more information.

What is a pure metal and where does it come from?

So, what is a pure metal in everyday terms? In short, a pure metal is an element that can’t be broken down into anything simpler by chemical means. It consists of only one type of atom. They are also known as single-phase metals. Gold, silver, copper, and iron are all examples of pure metals in their natural, unalloyed state. These metals form the backbone of modern civilisation and are found in almost everything, from electronics to cutlery, cars, and coins.

In contrast, alloys like steel, brass, and bronze are born from mixing pure metals together. A dash of non-metallic elements, like carbon, is also often introduced to boost performance in specific applications. But it’s the pure metals themselves that offer the original, distinctive set of characteristics. This includes electrical conductivity, corrosion resistance, and ductility.

The origins of pure metals

Most pure metals aren’t just lying around waiting to be picked up. They are typically locked away inside rocks as ores. Through mining, crushing, and various extraction processes (like smelting or electrolysis), these ores are transformed into the metallic materials we use today.

Major mining operations around the globe dig for metals like iron, copper, aluminium, and nickel to supply the raw materials that keep the modern world turning. Some, like gold and platinum, are far rarer, which makes them precious and often pricey. Estimations of the gold content of the Earth’s crust are in the range of 0.001 to 0.006 parts per million.

What is a pure metal VS an alloy metal?

While pure metals are made up of one element, alloys are blends of two or more elements. These are often designed to make the metal harder, stronger, or more resistant to corrosion and wear. For example, copper and tin create bronze; iron and carbon make steel; and gold and silver produce the luxurious white gold.

Most metal items around us these days are actually alloys. Yet, the unique qualities of pure metals remain in high demand for critical applications.

If you have liked reading this blog so far you should take a look at this one next – What is the Strongest Metal?

Full list of pure metals

To answer the question, what is the full list of pure metals? – Here’s a comprehensive table featuring the most significant pure metals, their properties, real world uses, and where they are primarily found around the world.

For more information like this you can check out our other blog – The Different Types of Metals; Their Properties, And Their Applications.

Unique features and properties of pure metals

So now we’ve discussed what is a pure metal and highlighted the full list of pure metals, let’s take a look at some of their collective unique qualities. Pure metals display a fascinating array of properties that set them apart from their alloyed counterparts. 

Here are a few highlights:

• Conductivity: Silver and copper are world beating conductors, making them essential for most electrical applications.
• Corrosion resistance: Gold, platinum, and titanium hardly ever tarnish or rust. This makes them ideal for jewellery, dentistry, and chemical equipment.
• Strength to weight ratio: Aluminium and titanium are both very strong and incredibly light, revolutionising both the transport and aerospace industries.
• Rarity and value: Gold, platinum and their associated group of metals are highly prized, not just for beauty and rarity, but their use in cutting edge technology.

Key Applications

• Electronics: Copper, silver, and gold wires power circuits and connections.
• Transport: Aluminium and titanium make trains, planes, and cars lighter and stronger.
• Construction: Iron and steel (mainly alloyed, but pure iron is the starting point) are used for beams and girders.
• Jewellery: Gold, platinum, silver, and palladium create stunning keepsakes.
• Healthcare: Titanium, platinum, and silver are used in implants, medical instruments, and antimicrobial coatings.
• Batteries: Lithium, cobalt, and nickel power everything from electric vehicles to mobile phones.

Contact Salamander Fabrications today for your sheet metal fabrication needs! 

What is a pure metal without metal fabrication services? A blank canvas for the team here at Salamander Fabrications to work their magic on! In truth and despite their unique qualities, pure metals are rarely used alone for most practical purposes these days. They are either too soft or brittle, too expensive, or outperformed by alloyed alternatives. Most of the metals we work on are from the alloy family of metals.

Whether you’re searching for more info on what is a pure metal, exploring the full list of pure metals, or considering a custom fabrication project, Salamander Fabrications can help. With over 50 years’ experience in the industry, we offer a full suite of services, including:

• Laser cutting services
• Welding services
• Metal folding services
• Sheet metal fabrication services
• Powder coating services

For any queries or bespoke requirements, get in touch via our contact page, call us on 01484 843599, or email sales@salamanderfabs.com. Our expert team are always happy to share their knowledge and help you select the right metal for your project.

If you’d like some more information similar to this you can have a read of our other associated blog – Where Does Metal Come From?

By Embryo

Welcome to our definitive guide on how to cut aluminium, brought to you by the team here at Salamander Fabrications. We’re here to help with your project in any way that we can, whether you need a sheet metal contractor to help facilitate your project, or just some tips and advice on how to cut aluminium sheet. 

Aluminium’s lightweight strength, corrosion resistance, and versatility make it an extremely popular material. It is used in everything from garden furniture to commercial vehicles and architectural features. But its unique combination of properties also means that knowing how to cut aluminium accurately and efficiently is essential, whether you’re a DIY hobbyist, tradesperson, or working on an industrial scale. 

In this comprehensive guide, we’ll discuss the best ways to cut aluminium sheet, the specialist tools and techniques available, and the fabrication processes that ensure your finished product looks and performs as it should.

Techniques for how to cut aluminium sheets

Aluminium sheets are available in a huge range of thicknesses, from ultra-thin foil to sturdy multi-millimetre plates. When it comes to the methods of how to cut aluminium sheet, the one you choose will depend on several factors. This includes the thickness and type of aluminium, the level of accuracy needed, and the tools you have at your disposal.

Picking the right technique not only ensures a neat, clean cut but also minimises material waste and reduces the risk of unwanted damage. This is especially crucial for parts that need to look sharp or fit together precisely.

Below, we’ll break down the most effective methods for cutting aluminium sheet, along with expert tips to help you achieve the best possible finish every time.

Laser cutting

Laser cutting services have revolutionised the metal fabrication industry, offering incredible precision and control that simply cannot be matched by manual tools. This method uses a focused laser beam to heat and melt through aluminium sheets along a pre-programmed path.

Advantages:

• Exceptional accuracy for intricate shapes
• Minimal material distortion and clean, burr-free edges
• Suitable for large scale or repetitive projects

Considerations:

• Requires specialist machinery and proper ventilation
• Best suited to lightweight metals and thin to moderately thick aluminium sheets

Ideal for:

• Architectural features
• Bespoke signage
• Detailed brackets
• Any project where tight tolerances or a smooth finish are required

Plasma cutting

Plasma cutting is another powerhouse of metal fabrication, ideal for tackling thicker sections of aluminium or making complex shapes where brute force and flexibility are needed. It works by blasting ionised gas (plasma) at extreme temperatures through a small nozzle, effectively slicing through metal.

Advantages:

• Powerful enough for thick aluminium plates
• Fast, with impressive edge quality for most uses
• Great for irregular or freeform shapes

Considerations:

• Leaves a slightly wider cut width compared to laser cutting
• May require additional edge finishing

Ideal for:

• Industrial fabrication
• Automotive repairs
• Structural frameworks
• Any job involving substantial aluminium profiles

Waterjet cutting

Waterjet cutting harnesses the raw force of high pressure water mixed with abrasive particles to slice through aluminium. This technique is prized for its ability to handle both very thin foils and extremely thick plates, all while keeping the metal cool.

Advantages:

• No heat distortion or structural weakening
• Ultra-precision makes it suitable for intricate designs or small batch work
• Cuts a wide range of thicknesses and alloys

Considerations:

• Can be more expensive due to equipment and abrasive costs
• Requires a skilled operator for the best results

Ideal for:

• Aerospace components
• Decorative screens
• Complex assemblies where material integrity is critical

Hand tools

For smaller projects, prototypes, or onsite adjustments, hand tools remain an important part of learning how to cut aluminium sheet. They require minimal setup and can be surprisingly effective when used correctly.

• Hacksaw: Best for straight cuts in thin aluminium sheets or bars
• Tin snips: Best for cutting curves or intricate shapes in thin aluminium
• Utility knife: Best for scoring and snapping very thin aluminium, especially for ductwork or foil

Power tools

When you need more muscle, power tools are the answer for efficient, repeatable cuts (especially in medium to thick aluminium sheets). You should always wear goggles, gloves, and a dust mask when cutting aluminium.

• Circular Saw: Best for long, straight cuts in thicker aluminium sheet or plate
• Jigsaw: Best for curved or intricate cuts in aluminium
• Band Saw: Best for both straight and curved cuts, especially in thicker stock

Alternative sheet metal fabrication services

Here at Salamander Fabrications, we understand that there’s more to working with aluminium than just cutting. Sometimes, a project needs bending, welding, or other fabrication processes to bring your vision to life. Here’s a quick overview of other essential metalworking techniques.

Welding

Welding services are at the heart of most metal fabrication projects, especially for joining aluminium parts together. Whether you’re building frames, enclosures, or bespoke pieces, welding creates robust, long lasting joints.

Different types of welding:

• MIG Welding: Great for thicker aluminium, providing fast, strong welds
• Robotic MIG Welding: Delivers consistent quality and is ideal for high volume or repetitive work
• TIG Welding: Perfect for thin sheet aluminium or work that demands a clean, attractive finish
• Spot Welding: Used to join thin sheets without filler, common in automotive and appliance manufacturing

Want to know more? Read our detailed blog post on the subject – What Are The Different Types of Welding?

Sheet metal folding

Sheet metal folding is vital for producing parts with bends or angles, and CNC-controlled folding machines ensure every bend is precise and repeatable.

Stand-out features:

• Precision: Allows for exact bends and identical pieces that meet strict quality standards
• Cost-effective: Lowers costs by reducing the need for welding or additional assembly

Coating and finishing

Aluminium’s natural oxide layer makes it resistant to corrosion, but the right finishing or powder coating process can enhance durability and appearance even further.

Popular finishing techniques:

• Powder coating: Creates a tough, colourful finish that resists scratching and UV fading.
• Electroplating: Adds a decorative or protective metal layer which is ideal for high wear or visible components.
• Polishing and brushing: Delivers a high shine or a modern, textured look for decorative aluminium.

Choosing the best method for how to cut aluminium

Selecting the best method for how to cut aluminium depends on your tools, the thickness and alloy of the sheet, and the demands of your project. Hand tools are great for light work, while power tools and advanced machinery offer the accuracy and speed required for larger or more complex jobs.

Don’t forget to clean, deburr, and finish all cut edges for safety and appearance. If in doubt, consult a professional sheet metal contractor. Working with aluminium is as much about experience as it is about equipment.

Contact Salamander Fabrications for more information on our laser cutter – our method for how to cut aluminium

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us any time. The team here at Salamander Fabrications are more than happy to talk through the services we have to offer and share our expertise.

Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Wondering how to engrave metal? Want to know if there is a single technique that works for everything, or do different methods suit different projects? If you’re looking for guidance on the full range of options and want to understand the strengths and uses of each, you’ve landed in the perfect spot. Here at Salamander Fabrications, the home of expert metal fabrication services, we specialise in all things sheet metal – a common material used for engraving.

In this guide, we’ll break down the five main ways of how to engrave metal, covering both timeless hand skills and the latest machinery. We’ll explore what makes each method unique, the tools you’ll need, best practices, and what types of jobs each approach is suitable for.

1. Engraving metal by hand

Let’s start with the old faithful and the most traditional method of how to engrave metal. The classic image of an artisan at a workbench springs to mind. Hand engraving has centuries of tradition behind it and is still favoured for intricate jewellery, ceremonial objects, and one off pieces where artistry is prized over speed.

This method is best for softer metals like silver, gold, copper, and brass. It is a time consuming process that demands patience and practice. For batch production or very hard metals, other methods may be preferable. The tools you’ll need include gravers (burins), a ball vice, and sharpening stones.

Hand to engrave metal by hand

1. Sketch or print your design, then transfer it onto the metal surface (using paper, acetone, or a vinyl sticker).
2. Secure the metal piece in a ball vice to hold it steady.
3. Select the right graver for your design and sharpen if necessary.
4. Hold the graver at a roughly 45-degree angle to the metal.
5. Push or glide the graver along the design, using consistent, controlled pressure to etch lines.
6. Rotate the metal as needed for curves and intricate patterns.
7. Brush away any debris and clean the surface after engraving.
8. Apply a protective coating or lacquer if desired, especially for metals that tarnish.

Why choose hand engraving?

• Personal touch: Every mark is unique, resulting in truly individual pieces.
• Perfect for: Bespoke jewellery, commemorative items, fine art, and restoration work.

2. Laser engraving

Laser engraving is now one of the most popular ways to engrave metal in the UK and worldwide. Fast, precise, and repeatable – much like our laser cutting services – it’s the go to choice for modern industrial applications.

For this, you will of course need a laser engraving machine (fibre or diode lasers are common for metal). This method is suitable for most metals, including stainless steel, aluminium, copper, and more. The initial setup cost of running your own laser machine can be high, but running costs are generally quite low. It’s a lot more cost-effective to use a professional service that can handle your project from design through to the final product.

Laser engraving can also be utilised alongside CAD design services to help make designs better and more effective. It allows you to accurately set out what you wish to design and then implement it with high precision and speed. For more information on this, you can check out our other blog – What Are The Advantages of CAD?

How to engrave metal with lasers

1. Prepare and set up your laser engraving machine according to manufacturer’s guidelines.
2. Choose your metal blank and position it securely in the engraver.
3. Load your digital design into the engraving software.
4. Adjust laser power, speed, and other settings to suit your metal type.
5. Begin engraving, following all safety precautions (eye protection, ventilation, safety screens).
6. Allow the machine to complete the engraving, then remove and inspect your piece.

Why choose laser engraving?

• Speed and repeatability: Excellent for mass production and high detail work.
• Perfect for: Promotional items, signage, industrial labelling, machine parts, and complex patterns.

3. Rotary engraving with a power tool

For DIY enthusiasts or workshops that need versatility, rotary engraving with an electric tool (like a Dremel) is a practical option. This method combines the control of hand engraving with the efficiency of power tools. This method works well on most common metals, but harder metals may require specialist tool bits.

For this method, you will need your rotary tool, a range of engraving bits, clamps or a vice. Be mindful, though, the rotary tool technique is less precise than laser or CNC engraving for very fine work. You should also always wear eye protection and secure your workpiece to prevent accidents. Fine metal dust can also be produced, so consider respiratory protection or a dust extraction system too.

How to engrave metal with a rotary power tool

1. Clean your metal item thoroughly with alcohol.
2. Mark out your design using a vinyl sticker, transferred print, or permanent marker.
3. Clamp the metal securely in place.
4. Insert the appropriate engraving bit into your rotary tool (diamond bits are ideal for metal).
5. Set the tool to a lower speed, increasing as needed for your metal type.
6. Carefully follow your design, engraving lines with steady pressure
7. Repeat for deeper marks if desired.
8. Switch off the tool and brush away any metal filings or dust.
9. Polish or clean the area to finish.

Why choose rotary engraving?

• Versatility: Suitable for a wide range of projects and can be done at home.
• Perfect for: Custom tools, trophies, signs, hobbyist crafts, and repairs.

4. CNC engraving

Computer Numerical Control (CNC) engraving brings automation to the process, using computer-guided tools to cut complex or repetitive designs with minimal manual effort. It uses the same CNC technology we use for our Press Brakes and Metal Folding Services.

This technique is ideal for metals such as aluminium, brass, copper, stainless steel, and many others. The tools you will need include a CNC engraving machine, various cutting bits, and the required computer software. You may also use a nylon flap or soft brush to remove burrs and sharp edges and achieve a smooth, professional finish.

This method requires investment in equipment and software, as well as programming knowledge, unless you have a professional team handle your project for you.

How to engrave metal with a CNC machine

1. Securely fasten your metal workpiece onto the CNC machine bed.
2. Choose the appropriate bit (diamond cutter, twist drill, or v-bit).
3. Import your design into the CNC software and set your engraving parameters (depth, speed, etc.).
4. Start the engraving operation and monitor progress.
5. Once finished, use a nylon flap or brush to clean off any burrs or debris.
6. Apply a polish or lacquer for extra shine and protection, if needed.

Why choose CNC engraving?

• Automation: Excellent for high volume production or detailed, repeatable designs.
• Perfect for: Industrial parts, machine plates, serial numbers, and complex artwork.

5. Chemical etching

The last one on our list is not technically engraving but the process is very similar and used to achieve the same results. Chemical etching is a powerful and flexible technique widely used in industry for precise, intricate designs that might be too delicate or complex for mechanical engraving. It’s used for items like circuit boards, nameplates, and fine art.

For this technique, you will need metal blanks, photoresist or acid resistant mask, etching solution (usually acid or ferric chloride), a design stencil, and protective equipment. This requires careful handling of chemicals, proper ventilation, and safety precautions. You must also always dispose of used chemicals responsibly according to local environmental regulations.

The chemical etching process

First, a design is applied to the metal using a photoresist film or acid-resistant mask—this can be as simple as hand-drawn patterns or as sophisticated as photographic transfers. The metal is then immersed in an etching solution, which eats away the exposed areas while the masked sections remain untouched. The duration of etching determines the depth of the design. Once etched, the mask is removed, and the piece is thoroughly cleaned and neutralised.

Why choose chemical etching?

• Intricate detail: Can achieve extremely fine and crisp designs, even on thin metals.
• Perfect for: Electronic components, decorative panels, labels, jewellery, and architectural features.

Discover how to engrave metal and much more with Salamander Fabrications.

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us at any time. 

Our other metal fabrication techniques include:

• Welding services
• Sheet metal fabrication services
• Powder coating services

If you’re considering a metal engraving project, looking for advice on how to engrave metal, or need expert help with laser cutting and fabrication, Salamander Fabrications has decades of experience and the right tools for the job.

Our advanced facilities, skilled workforce, and commitment to quality mean every project gets the attention to detail it deserves. We’re always happy to discuss your ideas and recommend the best approach for your idea, no matter how big or small.

Give us a call if you think we can help you on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Are you curious about what metals don’t rust? Whether you’re a DIY enthusiast, engineer, or architect, rust resistance is a hot topic in the world of metalwork. Especially in Britain’s famously unpredictable weather! Knowing which metals can stand up to rain, salt, and the test of time is key to building long-lasting, low-maintenance structures, gadgets, and artworks.

We’ve been working in the world of sheet metal fabricators for over 50 years now, so we know a thing or two about metal! From gleaming stainless steel to lightweight aluminium, the world offers a host of metals that shrug off rust and corrosion, each with unique advantages. In this guide, we’ll explain the difference between rust and corrosion, explore why certain metals hold up better than others, and showcase the top 10 rust-proof metals.

What causes metal to rust?

Rust is a specific form of corrosion and is a form of iron oxide. It is the enemy of iron and its alloys, like steel. The science is simple – when iron meets oxygen and moisture, a chemical reaction forms iron oxide, better known as rust. This familiar orange, brown layer is more than unsightly, it also expands as it forms. This puts stress on metal structures, making them brittle and exposing them to the risk of failure.

What makes rust especially challenging in the UK is our climate. We have plenty of rain, high humidity, and coastal salt, all of which accelerate rust formation. And if sulphur dioxide or carbon dioxide are present (in city air or industrial settings) the process is even quicker.

Rust is also permeable. That means even once the surface has rusted, water and air can keep seeping in, allowing the corrosion to fester deeper into the metal. For engineers, homeowners, and fabricators, preventing rust is all about careful material choice and protection.

The difference between rust and corrosion 

Although the terms are sometimes used interchangeably, there’s a crucial distinction between rust and corrosion. Corrosion is the broad term for the gradual destruction of metals due to chemical reactions. Any metal can corrode, though some do so much more readily than others.

Rust, on the other hand, is specific to iron and iron-based alloys. This can weaken anything iron from old garden gates to the Cliff Bridge. Other metals, like aluminium or copper, may tarnish or form their own oxides, but these layers are usually much more stable and protective, rather than destructive.

Top 10 metals that don’t rust

So, what metals don’t rust? Below, we reveal the top ten, detailing why they resist rust, where they’re used, and their key properties.

What makes these metals resistant to rust?

The main secret behind what metals don’t rust comes down to chemistry. Metals like stainless steel, aluminium, and titanium form a thin, invisible oxide layer that acts as a barrier. This protects the rest of the metal beneath from air and moisture.

For others, like copper and bronze, a natural patina forms on the surface. This is a green or brown coating that’s not only attractive, but also keeps out further corrosion. Meanwhile, metals like gold and platinum simply don’t react with air or water, making them impervious to rust.

Galvanised steel takes another route. By coating steel in zinc, it gets a protective shield. Even if scratched, the zinc corrodes first, sacrificing itself to protect the steel underneath. This process is known as ‘cathodic protection.’

When to choose rust resistant metals

The choice of what metals don’t rust should be guided by your project’s needs.

• Outdoor structures: Opt for stainless steel, aluminium, or bronze for railings, sculptures, or signage.
• Marine applications: Bronze and titanium excel in saltwater environments, while galvanised steel offers cost-effective protection for short-term uses.
• Medical and food use: Stainless steel and titanium are biocompatible and easy to sterilise.
• Aesthetic projects: Copper, brass, and bronze provide rich, lasting colours and patinas.
• Electronics: Gold and nickel are invaluable for reliable, rust-free connections.

5 metals that are prone to rust or corrosion

Now we’ve highlighted our top 10 list for what metals don’t rust, let’s take a quick look at some that are on the opposite side of the scale.

1. Iron: Pure iron rusts very quickly when exposed to air and water, forming iron oxide (rust). This is commonly found in structural beams, old pipes, and cast iron items.
2. Carbon steel: An alloy of iron and carbon with little or no protective alloying elements. This is widely used in construction and manufacturing, but will rust rapidly if not coated or protected.
3. Cast iron: Another iron and carbon alloy, even more brittle than steel, and highly susceptible to rusting if left unprotected. Used for manhole covers, old cookware, and some pipes.
4. Low alloy steel: This steel has only minor additions of other elements like manganese or nickel. This offers little corrosion resistance compared to stainless steel. This can be found in bridges, frames, and machinery parts.
5. Wrought iron: Malleable iron with a very low carbon content, historically used for gates and fences. Although it has some natural corrosion resistance compared to pure iron, it still rusts easily if exposed to the elements.

How to prevent rust

• Pick rust resistant metals: Opt for stainless steel, aluminium, titanium, and other metals from our top 10 list, especially for outdoor or marine applications.
• Apply protective coatings: Paint, powder coating, oil, or specialised sealants can prevent moisture from reaching metal surfaces.
• Use galvanised or plated finishes: Galvanising coats steel in zinc, while other metals can be nickel or chrome plated for extra protection.
• Keep metals clean and dry: Regular cleaning removes corrosive salts, acids, and pollutants.
• Consider cathodic protection: Especially in marine or underground settings, sacrificial anodes made from zinc or magnesium help protect key metalwork.
• Environmental control: For valuable metalwork (like classic cars or art), use dehumidifiers, climate control, or silica gel packs to minimise moisture exposure.

How to prevent corrosion 

• Choose corrosion free metals: Aluminium and stainless steel are both versatile and eco-friendly choices for a range of environments.
• Laser treatment: Advanced laser technology can create a non-crystalline surface, increasing resistance to corrosion.
• Non-metallic coatings: Grease, carbon fibre, plastics, paint, and oil create effective moisture barriers.
• Specialist anti-corrosion coatings: Modern products provide strong, UV-resistant layers that don’t chalk, fade, or require multiple coats.
• Use drying agents: Keep equipment and storage areas free from dampness and check regularly for leaks.
• Regular maintenance: Inspect and maintain all metal items, addressing any damage to coatings immediately.

Contact Salamander Fabrications for your metal protection needs today!

If you would like any more information on how to ensure your metal projects are protected from the elements, please give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

We’re also happy to talk you through any of our services, including our:

• Welding services
• Metal folding services
• Sheet metal fabrication services
• CAD design services
• Electro mechanical assembly services

If you liked reading this blog then you may like to check out our other post – How to Cut Metal: 10 Techniques to Know.

By Embryo

What is a pure metal in comparison to an alloy metal? Also, ever wondered what the full list of pure metals actually is? You’ve come to the right place for the answer! We like to think of ourselves as more than just a sheet metal company, with over 50 years of industry experience, we believe we know everything there is to know about metal!

So we’ve brought you this handy guide to discuss what a pure metal is, the difference between pure and alloy metals, and a table of pure metals with their associated features and properties. Keep reading for more information.

What is a pure metal and where does it come from?

So, what is a pure metal in everyday terms? In short, a pure metal is an element that can’t be broken down into anything simpler by chemical means. It consists of only one type of atom. They are also known as single-phase metals. Gold, silver, copper, and iron are all examples of pure metals in their natural, unalloyed state. These metals form the backbone of modern civilisation and are found in almost everything, from electronics to cutlery, cars, and coins.

In contrast, alloys like steel, brass, and bronze are born from mixing pure metals together. A dash of non-metallic elements, like carbon, is also often introduced to boost performance in specific applications. But it’s the pure metals themselves that offer the original, distinctive set of characteristics. This includes electrical conductivity, corrosion resistance, and ductility.

The origins of pure metals

Most pure metals aren’t just lying around waiting to be picked up. They are typically locked away inside rocks as ores. Through mining, crushing, and various extraction processes (like smelting or electrolysis), these ores are transformed into the metallic materials we use today.

Major mining operations around the globe dig for metals like iron, copper, aluminium, and nickel to supply the raw materials that keep the modern world turning. Some, like gold and platinum, are far rarer, which makes them precious and often pricey. Estimations of the gold content of the Earth’s crust are in the range of 0.001 to 0.006 parts per million.

What is a pure metal vs an alloy metal?

While pure metals are made up of one element, alloys are blends of two or more elements. These are often designed to make the metal harder, stronger, or more resistant to corrosion and wear. For example, copper and tin create bronze; iron and carbon make steel; and gold and silver produce the luxurious white gold.

Most metal items around us these days are actually alloys. Yet, the unique qualities of pure metals remain in high demand for critical applications.

If you have liked reading this blog so far you should take a look at this one next – What is the Strongest Metal?

Full list of pure metals

To answer the question, what is the full list of pure metals? – Here’s a comprehensive table featuring the most significant pure metals, their properties, real world uses, and where they are primarily found around the world.

For more information like this you can check out our other blog – The Different Types of Metals; Their Properties, And Their Applications.

Unique features and properties of pure metals

So now we’ve discussed what is a pure metal and highlighted the full list of pure metals, let’s take a look at some of their collective unique qualities. Pure metals display a fascinating array of properties that set them apart from their alloyed counterparts. 

Here are a few highlights:

• Conductivity: Silver and copper are world beating conductors, making them essential for most electrical applications.
• Corrosion resistance: Gold, platinum, and titanium hardly ever tarnish or rust. This makes them ideal for jewellery, dentistry, and chemical equipment.
• Strength to weight ratio: Aluminium and titanium are both very strong and incredibly light, revolutionising both the transport and aerospace industries.
• Rarity and value: Gold, platinum and their associated group of metals are highly prized, not just for beauty and rarity, but their use in cutting edge technology.

Key Applications

• Electronics: Copper, silver, and gold wires power circuits and connections.
• Transport: Aluminium and titanium make trains, planes, and cars lighter and stronger.
• Construction: Iron and steel (mainly alloyed, but pure iron is the starting point) are used for beams and girders.
• Jewellery: Gold, platinum, silver, and palladium create stunning keepsakes.
• Healthcare: Titanium, platinum, and silver are used in implants, medical instruments, and antimicrobial coatings.
• Batteries: Lithium, cobalt, and nickel power everything from electric vehicles to mobile phones.

Contact Salamander Fabrications today for your sheet metal fabrication needs! 

What is a pure metal without metal fabrication services? A blank canvas for the team here at Salamander Fabrications to work their magic on! In truth and despite their unique qualities, pure metals are rarely used alone for most practical purposes these days. They are either too soft or brittle, too expensive, or outperformed by alloyed alternatives. Most of the metals we work on are from the alloy family of metals.

Whether you’re searching for more info on what is a pure metal, exploring the full list of pure metals, or considering a custom fabrication project, Salamander Fabrications can help. With over 50 years’ experience in the industry, we offer a full suite of services, including:

• Laser cutting services
• Welding services
• Metal folding services
• Sheet metal fabrication services
• Powder coating services

For any queries or bespoke requirements, get in touch via our contact page, call us on 01484 843599, or email sales@salamanderfabs.com. Our expert team are always happy to share their knowledge and help you select the right metal for your project.

By Embryo

Welcome to our definitive guide on how to cut aluminium, brought to you by the team here at Salamander Fabrications. We’re here to help with your project in any way that we can, whether you need a sheet metal contractor to help facilitate your project, or just some tips and advice on how to cut aluminium sheet. 

Aluminium’s lightweight strength, corrosion resistance, and versatility make it an extremely popular material. It is used in everything from garden furniture to commercial vehicles and architectural features. But its unique combination of properties also means that knowing how to cut aluminium accurately and efficiently is essential, whether you’re a DIY hobbyist, tradesperson, or working on an industrial scale. 

In this comprehensive guide, we’ll discuss the best ways to cut aluminium sheet, the specialist tools and techniques available, and the fabrication processes that ensure your finished product looks and performs as it should.

Techniques for how to cut aluminium sheets

Aluminium sheets are available in a huge range of thicknesses, from ultra-thin foil to sturdy multi-millimetre plates. When it comes to the methods of how to cut aluminium sheet, the one you choose will depend on several factors. This includes the thickness and type of aluminium, the level of accuracy needed, and the tools you have at your disposal.

Picking the right technique not only ensures a neat, clean cut but also minimises material waste and reduces the risk of unwanted damage. This is especially crucial for parts that need to look sharp or fit together precisely.

Below, we’ll break down the most effective methods for cutting aluminium sheet, along with expert tips to help you achieve the best possible finish every time.

Laser cutting

Laser cutting services have revolutionised the metal fabrication industry, offering incredible precision and control that simply cannot be matched by manual tools. This method uses a focused laser beam to heat and melt through aluminium sheets along a pre-programmed path.

Advantages:

• Exceptional accuracy for intricate shapes
• Minimal material distortion and clean, burr-free edges
• Suitable for large scale or repetitive projects

Considerations:

• Requires specialist machinery and proper ventilation
• Best suited to lightweight metals and thin to moderately thick aluminium sheets

Ideal for:

• Architectural features
• Bespoke signage
• Detailed brackets
• Any project where tight tolerances or a smooth finish are required

Plasma cutting

Plasma cutting is another powerhouse of metal fabrication, ideal for tackling thicker sections of aluminium or making complex shapes where brute force and flexibility are needed. It works by blasting ionised gas (plasma) at extreme temperatures through a small nozzle, effectively slicing through metal.

Advantages:

• Powerful enough for thick aluminium plates
• Fast, with impressive edge quality for most uses
• Great for irregular or freeform shapes

Considerations:

• Leaves a slightly wider cut width compared to laser cutting
• May require additional edge finishing

Ideal for:

• Industrial fabrication
• Automotive repairs
• Structural frameworks
• Any job involving substantial aluminium profiles

Waterjet cutting

Waterjet cutting harnesses the raw force of high pressure water mixed with abrasive particles to slice through aluminium. This technique is prized for its ability to handle both very thin foils and extremely thick plates, all while keeping the metal cool.

Advantages:

• No heat distortion or structural weakening
• Ultra-precision makes it suitable for intricate designs or small batch work
• Cuts a wide range of thicknesses and alloys

Considerations:

• Can be more expensive due to equipment and abrasive costs
• Requires a skilled operator for the best results

Ideal for:

• Aerospace components
• Decorative screens
• Complex assemblies where material integrity is critical

Hand tools

For smaller projects, prototypes, or onsite adjustments, hand tools remain an important part of learning how to cut aluminium sheet. They require minimal setup and can be surprisingly effective when used correctly.

• Hacksaw: Best for straight cuts in thin aluminium sheets or bars
• Tin snips: Best for cutting curves or intricate shapes in thin aluminium
• Utility knife: Best for scoring and snapping very thin aluminium, especially for ductwork or foil

Power tools

When you need more muscle, power tools are the answer for efficient, repeatable cuts (especially in medium to thick aluminium sheets). You should always wear goggles, gloves, and a dust mask when cutting aluminium.

• Circular Saw: Best for long, straight cuts in thicker aluminium sheet or plate
• Jigsaw: Best for curved or intricate cuts in aluminium
• Band Saw: Best for both straight and curved cuts, especially in thicker stock

Alternative sheet metal fabrication services

Here at Salamander Fabrications, we understand that there’s more to working with aluminium than just cutting. Sometimes, a project needs bending, welding, or other fabrication processes to bring your vision to life. Here’s a quick overview of other essential metalworking techniques.

Welding

Welding services are at the heart of most metal fabrication projects, especially for joining aluminium parts together. Whether you’re building frames, enclosures, or bespoke pieces, welding creates robust, long lasting joints.

Different types of welding:

• MIG Welding: Great for thicker aluminium, providing fast, strong welds
• Robotic MIG Welding: Delivers consistent quality and is ideal for high volume or repetitive work
• TIG Welding: Perfect for thin sheet aluminium or work that demands a clean, attractive finish
• Spot Welding: Used to join thin sheets without filler, common in automotive and appliance manufacturing

Want to know more? Read our detailed blog post on the subject – What Are The Different Types of Welding?

Sheet metal folding

Sheet metal folding is vital for producing parts with bends or angles, and CNC-controlled folding machines ensure every bend is precise and repeatable.

Stand-out features:

• Precision: Allows for exact bends and identical pieces that meet strict quality standards
• Cost-effective: Lowers costs by reducing the need for welding or additional assembly

Coating and finishing

Aluminium’s natural oxide layer makes it resistant to corrosion, but the right finishing or powder coating process can enhance durability and appearance even further.

Popular finishing techniques:

• Powder coating: Creates a tough, colourful finish that resists scratching and UV fading.
• Electroplating: Adds a decorative or protective metal layer which is ideal for high wear or visible components.
• Polishing and brushing: Delivers a high shine or a modern, textured look for decorative aluminium.

Choosing the best method for how to cut aluminium

Selecting the best method for how to cut aluminium depends on your tools, the thickness and alloy of the sheet, and the demands of your project. Hand tools are great for light work, while power tools and advanced machinery offer the accuracy and speed required for larger or more complex jobs.

Don’t forget to clean, deburr, and finish all cut edges for safety and appearance. If in doubt, consult a professional sheet metal contractor. Working with aluminium is as much about experience as it is about equipment.

Contact Salamander Fabrications for more information on our laser cutter – our method for how to cut aluminium

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us any time. The team here at Salamander Fabrications are more than happy to talk through the services we have to offer and share our expertise.

Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Wondering how to engrave metal? Want to know if there is a single technique that works for everything, or do different methods suit different projects? If you’re looking for guidance on the full range of options and want to understand the strengths and uses of each, you’ve landed in the perfect spot. Here at Salamander Fabrications, the home of expert metal fabrication services, we specialise in all things sheet metal – a common material used for engraving.

In this guide, we’ll break down the five main ways of how to engrave metal, covering both timeless hand skills and the latest machinery. We’ll explore what makes each method unique, the tools you’ll need, best practices, and what types of jobs each approach is suitable for.

1. Engraving metal by hand

Let’s start with the old faithful and the most traditional method of how to engrave metal. The classic image of an artisan at a workbench springs to mind. Hand engraving has centuries of tradition behind it and is still favoured for intricate jewellery, ceremonial objects, and one off pieces where artistry is prized over speed.

This method is best for softer metals like silver, gold, copper, and brass. It is a time consuming process that demands patience and practice. For batch production or very hard metals, other methods may be preferable. The tools you’ll need include gravers (burins), a ball vice, and sharpening stones.

Hand to engrave metal by hand

1. Sketch or print your design, then transfer it onto the metal surface (using paper, acetone, or a vinyl sticker).
2. Secure the metal piece in a ball vice to hold it steady.
3. Select the right graver for your design and sharpen if necessary.
4. Hold the graver at a roughly 45-degree angle to the metal.
5. Push or glide the graver along the design, using consistent, controlled pressure to etch lines.
6. Rotate the metal as needed for curves and intricate patterns.
7. Brush away any debris and clean the surface after engraving.
8. Apply a protective coating or lacquer if desired, especially for metals that tarnish.

Why choose hand engraving?

• Personal touch: Every mark is unique, resulting in truly individual pieces.
• Perfect for: Bespoke jewellery, commemorative items, fine art, and restoration work.

2. Laser engraving

Laser engraving is now one of the most popular ways to engrave metal in the UK and worldwide. Fast, precise, and repeatable – much like our laser cutting services – it’s the go to choice for modern industrial applications.

For this, you will of course need a laser engraving machine (fibre or diode lasers are common for metal). This method is suitable for most metals, including stainless steel, aluminium, copper, and more. The initial setup cost of running your own laser machine can be high, but running costs are generally quite low. It’s a lot more cost-effective to use a professional service that can handle your project from design through to the final product.

Laser engraving can also be utilised alongside CAD design services to help make designs better and more effective. It allows you to accurately set out what you wish to design and then implement it with high precision and speed. For more information on this, you can check out our other blog – What Are The Advantages of CAD?

How to engrave metal with lasers

1. Prepare and set up your laser engraving machine according to manufacturer’s guidelines.
2. Choose your metal blank and position it securely in the engraver.
3. Load your digital design into the engraving software.
4. Adjust laser power, speed, and other settings to suit your metal type.
5. Begin engraving, following all safety precautions (eye protection, ventilation, safety screens).
6. Allow the machine to complete the engraving, then remove and inspect your piece.

Why choose laser engraving?

• Speed and repeatability: Excellent for mass production and high detail work.
• Perfect for: Promotional items, signage, industrial labelling, machine parts, and complex patterns.

3. Rotary engraving with a power tool

For DIY enthusiasts or workshops that need versatility, rotary engraving with an electric tool (like a Dremel) is a practical option. This method combines the control of hand engraving with the efficiency of power tools. This method works well on most common metals, but harder metals may require specialist tool bits.

For this method, you will need your rotary tool, a range of engraving bits, clamps or a vice. Be mindful, though, the rotary tool technique is less precise than laser or CNC engraving for very fine work. You should also always wear eye protection and secure your workpiece to prevent accidents. Fine metal dust can also be produced, so consider respiratory protection or a dust extraction system too.

How to engrave metal with a rotary power tool

1. Clean your metal item thoroughly with alcohol.
2. Mark out your design using a vinyl sticker, transferred print, or permanent marker.
3. Clamp the metal securely in place.
4. Insert the appropriate engraving bit into your rotary tool (diamond bits are ideal for metal).
5. Set the tool to a lower speed, increasing as needed for your metal type.
6. Carefully follow your design, engraving lines with steady pressure
7. Repeat for deeper marks if desired.
8. Switch off the tool and brush away any metal filings or dust.
9. Polish or clean the area to finish.

Why choose rotary engraving?

• Versatility: Suitable for a wide range of projects and can be done at home.
• Perfect for: Custom tools, trophies, signs, hobbyist crafts, and repairs.

4. CNC engraving

Computer Numerical Control (CNC) engraving brings automation to the process, using computer-guided tools to cut complex or repetitive designs with minimal manual effort. It uses the same CNC technology we use for our Press Brakes and Metal Folding Services.

This technique is ideal for metals such as aluminium, brass, copper, stainless steel, and many others. The tools you will need include a CNC engraving machine, various cutting bits, and the required computer software. You may also use a nylon flap or soft brush to remove burrs and sharp edges and achieve a smooth, professional finish.

This method requires investment in equipment and software, as well as programming knowledge, unless you have a professional team handle your project for you.

How to engrave metal with a CNC machine

1. Securely fasten your metal workpiece onto the CNC machine bed.
2. Choose the appropriate bit (diamond cutter, twist drill, or v-bit).
3. Import your design into the CNC software and set your engraving parameters (depth, speed, etc.).
4. Start the engraving operation and monitor progress.
5. Once finished, use a nylon flap or brush to clean off any burrs or debris.
6. Apply a polish or lacquer for extra shine and protection, if needed.

Why choose CNC engraving?

• Automation: Excellent for high volume production or detailed, repeatable designs.
• Perfect for: Industrial parts, machine plates, serial numbers, and complex artwork.

5. Chemical etching

The last one on our list is not technically engraving but the process is very similar and used to achieve the same results. Chemical etching is a powerful and flexible technique widely used in industry for precise, intricate designs that might be too delicate or complex for mechanical engraving. It’s used for items like circuit boards, nameplates, and fine art.

For this technique, you will need metal blanks, photoresist or acid resistant mask, etching solution (usually acid or ferric chloride), a design stencil, and protective equipment. This requires careful handling of chemicals, proper ventilation, and safety precautions. You must also always dispose of used chemicals responsibly according to local environmental regulations.

The chemical etching process

First, a design is applied to the metal using a photoresist film or acid-resistant mask—this can be as simple as hand-drawn patterns or as sophisticated as photographic transfers. The metal is then immersed in an etching solution, which eats away the exposed areas while the masked sections remain untouched. The duration of etching determines the depth of the design. Once etched, the mask is removed, and the piece is thoroughly cleaned and neutralised.

Why choose chemical etching?

• Intricate detail: Can achieve extremely fine and crisp designs, even on thin metals.
• Perfect for: Electronic components, decorative panels, labels, jewellery, and architectural features.

Discover how to engrave metal and much more with Salamander Fabrications.

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us at any time. 

Our other metal fabrication techniques include:

• Welding services
• Sheet metal fabrication services
• Powder coating services

If you’re considering a metal engraving project, looking for advice on how to engrave metal, or need expert help with laser cutting and fabrication, Salamander Fabrications has decades of experience and the right tools for the job.

Our advanced facilities, skilled workforce, and commitment to quality mean every project gets the attention to detail it deserves. We’re always happy to discuss your ideas and recommend the best approach for your idea, no matter how big or small.

Give us a call if you think we can help you on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Metals are known for their ability to conduct heat and electricity. They’re also extremely ductile, versatile, and machinable. For these reasons and many more, metal is part of our everyday lives and is pretty much everywhere. You’re probably within inches of something metal reading this blog right now. But, have you ever wondered, exactly where does metal come from? 

Here at Salamander Fabrications, we are specialists in sheet metal fabrication services, so it’s safe to say we know a thing or two about the material. If you’d like to know more about what metal is made of and how metal is made, continue reading…

So…where does metal come from?

Every single metal that exists on Earth today originated billions of years ago, way before we did. The first humans to discover metal stumbled upon copper, tin, and gold by hammering into rocks. Over time we have learned how to mix metals with other metals, and other substances, to create new metals that we now refer to as alloys. This is primarily done to improve strength amongst other characteristics.

For example, if you combine copper with tin, then you create bronze. Or if you mix iron and a little bit of carbon, you get steel, and so on and so forth. Most natural metals come from the earth’s crust, found in ores. An ore is a solid material that minerals can be extracted from. To extract the metal ores from the ground, huge mining operations are used across the world.

Our planet approximately consists of:

• 30% iron
• 14% magnesium
• 1.5% nickel
• 1.4% aluminium

This makes up almost half of the Earth – meaning we are almost 50% metal! Precious metals like gold, silver, or platinum exist in very, very small amounts. Estimations of the gold content of the earth’s crust are in the range of 0.001 to 0.006 parts per million. Extremely low in comparison to iron and magnesium. 

Where are metals found?

As mentioned in the previous section, the vast majority of metals on Earth are mined from the Earth’s core and crust. This means the metals you see all around you may have come from all different corners of the world. Australia and Brazil are some of the highest exporters and miners of metal, but there are many other countries that contribute to global production too.

This table provides a detailed look at where major metals are mined, their contributions to global supply, and their key applications.

What is metal made of?

Natural metals are mined and extracted, refined, and then smelted – so in essence they already exist and are not ‘made of’ anything. They are pure metals. In relation to metal alloys – these are a combination of two or more metals or other materials.

Almost all metal elements can be alloyed into different types. Different types of metal alloys are made of different things. Each one offers its own unique physical beneficial features and characteristics. 

This table shows a variety of metal alloys, their compositions, key applications, and important properties.

Check out our other blog – Examples of Ferrous and Non-Ferrous Metals to find out more about the difference between the two. This includes a deep dive into ferrous and non-ferrous metals, including their features and properties in comparison to each other.

How is metal made?

To answer this question, let’s take a look at the process of metal manufacturing at a basic level. The steps include:

1. Extract the raw ore from the Earth’s crust
2. Remove any non-metal material, such as rock and debris
3. Crush the ore into a fine powder
4. Heat the resulting powder to a high temperature
5. Rinse with cold water or a chemical bath
6. Filter the sludge
7. Separate the solid from the liquid
8. Apply an electrical current to break chemical bonds

Let’s take a look at the finer details of how some common metals are made.

Aluminium: The most common ore used for aluminium production is bauxite. This is crushed and then electrolysis is used to split it into aluminium and oxygen. The pure metal is cast into blocks known as ingots. To find out more about aluminium, check out our guide on the top ten uses of aluminium. 

Zinc: Zinc extraction commonly involves a method called froth flotation, which is also used for refining copper and lead. The zinc ore is ground into a fine powder and mixed with water, pine oil, and flotation agents. This mixture is stirred, causing the zinc particles to rise to the surface, where they are collected and further refined.

Lead: Lead ore is typically found deep underground and contains a significant amount of sulphur. The ore is first crushed and mixed with water, where it undergoes flotation to separate it from unwanted materials. However, additional refining is required – heating the lead further helps remove excess sulphur and other impurities.

Copper: Copper ores generally contain only a small percentage of copper, often around 4%. The refining process gradually increases its purity. The ore is first broken down into tiny fragments and combined with water before being placed in large tanks, where air and chemical agents help separate copper particles from other minerals. The resulting material is then heated in a large furnace called a smelter. This process burns off additional impurities, leaving behind copper matte, a substance that is at least 50% pure copper.

Brass: Unlike natural metals, brass is an engineered alloy made primarily from copper and zinc. Since it is not extracted from an ore, it is produced by melting these two metals together in a furnace. The molten brass is then shaped into pipes, tubes, or sheets, depending on its intended use. Brass is classified as a type of copper alloy due to its high copper content.

Steel: Steel production begins with iron extraction, primarily from hematite and magnetite ores. These iron-rich minerals are found in rock formations and deposits, with hematite easily identified by its distinctive reddish colour. The method of extraction varies based on the depth and location of the iron ore, but once it is mined, the refining process begins. The first stage involves processing the ore in a blast furnace, where it is heated and purified to prepare it for steelmaking. For more information on steel you can check out our other blog – Mild Steel Vs Stainless Steel: What’s The Difference?

Where are metals found and expertly fabricated? Right here at Salamander Fabrications! 

Where does metal come from before it enters our workshops? Well, we don’t always know the origin (in terms of the country) where the key elements were originally extracted. But what we do know is the quality of the metals that leave our workshop before they go on to fulfil their applications. 

Whether you require laser cutting services, expert welding services or metal folding services, our expert team will use their decades of experience to ensure your exact needs are met. The team here at Salamander Fabrications is more than happy to share their expertise and talk to you more about some of the services we have to offer. 

Visit our contact page or just give us a ring on 01484 843599. Or you can email us at sales@salamanderfabs.com.

By Embryo

Out of the 118 elements on the periodic table, around 75 to 80 are considered to be metal. So the competition for what is the strongest metal is pretty fierce. Here at Salamander Fabrications we have cut, bent, rolled, welded, and coated quite a few different types of metal in our time – including some of the strongest metals in the world.

Our metal fabrication services have provided us with opportunities to work with a variety of different metals, across a number of different projects. So we know a thing or two about metal strength and some of the strongest metals in the world. Carry on reading to find out what is the strongest metal…

Different types of metal strength

When thinking about the strongest metals in the world, there are several factors to consider, as there are several different types of strength.

Tensile strength

Tensile strength is all about tension. This refers to the amount of force needed to stretch or pull a metal apart. The higher the tensile strength, the more force required to pull it apart. 

Compressive strength

How far can a metal withstand being compressed or squeezed together? This is compressive strength. To test this, pressure is placed on the metal between the plates of a compression testing machine. A load is gradually applied until the metal breaks, reduces in size, or reaches a predetermined load value. Compressive strength is often measured using the Mohs Hardness Test. 

Yield strength

This refers to a metal’s capability to withstand bending. It tests the elastic limit of a piece of metal. This often involves gripping either side of it and applying stress to bend it. This will tell you how much stress is required until the metal will not return to its original shape when the stress is removed. 

Impact strength

Impact strength refers to a metal’s ability to withstand a blow without shattering or fracturing. 

Alloys vs natural metals

Now that we’ve discussed the different types of metal strength, there’s something else we need to highlight before we get into the strongest metal. That means discussing what is actually a ‘metal.’ There are metals and then there are metal alloys.

As we mentioned at the start, out of the 118 elements on the periodic table, around 75 to 80 are considered metal. Natural metals, also known as native metals, exist in pure, elemental form in nature. This means they are not chemically combined with any other elements. Gold, copper, silver, tin, lead, and iron are all examples of naturally occurring metals.

Metal alloys are combinations of two or more metals. The main reason for making metal alloys is to create a stronger material. Examples include steel (iron and carbon), brass (copper and zinc), and bronze (copper and tin).

Our list of the strongest metals in the world contains both metals and metal alloys. But for argument’s sake, we will just consider them all to be simply metal – as does most of the rest of the world.

Comparing the strongest metals in the world

So without further ado, and in no particular order at all, here is our list to answer the question – what is the strongest metal in the world? We thought it would be quite boring to list just the one, and in truth, it’s a close call at the top, so we’ve included a few for you to check out.

Stainless steel

Let’s start our list of the strongest metals in the world with one of the most common and perhaps unexpected – stainless steel. This is often referred to as the strongest alloy in the world and is highly resistant to rusting and corrosion. It is made from iron and carbon and is a highly versatile alloy.

You may be surprised by this, as stainless steel is almost everywhere. Bending one of your stainless steel spoons might make you think we’re talking nonsense. But this is just a very thin piece of metal that is also often coated with stainless steel, rather than being constructed entirely from it. The strength of each alloy can differ significantly too. Some grades of stainless steel offer incredible tensile strength, making it an incredibly popular choice across countless industries.

So stainless steel is very much a type of metal with great tensile strength qualities. It’s also widely used in metal fabrication services due to its popularity, durability, and availability.

Common applications include:

• Construction materials
• Medical equipment
• Automotive parts
• Kitchenware and appliances
• Aerospace components

We have even more information on stainless steel in our other blog – Stainless Steel Properties, Grades, and Applications.

Chromium

Chromium sounds expensive just from the name, but in truth, it is a relatively inexpensive metal that is abundant in the Earth’s crust. It is often referred to as the hardest metal in the world. chromium scores very high on the Moh’s Hardness Test, meaning it has incredible compressive strength. There are only two metals above chromium in this respect, and they are boron and diamond. Despite its incredible compressive strength, however, it does fail to offer a lot of tensile strength.

So whereas it cannot be easily squished or crushed, it can be torn apart a lot easier in comparison. You don’t often find a lot of things made of chromium alone either, as it is often combined with other materials to provide added strength. 

Common applications include:

• Coatings and plating for corrosion resistance
• Stainless steel production
• Automotive trim and parts
• Aerospace applications
• Industrial tools and cutting equipment

Inconel

This is one of the lesser-known metals on the list of what is the strongest metal. Inconel is a group of nickel-based superalloys. Its superpower is tensile strength and the ability to withstand extremely high temperatures. It also has high corrosion and oxidation resistance and excellent mechanical properties.

Common applications include:

• Jet engines and aerospace engineering
• Marine applications
• Chemical processing plants
• High-temperature industrial applications
• Gas turbines

Titanium

Now we’re into the big players in the league of extraordinary metals! Almost everyone has heard of titanium and is pretty much aware of how strong it is. Titanium has an extremely high melting point and incredibly high strength to weight ratio. If you need maximum strength but minimum weight, this is a common choice.

Common applications include:

• Aerospace and aviation components
• Medical implants and prosthetics
• High-performance automotive parts
• Military and defense applications
• Sporting goods and high-performance equipment

Tungsten 

The last on our list of the strongest metals in the world. It’s a fight for the top spot alongside titanium. Tungsten is often referred to as the strongest natural metal in the world (different from the strongest alloy). Despite its incredible strength, with the highest tensile strength of any metal, tungsten is brittle and prone to shattering. So impact strength is not up there with its tensile qualities. This metal is often combined with steel and other metals. It also has the highest melting point of any natural metal.

• Cutting tools and industrial machinery
• Military armour and ammunition
• Electrical contacts and electrodes
• Aerospace components
• High temperature applications

Tungsten vs Titanium

Since these are the strongest metals in our discovery, it’s only fair we give them their own section and stand-off.

Tungsten

• Highest tensile strength of any natural metal, making it incredibly resistant to being pulled apart.
• Highest melting point of any metal (3,422°C), making it ideal for high temperature applications.
• Extremely dense, almost twice as heavy as lead.
• Less practical for applications requiring lightweight materials.
• Brittle in its pure form, meaning it can shatter under high impact.
• Often used in alloys with steel to improve strength and durability while reducing brittleness.

Titanium

• Excellent strength to weight ratio.
• Highly resistant to corrosion, even in extreme environments like seawater and acidic conditions.
• High melting point (1,668°C), making it useful for aerospace and high-performance applications.
• More flexible and less brittle than tungsten, meaning it can absorb impact without breaking.
• Biocompatible with the human body.

Which is the strongest?

The choice between tungsten and titanium depends on the application. 

If you need maximum tensile strength and heat resistance, tungsten is the winner. However, if you need a strong, lightweight, and impact resistant metal, titanium is the better choice. Tungsten is ideal for industrial applications like cutting tools and military uses, whereas titanium excels in aerospace, medical, and sporting applications. 

If this has been an interesting read then you may be interested in our other blog – Melting Point of Metals. This includes a chart showing the melting point of various metals and a guide on how to measure the melting point.

Find out more about working with Salamander Fabrications on your next sheet metal project…

Here at Salamander Fabrications, we use a variety of techniques to shape, design, and transform some of the strongest metals in the world. This includes laser cutting services, expert welding services, and metal folding services.

If you would like some more information or advice on what we have to offer, please feel free to contact us. You can call us on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo