Stainless steel corrosion resistance: Which process is really right for your application?

There is no one-size-fits-all solution for making steel corrosion-resistant. There are several established methods, but only one of them effectively addresses the issues of weight, cost, and durability.

This article explains where stainless steel, coatings, electroplating and roll bonding are effective and where they reach their limits.

The problem: Why standard steel is often not enough

When steel is used in corrosive environments, damp conditions or under fluctuating temperatures, untreated structural steel is not sufficient.

The result: component failure, downtime and associated costs.

Typical industries that face this challenge on a daily basis:

Chemical Engineering: Pressure vessels, reactors, piping
Automotive and Energy Technology: Heat shields, oil coolers, heat exchangers
Food and Pharmaceutical Industries: Hygienic surfaces subject to mechanical stress

The most common response: switching entirely to stainless steel. That’s understandable, but there are ways to make steel corrosion-resistant without switching entirely to stainless steel.

An overview of the most important methods

No single method is inherently better. Each has its place, its cost, and its limitations.

Process	Advantages	Disadvantages
Stainless steel (solid)	High durability, proven	Heavy, expensive
(Hot-dip) galvanizing	Affordable, standard for outdoor use	Limited range of applications
Coating / Paint	Affordable, versatile	Not durable, susceptible to mechanical damage
Electroplating	A thin layer, applied precisely	Limited coating thickness, environmental impact from chemicals
Roll Bonding	Durable bonding, even for small quantities, wide range of material combinations	Less well known, requires technical coordination

Stainless steel: Safe, but not always practical

Solid stainless steel is the top choice if you want steel that is permanently corrosion-resistant. However, stainless steel has two characteristics that can pose problems in many applications:

greater weight
high material costs

A stainless steel component can be up to 30% more expensive than a clad material with a steel core, even though the surface corrosion protection is the same.

For components where only the surface needs to be corrosion-resistant, you’re paying for properties in solid stainless steel that you don’t actually need in the core.

Coating and electroplating: Where they work and where they don't

Coatings and paints are inexpensive and quick to apply. They are suitable for applications without mechanical stress and without direct contact with media.

As soon as scratches, temperature fluctuations, or aggressive media come into play, the coating fails. This can lead to corrosion of the steel underneath.

Electroplating partially solves the coating problem: it allows for thinner, more precise coatings, such as chrome, nickel, or zinc on steel.

However, the coating thickness remains limited, typically in the micrometer range. For components subjected to continuous mechanical stress, this is insufficient.

Making steel corrosion-resistant through roll bonding

Roll bonding permanently bonds two layers of metal under high pressure and temperature. The result is not a coating; it is a composite material.

The corrosion-resistant outer layer—such as stainless steel or aluminum—is metallurgically bonded to the substrate without an adhesive interlayer or risk of delamination.

How the process works:

In roll bonding, two sheets are rolled together under pressure and, if necessary, heat to form a composite. The bond is created through atomic diffusion at the interface.

The result: A bond that does not delaminate, even under mechanical stress or temperature changes.

Possible material combinations:

Stainless steel on structural steel (most common combination for pressure vessels and apparatus engineering)
Aluminum on steel (weight reduction combined with corrosion protection)
Copper on steel (for heat exchangers and electrical applications)

Roll bonding is thus one of the few methods that makes steel corrosion-resistant without altering the mechanical properties of the substrate. Ideal for applications that require a balanced combination of cost, performance and weight.

What does this mean for your calculations?

A clad sheet with a 3-mm stainless steel layer on top of 20-mm structural steel costs significantly less than a 23-mm solid stainless steel sheet.

The corrosion protection on the surface in contact with the medium is identical. The weight is also reduced because part of the material consists of lightweight aluminum.

Small quantities are available. This is a common misconception. If you want to make steel corrosion-resistant, you don’t have to purchase in large quantities. Clad composite sheets are also available in small batch sizes.

When to choose which method

No single method is suitable for every application. This table can help you make an initial assessment

Use case	Recommended procedure
High corrosion exposure, direct contact with the medium, mechanical stress	Roll bonding or solid stainless steel
Low budget, no mechanical stress	Coating / Paint
Thin film on small components, electronics	Electroplating
Weight reduction combined with corrosion protection	Roll bonding (e.g., aluminum onto steel)
Small quantity, specific material combination	Roll-clad sheets (also available as cut-to-size sheets)

Examples from practice

Oil coolers and heat exchangers: Copper-steel composite for optimal thermal conductivity with a corrosion-resistant outer surface

Heat shields: Aluminum-steel composite, lighter than solid steel, corrosion-resistant thanks to the aluminum coating

FAQs stainless steel corrosion resistance

What is the difference between plating and coating?

Cladding involves permanently bonding two layers of metal to form a composite material. The bond is created metallurgically, not through the use of adhesives or bonding agents. Clad sheets can be welded, bent, and machined just like solid material.

Coating involves applying a layer to the surface, such as paint or a galvanized layer.

What material combinations are possible in roll bonding?

Common combinations include stainless steel on structural steel, aluminum on steel, and copper on steel. The choice depends on the medium, the temperature, and the mechanical requirements. Multilayer composites are also possible.

Is roll bonding also suitable for small quantities?

Yes. Clad materials are not only available for large-scale production. They can also be purchased in smaller quantities.

Determining the appropriate material combination and dimensions requires technical consultation, but this is still cost-effective even for small quantities.

Why is clad steel often less expensive than solid stainless steel?

This is because only the side that comes into contact with the medium is made of the more expensive material. This allows steel to be made corrosion-resistant without having to manufacture the entire component from stainless steel.

The core consists of structural steel, which is significantly less expensive. For wall thicknesses of 10 mm or more, the cost of the core material becomes the dominant factor.

The result: the same corrosion protection on the surface, lower overall material costs.

Talk to our materials experts

Are you looking to make steel corrosion-resistant but aren’t sure which process is right for your application?

Our materials experts will analyze your requirements and help you determine whether roll cladding is the right choice for your production volume, material, and specifications.

Contact us now!

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