Galvanization is a process designed to help steel resist corrosion and provide protection to keep it looking and performing great.

However, these are all key traits of stainless steel as well.

So which is better for your next project?

In this guide, we’ll compare stainless steel and galvanized steel across a variety of common considerations and use types to help highlight the strengths and weaknesses of these two popular steel variations.

What is Galvanized Steel Anyhow?

Before we can compare them, it’s essential to understand how galvanized steel is made. 

Essentially, galvanized steel is simply zinc-plated steel. 

There are multiple ways to galvanize steel parts and components, but they all provide similar results as long as they are correctly performed.

The most common method of galvanizing steel is hot-dipping. 

In this process, standard steel is dipped in molten zinc, creating a layer of zinc that bonds with the surface of the steel, providing protective benefits and an appealing appearance.

Electro-dipping and thermal diffusion methods are also used when parts are particularly small or complex.

This layer of zinc serves the same purpose as the passive layer of chromium oxide on the surface of stainless steel, helping the metal resist corrosion and repel scuffs, dings, and other minor physical abuses.

This also means that you end up with a layered finished product instead of a fully alloyed product like stainless steel.

So Is Galvanized Steel as Corrosion Resistant as Stainless Steel?

In general, no.

However, this will depend on the specific situations in which you plan to use your galvanized or stainless steel parts.

Galvanized steel offers excellent resistance against water and chlorine but pales in comparison to stainless steel’s corrosion resistance when dealing with marine environments.

The protective layer on galvanized is also not self-healing like the passive layer on stainless steel. 

This means that over extended periods, galvanized parts are generally less durable than stainless ones.

However, even if the zinc layer on a galvanized component is damaged, it will still serve as a sacrificial cell in galvanic corrosion processes, encouraging rust formation on the damaged zinc areas instead of the underlying steel.

In general, stainless will offer better corrosion resistance and offer it for a longer period as well.

Which is Stronger: Galvanized or Stainless Steel?

When compared at similar thicknesses and forms, stainless steel is always stronger than galvanized steel.

An effective way to compare this is by looking at the tensile strength of each material. 

Tensile strength is the resistance of a material to breaking under tension. 

Exact figures will vary by the alloy in use. 

The tensile strength of stainless steel alloys typically starts around 515 megapascals (MPa) and can reach as high as 1300 megapascals (MPa) in some cases. 

Structural steel has a tensile strength of 400 megapascals (MPa), while carbon steel has a tensile strength of 841 megapascals (MPa). 

Both are commonly used for creating galvanized steel productions.

Since galvanization does not impact the tensile strength of the underlying metal, you could reasonably expect galvanized steels made from various steel grades to have comparable tensile strength compared to the original steel.

Is Stainless Steel Heavier than Galvanized Steel?

In most cases, stainless steel and galvanized steel will have a very similar weight. 

The specific differences will vary depending on the exact stainless steel alloys in question and the zinc coating thickness on the galvanized steel product.

More alloyed metals or a thicker coating will result in greater weight. This is unavoidable.

How Malleable are Stainless Steel and Galvanized Steel?

Galvanized steel offers the same malleability as the underlying steel used. 

This means that in most cases, it will be more malleable than comparably shaped stainless steel forms. 

If you must use stainless steel and want greater malleability but aren’t sure how to pick the perfect stainless steel grade, consider austenitic grades. 

These contain higher amounts of nickel, making them more formable for larger objects like sinks, basins, and tanks.

How Well Do Stainless Steel and Galvanized Steel Conduct Heat?

Both stainless steel and galvanized steel should conduct heat in a relatively similar manner. 

However, in the case of galvanized steel, you must keep the melting temperature of zinc in mind. 

While molten zinc is non-toxic, heating galvanized steel past zinc’s melting point could create burn or fire hazards as the zinc coating liquefies and separates from the underlying steel.

On a structural level, both types of steel should provide excellent heat tolerances for use in high heat areas.