What is the Advantage and Disadvantage of alloy and stainless piping

Stainless steel pipe has various uses, however, like all other pipes, stainless steel pipe has its advantages and disadvantages. In this article, let's take a closer look at the pros and cons of stainless steel pipe to determine if it's right for your project.

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Advantages of Stainless Steel Pipe:

- High Corrosion Resistance: This means stainless steel pipe won't rust or corrode over time like other metal pipes. Even with constant water in the pipe, the metal will retain its rust-free appearance for years.

- High Durability: This means the appearance and performance of stainless steel pipe will not rust or degrade over time.

- Appealing Appearance: Stainless steel has a bright, shiny, highly reflective finish. This can give your project a high-end look not possible with other materials.

- Strong: Stainless steel pipe is very strong and resistant to damaging elements that can destroy other types of pipe, making them ideal for applications where strength is important.

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- 100% Recyclable: When stainless steel pipes are no longer needed, they can be melted down and turned back into other usable metal pieces for other industries.

Disadvantages of Stainless Steel Pipe:

- High Cost: Stainless steel piping is generally more expensive than other types of piping. This is because they are made from higher quality materials and require more labor to produce.

- Heavy Weight: Stainless steel pipe is much heavier than other types of pipe, which can make them difficult to transport and install.

- Difficulty Welding: Stainless steel tubing is heat resistant, so it is difficult to melt the solder and form a seal. If the weld is not done properly, the pipe may leak at the joint.

- Special Tools Required: Stainless steel metal is too hard for regular tools like hammers and screwdrivers to work on it. Special tools, such as pipe cutters and reamers, must be used to properly install stainless steel pipe.

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Well I am at the point in my ALH build where I need to start planning my intercooler pipe routing and I got to thinking, which material should I use? In the past I have always used aluminum because it was light weight and I had all the room in the world to work with so size didn't matter. In all my searching on here, I have found both aluminum and SS. So I figured I would start a conversation with all of you about the pros and cons of each. Also, what size tubing would you suggest and why?

Thanks for your input Whatever material you decide to use, get a set of these to help in the mock up. They're a bit pricey but high quality and if you've ever done this kind of work without them, you won't hesitate at picking up a set (I think I have 3 different sizes)

https://www.icengineworks.com/product/series-tack-welding-clamps-set-4/

I'd go with 2" tube (not pipe) since it's commonly available and a tick bigger than OEM.

I've fabbed tubing with all 3 materials and mild steel is by far the easiest to work with, least expensive and a good coat of paint goes a long ways in keeping it from rusting out.

Stainless looks nice, stays that way, but is heavy and really unnecessary for boost piping in my opinion. Most difficult to cut/form, has the lowest heat transfer coefficient of the 3, and is more difficult to weld than mild steel, but easier than aluminum.

Aluminum is likely the best due to weight and heat dissipation (this works both ways as it absorbs heat equally well), but is the most difficult to work with - particularly the welding part but it scratches and dents easily as well.

Woolf Aircraft is a good source for the tubing and has most all sizes/materials in 1D CLR (really tight bend radius) so you can fit in tight places. Made in USA and fair prices as well.

http://catalog.woolfaircraft.com/viewitems/bent-elbows/aluminum-bent-elbows I like aluminum, even though it's tougher to weld up it's worth that much.

Realities of life say that I use mostly junkyard sourced 409 exhaust tubing, rust and all.
What aluminum I've got is mainly junkyard sourced as well, in the form of cold air intakes. Sadly it's all much larger than I'd use on a TDI.

Stainless is cool because you can burn it together with normal mild steel mig wire long as you don't care about it rusting eventually.

most people think im nuts but use mild steel on most stuff i do. most people like aluminum for its light weight and heat dispensation. stainless looks nice but cracks sometimes. if i was doing a weekend car id to stainless or aluminum. dd i use mild steel but thats just my preference.

I use mild steel exhaust tubing and MIG it togeather. Then I smooth the welds out and coat it with this.


The stuff drys with a hard, textured rubbery surface. People always compliment my piping and ask what it is. It ends up looking somewhat like and OEM product when the piping is fit nicely.

I would use aluminum if I had a TIG. So far I am leaning towards aluminum. I have a TIG welder, and will be getting a MIG soon with a spool gun so I can weld aluminum with either. I am certainly not good at welding, but I can make things seal. I like the idea of grining down the welds and using that textured paint that vtpsd suggested. Its kinda cheating (according to the welders I have worked with), but you gotta do what you gotta do. Thanks for the input so far! It depends more on what you're capable of working with and what you're attaching it to. If you're welding to an aluminum intercooler you should use aluminum obviously. If you're making connecting pipes that will be joined with rubber sleeves it doesn't matter. They all have their advantages. I like mild steel for a lot of stuff but it can rust inside where you really don't want rust unless you paint inside and out. Stainless and Aluminum won't have that problem. Powder coating can fix that issue too. Mild steel is easier to weld even with a glue gun (mig) though I'd like to have access to the insides of the welds for cleanup.

Frank