Benefits of Aluminum vs steel:
- Biggest is cost ... you can almost always find one for near $100, which is about what the tank & valve costs the shop. A steel tank will cost 2x - 3x as much.
- The AL80 is nearly ubiquituous ... boats are designed, most often, to hold them. My Steel 80 almost never fits, although I do mostly beach diving anyway. Nearly all boat compressors fill only to 3000 PSI ... a "full" tank with an AL80, but a "light" fill for an HP Steel tank.
- They don't rust like steel .. read the latest issue of "Lessons for Life" in Rodale's and you'll see a real-life example of this hazard. Having said this, it should NEVER happen from purposefully running down all your air.
Benefits of Steel vs Aluminum:
- Steel is stronger than Aluminum, so they typically hold more air in less space (i.e. higher pressure). That can be a + for smaller folks, for whom an AL80 would hang down well past their butt.
- Steel tanks are stronger than AL tanks ... they hold up a bit more to abuses like banging, etc. The crimping process which forms the necks of AL tanks also tends to create a potential weak spot ... if the AL tanks fail a visual, this is most often where it occurs. A VIP inspection for an AL tank, because of this, includes an electronic check for cracks at the threads.
- Bouyancy characteristics (probably the biggest +). An AL80 tank is 2 lbs negative at the beginning of a dive but 4 lbs positive at te end. Contrast this with a steel tank, which is typically neutral (or even negative) at the end of the dive. This means that I have to add 6 lbs to my weight pockets when I dive with an AL80 vs my steel 80.
My recommendation: There's a new LP steel tank on the market that seems to offer the best of AL and Steel. It has all the bouyancy characteristics of steel, but is the size of an AL80. Because the fill pressure is 2475 PSI, you'll get great (sometimes TOO great) fills when boat diving. It'll fit into the standard AL80 tank recepticles.