Is Cast Aluminum Better Than Aluminum?


Two often utilized metal materials in manufacturing and industrial sectors are cast aluminum and aluminum itself. While cast aluminum, made by pouring molten aluminum into molds, has certain great qualities, aluminum is preferred for its lightweight, corrosion resistance, and strong electrical conductivity. To investigate whether cast aluminum is preferable in some respects, this article will evaluate cast aluminum and normal aluminum in terms of physical characteristics, mechanical qualities, corrosion resistance, production and processing technical factors.


Basic Introduction to Aluminum and Cast Aluminum

Basic Properties and Uses of Aluminum

Having a density of roughly 2.7 g/cm³ and a melting point of 660.3°C, aluminum is a lightweight metal. Its thermal and electrical conductivities are outstanding as well as its corrosion resistance. Aluminum’s several qualities make it a valuable component in the transportation, building, and aerospace sectors. For instance, aluminum’s lightweight and high-strength properties make it rather common in the aerospace sector for aircraft bodies and other structural parts. Designed and preferred by designers and engineers for its weather resistance and aesthetic appeal, aluminum is utilized in the building sector for doors, windows, and curtain walls.

Basic Properties and Uses of Cast Aluminum

Made from melted aluminum alloys poured into molds to cool and create shapes, cast aluminum is one kind of aluminum material. To improve castability and mechanical qualities, cast aluminum typically includes alloying materials such magnesium and silicon. Good fluidity and fillability of cast aluminum make it appropriate for creating complex-shaped objects. The automotive sector makes engine blocks, gearboxes, etc. from it extensively. Because cast aluminum is lightweight and has great heat dissipation qualities, it is also employed in household appliances and electronic product housings; hence, it is the chosen material for many high-tech items.


Technical Parameter Comparison

Physical Properties Comparison

  • Strength: Depending on the particular aluminum alloy, aluminum’s tensile strength falls between 70 and 700 MPa; its yield strength falls between 35 and 410 MPa. Tensile strength of cast aluminum is usually between 150 and 330 MPa; its yield strength falls between 90 and 270 MPa. For many structural uses, cast aluminum’s strength is adequate even if it is not as great as some high-strength aluminum alloys.
  • Hardness: While cast aluminum normally has a higher hardness, usually between 55 and 120 HBW, aluminum’s Brinell hardness usually falls between 15 and 80 HBW. This makes cast aluminum desirable in uses needing more hardness, including wear-resistant parts.

Mechanical Properties Comparison

  • Ductility: Aluminum is fit for manufacturing sheets, tubes, and other products because of its great ductility and extrusion and rolling ability to shape it into many forms. Because of its alloying components, cast aluminum has less ductility and increased processing difficulty, which makes it inappropriate for uses needing significant deformations.
  • Toughness: Aluminum can keep great performance in hostile conditions since it shows good hardness at both low and high temperatures. At low temperatures, cast aluminum has poor toughness; at room and high temperatures, it retains some hardness appropriate for most common settings.

Corrosion Resistance Comparison

  • Corrosion Resistance of Aluminum: Dense aluminum oxide protective coating created by aluminum forms in the air and efficiently stops more corrosion. Aluminum is so extensively utilized in ships and chemical equipment since it has great corrosion resistance in marine and industrial environments.
  • Corrosion Resistance of Cast Aluminum: Because of its alloying components, cast aluminum has rather less corrosion resistance than pure aluminum. But by including suitable alloying elements like magnesium and silicon, cast aluminum’s corrosion resistance can be much enhanced, rendering it suitable for most use settings.



Production and Processing Technical Parameters

Casting Process

  • Common Casting Processes for Aluminum: Usually using extrusion and rolling techniques, aluminum is turned into sheets, tubes, and other goods. Long goods like aluminum profiles are suited for extrusion; rolling is appropriate for aluminum sheets and foils.
  • Casting Processes for Cast Aluminum: Mostly made using gravity casting and die casting techniques, cast aluminum While die casting is appropriate for generating thin-walled, complex-shaped parts and is quite efficient, gravity casting is appropriate for producing massive, thick-walled castings. Mass production would thus benefit from this method.

Cost-Effectiveness Analysis

  • Production Cost of Aluminum: Although aluminum’s raw material cost is rather inexpensive, processing costs—especially for complex-shaped items requiring sophisticated equipment and techniques—are higher.
  • Production Cost of Cast Aluminum: Although cast aluminum’s raw material cost is somewhat more than pure aluminum, the simplicity of the casting process results in a cheaper processing cost overall. Furthermore ideal for mass manufacturing is cast aluminum, which can help to reduce product unit cost.


Application Cases and Practical Performance

  • Performance of Aluminum in Specific Applications: Aluminum’s light weight qualities make it the perfect material for building airplane bodies and other structural parts in the aerospace sector. Aluminum is used widely by companies like Boeing and Airbus to light aircraft overall and increase fuel economy. Aluminum’s corrosion resistance and aesthetic appeal make it extensively employed in doors, windows, and curtain walls in the building sector, so offering strong and fashionable looks.
  • Performance of Cast Aluminum in Specific Applications: Because of its great strength and exceptional castability—which must resist high temperatures and pressures—cast aluminum is extensively employed in the automotive sector for creating important parts such as engine blocks and transmission housings. Because of its lightweight, good heat dissipation, and pleasing appearance—favored by consumers—cast aluminum is also heavily employed in electronic product housings like laptops and cellphones.



It is clear from a thorough comparison of aluminum and cast aluminum in terms of physical characteristics, mechanical qualities, corrosion resistance, production and processing technical factors that both have benefits. Applications needing lightweight and great corrosion resistance will find aluminum appropriate since it has better ductility and great resistance against corrosion. Strength and hardness are where cast aluminum shines, which qualifies for high-strength, complicated-shaped parts. Therefore, while selecting materials, it is crucial to take certain application criteria into account to decide whether to utilize aluminum or cast aluminum for best performance and economy.

Honjenny, established in 1996, is a global manufacturer of precision metal components. Honjenny specializes in zinc alloy and aluminum alloy die casting technology, providing robust solutions for various industries, including home hardware, perfume bottle caps, and consumer electronics. If you have aluminum alloy die casting needs, consider contacting Honjenny.

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