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Home 9 Die Casting 9 Aluminum vs Cast Aluminum: An In-depth Comparison

Aluminum vs Cast Aluminum: An In-depth Comparison

Published on: 2025-01-18
Categories: Die Casting

Two small captures of aluminum and cast aluminum with texts in the image

Aluminum and its alloys are prominent materials in industrial applications. Its high ductility, high strength-to-weight ratio, and high corrosion resistance suit the requirements of many uses across different industries. 

Cast aluminum is equally essential, with its light, versatile, and robust nature adding value to projects. While these materials are crucial, they are different in some aspects. This is mostly evident in applications, with aluminum and its alloys featuring in the automotive, aerospace, and marine industries. 

Cast aluminum is also featured in automotive, aerospace, and such applications. The fact is that when choosing between the two materials, you will need to scrutinize your project’s requirements. 

ProleanTech can help you choose between the two aluminum materials for the success of your project. 

 

Aluminum: Crucial Material for Your Business

Aluminum is a versatile lightweight material less common than only oxygen and silicon. Estimates show that at least 8% of the Earth’s crust is aluminum. In its pure form, aluminum has limited uses. It becomes more useful when alloyed. 

Several layers of square tubes of aluminum viewed from the side showing the profiles 

Aluminum Extrusions

 

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Pros of Aluminum

Low Weight

As indicated by its low density, aluminum is a lightweight material. Many industries, from aerospace to transportation and others covered in our blog, find this property important. 

Corrosion Resistance

A metal sheet covered by spots of rust 

Corroded metal sheet

Aluminum has the natural capability to form an anti-corrosion layer on its surface. Thanks to this feature, the material can last longer. Some artificial processes such as anodizing can enhance this corrosion resistance for even better performance.

Electrical Conductivity

Aluminum is popular for its electricity conduction capability. This property makes the material a strong alternative to copper in power transmissions or anywhere else requiring electrical conductivity. 

Two power transmission towers alongside each other with their conductors running parallel  

Power transmission lines

Strength-to-weight Ratio

This is another notable advantage offered by aluminum. Compared to many other metals, aluminum offers significant strength per unit weight. Industries that need lightweight, strong, and durable materials extensively use aluminum and its alloys. 

 

Cons of Aluminum

Welding Difficulty

Aluminum is difficult to weld, with challenges starting with a low melting point relative to steel and several other metals. The material tends to burn instead of melting.

Its high thermal expansion is also a drawback during the welding process. Another problem is that molten aluminum absorbs hydrogen, creating bubbles upon solidification. These bubbles are the reason for the porosity issue associated with welded aluminum. 

Adding all this to the metal’s tendency to attract oxygen can make the welding process extremely challenging. Fortunately, technology in the form of robots is slowly making welding aluminum easier. 

Contact us for insights on how to weld the material more easily. 

 

Common Aluminum Alloys to Consider

Aluminum alloys are grouped according to the primary alloying elements. The series falls between 1xxx and 8xxx and is further segmented into heat-treatable and non-heat-treatable alloys.  

Alloy series in the heat-treatable category are 2XXX, 4XXX, 6XXX, and 7XXX. 

2XXX

A higher copper percentage enhances tensile strength. The material is ideal for aerospace applications.

4XXX

Its main alloying element is silicon. It is easy to cast. 

6XXX

Silicon and magnesium are the main alloying elements. The enhanced strength makes these alloys applicable in architectural and structural jobs. Aluminum is common in architectural and structural jobs

Metallic roof trusses comprising curved horizontal and straight vertical members

Metallic roof 

7XXX

Since zinc is the main alloying element for this one, strength is a notable characteristic. Sports items often contain this aluminum alloy. 

The non-heat-treatable alloys are 1XXX, 3XXX, 4XXX, and 5XXX. 

1XXX

This refers to pure aluminum. The corrosion resistance and electrical conductivity for this group are excellent. 

3XXX

For its high manganese content, this alloy is excellent for heat exchangers.

4XXX

Has a significant silicon percentage. The materials in the group are easy to weld. Some of the aluminum alloys in this category are heat-treatable. 

5XXX

The main alloying element is magnesium. Aluminum alloys in this series are renowned for their high welded strength. 

8XXX

This series does not belong to either of these groups. It is called the novel series because it contains unique alloys and is rarely used. 

 

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What is Cast Aluminum and Can It be Your Option?

Flames as hot metal is poured from a larger container to a smaller one

Metal casting 

Cast aluminum is an alloy produced by melting and pouring into molds to create particular structures or shapes. Manufacturers use cast aluminum when they want to create intricate shapes. Such shapes would be extremely costly or difficult to manufacture through extrusion or machining.

 Intricately shaped engine component for a car placed on a table

A car engine part made from aluminum

You will find many cast aluminum products in areas where design flexibility and low weight are critical considerations. Examples of cast aluminum products are decorative items, engine blocks, and furniture. 

The molds that hold the molten aluminum can be made of any suitable material, but the most popular ones are sand and metal. The idea is to let the molten material settle in the mold. When the solidification process is complete, you get aluminum casting products that have the exact shape of the mold. 

Apart from alloy composition, other factors that determine the properties of cast aluminum are the specifics of the casting process and other processes undertaken on the product. 

A car engine block written “Porsche ”, blue and gray, with interconnections

A section of a car engine

 

Pros of Cast Aluminium

Here are a few pros of cast aluminum alloys as you consider aluminum vs cast aluminum for your project:

Versatility

Cast aluminum offers several attractive properties that make it popular for numerous projects. This material is renowned for overall good performance. A good example is a car’s transmission cover, which needs to be intricately shaped, lightweight, and durable.  

The inner side of a metallic silver transmission housing with intricate patterns and bolt holes

A Transmission Housing for a Car

Thermal Conductivity

Cast aluminum has high thermal conductivity. You can use aluminum casting products in cookery, heat exchangers, and other applications where this property is critical. You want to have it where heat dissipation is crucial. Add to that the high electrical conductivity of the material. An aluminum die-casting products manufacturer may create electrical components for this reason.  

Two shiny silver-colored cooking pots on a table and another pot on the floor

Aluminum Cooking Pots

Cost-Effectiveness

The cast aluminum manufacturing process is cost-effective, especially for high volumes. The method is highly viable for intricate shapes, which might be expensive to produce by other methods. Once the casting process is complete, very little or no further processes are required to get the final product.

 

What Are the Disadvantages of Cast Aluminum to Consider?

Product Defects

How strong is cast aluminum? A big drawback of aluminum casting products is the potential to form defects that weaken the material. Common casting defects are shrinkage and porosity. When they occur, you cannot afford to ignore them because they affect the mechanical properties of the item. 

To counter these defects, manufacturers can emphasize the casting process and apply heat treatment and other post-processing steps. 

 

Common Cast Aluminum Grades

What is cast aluminum in terms of available grades?

A356 Aluminum

This cast aluminum alloy is highly regarded for its load-carrying capability. This material is prominent in the aerospace industry, where other properties such as weldability and corrosion resistance are also critical.  

The material is also mechanically stable and relatively easy to manage. It also doesn’t heat-crack easily. Other industries that use this material are energy, automobile, and structural. 

A380 Aluminum

It has an excellent blend of elements such as silicon, aluminum, and magnesium. This alloy is ideal for marine and automotive components because it is corrosion-resistant and has the applicable mechanical properties.  

7075 Aluminum

The 7075 aluminum alloy contains aluminum, copper, and zinc as the main elements. If you are wondering “How strong is cast aluminum?”, 7075 aluminum is one of the best grades.  It is the strongest of the most commonly used cast aluminum grades. Its notable applications include aircraft structures, automotive components, and recreation gear. 

A hand in yellow/white gloves holding a grey carabiner and hooking it to a harness on the waist

Mountain Climbing Gear

6061 Aluminum

The main alloying elements of this metal-casting aluminum are magnesium and silicon. The alloy is heat-treatable and corrosion-resistant. These features are ideal for applications such as structures and marine components. 

A silver-coloured boat packed by the seashore 

A Boat Made from Aluminum

 

So, Is Cast Aluminum Better than Aluminum?

The similarities/differences between aluminum vs. cast aluminum as captured in the table below could help answer this question:

Factor  Aluminum  Cast aluminum
Strength  Generally stronger due to a uniform grain structure. How strong is cast aluminum? It is slightly lower owing to micro-porosity in the material.
Composition  Composition largely depends on the alloying requirements. Metal casting aluminum may contain slightly more silicon for smoother casting.
Manufacturing process Based on mechanical deformation and includes forging, rolling, and extrusion.  First, the aluminum is melted. The molten material is poured into molds to achieve the desired shapes. 
Cost  Could cost more – post-processing  Typically more cost-effective if you are producing complex shapes.
Applications  Popular where performance and strength are required eg. in aerospace components. Preferred where complex shapes and cost-effective production is required – engine parts, cookware. 
Machinability  Easy to machine with consistent results.  Could present challenges due to relative unevenness in grain structure. Improved machining methods have tended to reduce this problem. 
Electrical conductivity  Has excellent electrical conductivity. Its electrical conductivity is lower due to silicon and other impurities. 

 

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Consider Prolean Tech for Your Projects 

We have highlighted the basics of aluminum vs cast aluminum. At this point, you may already have decided which material is better for aluminum vs cast aluminum. The choice would depend on strength, machinability, and suitable applications. 

But if you are still uncertain about aluminum vs cast aluminum, experts at Prolean Tech can help. 

We are always ready to offer guidance that will lead to project success. Our years of experience working with different metals for a broad clientele range tells it all. 

Contact us to get a quote today! 

 

FAQs

Is cast aluminum cookware safe?

Yes, cast aluminum cookware is safe despite the myth that the material could be unsafe. 

Is cast aluminum safe to cook with?

Yes, cast aluminum is safe to cook with. 

Does cast aluminum crack easily?

Yes, but it depends on the usage or factors the material is exposed to. 

Is aluminum or cast aluminum better for outdoor furniture?

The suitability of either material depends on the specific goal. Cast aluminum is preferable for aesthetics and durability, while aluminum is better for functionality and less weight. 

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