Aluminum Vs Steel Casting: Which Material Is Right For Your Project?

In a modern metal foundry, steel and aluminum are two competitive materials. They contend for the top material of choice. Most metal manufacturers rely on these two metals to deliver robust, light metal products. However, you may find a lot of different grades and alloys for these two metals. Each of those grades and alloys has its unique pros and cons. Therefore, understanding aluminum vs steel is necessary for the right decision.

When it comes to casting, aluminum, and steel are widely popular choices. Aluminum is famous for its lightweight nature. On the other hand, steel is renowned for its strength, durability, and other physical properties. There are some factors to consider while choosing the ideal material from these two metals. And this article will provide a comprehensive guide to aluminum vs steel casting.

The article provides readers necessary knowledge to evaluate their project requirements. It also allows them to align the best with their goals. Readers will gain valuable insights by exploring these metals’ properties, prices, pros, and cons. In the subsequent sections, we will compare aluminum vs steel properties. In addition, we will also discuss the factors necessary to select the best metal for casting. Readers can make informed decisions at the end of this article that result in successful casting projects.

Understanding Aluminum Casting

aluminum vs steel

The aluminum casting process involves pouring molten aluminum into a mold to create complex and intricate shapes. It is famous for its lightweight nature, thermal conductivity, corrosion resistance, and machinability. Aluminum casting finds applications in automotive, aerospace, consumer electronics, and many more. Here are some properties of aluminum that make it suitable for casting:

  1. Aluminum casting is lighter than steel casting. Therefore it is suitable for weight reduction and improved fuel efficiency applications.
  2. These metal castings exhibit excellent thermal conductivity. Aluminum casting efficiently transfers and dissipate heat.
  3. This metal casting forms a protective oxide layer that provides inherent corrosion resistance. As a result, it is suitable for environments where corrosion protection is vital. Heat sinks and engine components are some typical examples here.
  4. Aluminum casting has a lower melting point than steel. As a result, it simplifies the casting process and reduces energy requirements.
  5. This metal s also famous for its excellent machinability. You can create precise shapes and achieve intricate designs with tight tolerances.

Limitations Against Steel Casting

  1. Aluminum casting provides lower strength compared to steel casting. Therefore, it is not ideal for heavy-load or high-stress applications.
  2. These metal castings provide reduced heat resistance capabilities compared to steel casting. Therefore, they are not suitable for high-temperature applications.
  3. Aluminum can be expensive.

Understanding Steel Casting

aluminum vs steel

Steel casting is a process that involves pouring molten steel into a mold to create various components and structures. It is famous for its exceptional strength. Therefore, it finds extensive applications in construction, automotive, power generation, and many more. Here are some properties that make them suitable for casting:

  1. Steel is famous for its high strength and durability. Therefore, it is incredibly suitable for applications that require robustness and load-bearing capacity. It can withstand heavy loads, impacts, and stresses and ensures long-lasting performance.
  2. This metal casting exhibits superior heat resistance compared to aluminum casting. It maintains its structural integrity at high temperatures. This characteristic makes steel suitable for high-temperature applications.
  3. Steel casting offers excellent mechanical properties. It has high tensile strength, hardness, and wear resistance. So, steel casting is suitable for applications where toughness and resistance to wear are essential.
  4. Steel casting also provides versatility in terms of alloy options and customization. Alloying with various materials enhances specific properties.

Limitations Against Aluminum Casting

  1. Steel is typically heavier than aluminum. Because of this weight, steel casting may not be suitable for some applications where weight reduction is crucial.
  2. These castings go through a more complex process than aluminum. Their melting point and viscosity require higher casting temperatures and more intricate molds. It increases the production time and costs.
  3. Steel is susceptible to corrosion if you don’t do an appropriate surface treatment.

Difference Between Aluminum And Stainless Steel: Factors to Consider

Regarding casting metals, aluminum, and steel are two popular choices. Each of these popular metals offers unique advantages and considerations. This section will explore several key factors to help you make an informed decision for your project.

Aluminum vs Steel Strength

“Which is stronger steel or aluminum?”; indeed, steel casting it is. In heavy-load-bearing applications, strength plays a significant role. Generally, steel is more robust than aluminum. However, steel casting is not the most robust metal.

Concerning tensile strength, aluminum alloys typically range from 70MPa to 700 Mpa. On the other hand, steel castings range from 400 Mpa to 2000 MPa. Involving yield strength, aluminum casting range from 30 MPa to 600 Mpa depending on the allow and temper. The yield strength of steel casting also varies depending on the grade and type. The typical range is from 250 MPa to 1000 MPa.

Aluminum vs Steel Weight

When choosing the best metal, weight is also a critical factor to consider. It is essential to consider those applications where weight reduction is crucial. In terms of aluminum, the density of it is approximately 2.7 g/cm³. For example, a 100 cm³ aluminum object weighs 270 grams. On the other hand, the density of steel casting varies depending on the specific grade. The typical limit ranges from 7.8 to 8.1 g/cm³. Therefore, a 100 cm³ steel object typically weighs 810 grams.

These numbers highlight the significant weight advantage of aluminum over steel. If we do the ratio, we can see that aluminum is one-third the weight of steel. Weight advantage improves fuel efficiency and provides easy handling and assembly. Therefore, it is ideal for applications where weight reduction is necessary.

Aluminum vs Steel Price

Price is also an important consideration to take into account when choosing a suitable metal for your project. It is important to note that the cost of each material depends on the specific alloy, grade, market condition, and complexity of your project. In terms of aluminum, the price ranges from $1.50 to $3.0 per pound ($3.3 to $6.6 per kg). On the other hand, steel costs from $0.5 to $1 per pound ($1.1 to $2.2 per kg).

When considering the best metal for the project, it is crucial to consider three primary factors. First, consider the long-term benefits of using the respective metal. For example, aluminum’s lighter weight reduces energy consumption and lower transportation costs. Second, consider manufacturing efficiency. And finally, consider the project budget.

Heat Resistance And Thermal Conductivity

When discussing the heat resistance capabilities, aluminum has a lower melting point than steel. The melting point ranges from 600°C to 660°C (1112°F to 1220°F). On the other hand, steel has a higher melting point compared to aluminum. The melting point of steel casting ranges from 1370°C to 1520°C (2500°F to 2770°F).

Concerning thermal conductivity, aluminum exhibits excellent thermal conductivity. As a result, it is ideal for heat transfer and dissipation application. The specific thermal conductivity ranges from 200 to 250 W/m·K. On the other hand, steel has thermal conductivity ranging from 15 to 50 W/m·K.

Corrosion Resistance

Aluminum provides corrosion resistance naturally due to the formation of an oxide layer on its surface. This layer acts as a barrier and prevents further corrosion. Aluminum castings are particularly resistant to atmospheric corrosion. Therefore they are trendy for outdoor applications.

On the other hand, steel is more susceptible to corrosion than aluminum. However, various measures can be taken to enhance the corrosion resistance of steel. Some popular methods include applying protective coatings, using corrosion-resistant alloys, galvanizing, or painting.

Aluminum vs Steel Application

Aluminum casting is widely popular in the automotive, aerospace, electrical, and manufacturing industries. Their lightweight nature improves fuel efficiency and reduces vehicle weight. Since they naturally resist corrosion, they are also popular in high-corrosive applications.

On the other hand, steel casting is widely popular in heavy-duty applications. They are popular in the construction industry because they offer high strength and durability in this field. They also find applications in the oil and gas industry.


The above discussion taught us some essential information about aluminum and steel. Aluminum casting is lightweight and provides a simplified casting process with good machinability. Although, aluminum castings are not suitable for heavy-load or high-stress applications. They have reduced heat resistance and higher manufacturing cost. On the other hand, steel casting provides exceptional strength and durability. They are excellent with heat resistance capabilities. Steel casting also offers excellent mechanical properties and versatility in alloy options. However, they are heavier than aluminum casting. It makes them inappropriate for light-duty applications.

While considering the factors, evaluating project requirements and specific applications is crucial. Strength, weight, price, and other mechanical properties are vital. Here is the summary table of aluminum vs steel casting differences:

FactorsAluminum castingSteel casting
StrengthWeaker than steel castingStronger than aluminum casting
WeightLighter than steel castingHeavier than aluminum casting
PriceMore expensiveRelatively less expensive
Heat ResistanceLower heat resistanceHigher heat resistance
Corrosion ResistanceNaturally corrosion resistantRequire additional measures
Application suitabilitySuitable for lightweight and corrosion-resistant applicationSuitable for heavy-load and high-stress applications


This article emphasizes the importance of making an informed material selection. Readers can easily compare the differences between aluminum and steel casting by referring to the table. They also can make an informed decision based on their project requirements and priorities. If you have any questions feel free to contact us.

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