Cast Aluminum vs. Aluminum – What’s the Difference

The world of manufacturing is replete with terms and descriptions that might sound arcane to the layman. Today, we will make a deep dive into two specific terms that are critical to the industry: cast aluminum and aluminum. As a leading aluminum casting manufacturer, CFS Foundry aims to clarify these concepts, highlighting the fundamental differences between them and their distinct advantages.

Understanding Aluminum: The Ubiquitous Lightweight Metal


Before we delve into specifics, it is crucial to understand the basic entity – aluminum. This silver-white metal is the third most abundant element in the Earth’s crust, making it a readily available material for various applications. What makes aluminum stand out is its unique combination of properties.

Aluminum is incredibly light, with a density of around 2.7 g/cm³, which is just over a third of the density of steel. Yet, despite its lightweight nature, aluminum is strong. This strength-to-weight ratio is what makes it such a popular choice in many industries, from automotive and aerospace to packaging and construction.

In addition to strength and lightness, aluminum is also noted for its resistance to corrosion, thanks to a thin layer of aluminum oxide that forms on its surface when exposed to air. Furthermore, aluminum is an excellent conductor of electricity and is 100% recyclable without losing its qualities.

What is Cast Aluminum?

Cast Aluminum

Having established a basic understanding of aluminum, let’s proceed to the term ‘cast aluminum’. Casting is a manufacturing process where a liquid material is typically poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is known as a cast, which is ejected or broken out of the mold to complete the process.

So, cast aluminum is essentially aluminum that has been subjected to the casting process. This method allows for the creation of complex and detailed shapes that would be difficult to achieve through other means, such as forging or machining.

At CFS Foundry, we specialize in cast aluminum, appreciating its unique advantages. First and foremost is the design flexibility. The casting process allows for intricate designs and shapes, which can be customized according to the specific requirements of the project. It is even possible to create a single, complex piece that would otherwise require assembly if made with other manufacturing methods.

Another key advantage of cast aluminum is its cost-effectiveness. The casting process can be highly automated, which significantly reduces labor costs. Furthermore, since the molds used in casting can be reused, the cost per unit decreases with higher production volumes, making cast aluminum a cost-effective choice for large production runs.

Additionally, cast aluminum boasts excellent corrosion resistance, which makes it ideal for applications that are exposed to harsh environments or weather conditions. Its heat resistance is another point in its favor, making it suitable for high-temperature applications.

The Differences Between Aluminum and Cast Aluminum

One of the main differences between aluminum and cast aluminum lies in the manufacturing process itself. While aluminum in its basic form can be shaped and manipulated in various ways, cast aluminum refers specifically to products that have been created through the casting process.

In terms of mechanical properties, there are also significant differences. Cast aluminum typically exhibits a lower tensile strength compared to wrought aluminum due to the porosity caused by the casting process. However, the casting process enables the production of complex geometries and designs that might be challenging to achieve with other fabrication methods.

The choice between aluminum and cast aluminum is largely dependent on the specific application. For instance, in situations where weight is a critical factor, such as in aerospace or automotive applications, the lighter weight of aluminum may be preferred. Conversely, when intricate designs and complex shapes are required, such as in the manufacturing of engine components or decorative items, cast aluminum could be the material of choice.

Choosing Between Cast Aluminum and Aluminum

The decision to use cast aluminum or aluminum largely depends on the requirements of your specific application. Each material has its strengths, and understanding these can help make an informed choice.

Aluminum’s key advantage lies in its lightweight yet strong nature, making it ideal for applications where weight is a crucial factor. On the other hand, cast aluminum offers design flexibility and cost-effectiveness, particularly for large production volumes or complex shapes.

At CFS Foundry, we pride ourselves on delivering quality cast aluminum products tailored to the needs of our clients. With our expertise in aluminum casting, we can guide you through the selection process, ensuring that you choose the material that best suits your project requirements.

By understanding the unique properties of both aluminum and cast aluminum, you can leverage the strengths of these materials to optimize your manufacturing process and produce high-quality, cost-effective products.

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