Cast aluminum is known for being lightweight, corrosion-resistant, and cost-effective, making it ideal for industries like automotive and electronics. Wrought iron, on the other hand, offers excellent strength, durability, and ductility, making it suitable for heavy-duty applications and decorative designs.
This article compares the pros and cons, properties, and applications between cast aluminum and wrought iron. By better understanding these two materials, you can make a more informed choice for your next project.
Cast Aluminum
Introduction
Cast aluminum is a material made from aluminum and its alloys.
With its low density and excellent corrosion resistance, it’s commonly used in high-performance, lightweight applications like automotive parts, aviation components, and electronics.
Advantages
Lightweight: One of cast aluminum’s most notable advantages is its lightweight nature.
It has a density of about 2.7g/cm³, significantly lower than that of wrought iron 7.8g/cm³, which makes it ideal for industries like automotive and aerospace that prioritize weight reduction.
Corrosion Resistance: The naturally occurring oxide film on aluminum alloys makes them resistant to corrosion, minimizing the need for frequent maintenance and extending the material’s lifespan.
Electrical Conductivity: Aluminum’s atomic structure allows electrons to move freely, making it an excellent conductor of electricity.
This property is valuable for electronic and electrical applications.
Thermal Conductivity: Thanks to its atomic structure, aluminum can efficiently transfer heat.
This makes it perfect for applications that require rapid heat dissipation, such as electronic devices and heat exchangers.
Cost-effectiveness: Cast aluminum is relatively economical due to its low material cost, recycling benefits, and efficient production process.
The simple mold manufacturing and low energy consumption make aluminum casting a cost-effective choice.
Disadvantages
Brittleness: Cast aluminum is more brittle than wrought iron, meaning it can break more easily under tension or impact.
This makes it less ideal for applications that demand high impact resistance or mechanical toughness.
Wrought Iron
Introduction
Wrought iron is a low-carbon iron alloy that’s typically processed by heating the wrought iron and forging it with a hammer or press.
It is renowned for its strength and plasticity, making it suitable for structural components and decorative elements like railings and gates.
Advantages
Strength and Plasticity: Wrought iron stands out due to its exceptional strength and plasticity.
It has a high tensile strength, allowing it to withstand heavy loads, making it ideal for demanding applications.
Its plasticity allows it to be shaped into complex forms without compromising its structural integrity.
Durability: Wrought iron is highly durable and can withstand harsh environmental conditions.
It is often used in structural applications like bridges, fences, and railings.
Disadvantages
Surface Anti-Corrosion Treatment Needed: The prerequisite for the durability of wrought iron is that it has undergone surface anti-corrosion treatment.
Unlike cast aluminum, wrought iron does not have natural corrosion resistance.
It requires additional protective coatings such as galvanizing, painting, or oiling to prevent rust and degradation over time.
Higher Cost: The production of wrought iron involves a labor-intensive forging process, which requires skilled workers and specialized equipment.
This makes wrought iron more expensive than cast aluminum, making it more suited for structural parts where strength and durability are paramount.
Comparison of Cast Aluminum and Wrought Iron
The following four tables provide a comprehensive comparison of cast aluminum and wrought iron in terms of elemental composition, mechanical properties, physical properties, and application areas:
Element Composition Comparison
|
Property |
Cast Aluminum |
Wrought Iron |
|
Main Element |
Aluminum (Al) |
Iron (Fe) |
|
Other Elements |
Silicon (Si), Copper (Cu), Magnesium (Mg) |
trace elements like Carbon (C), Sulfur (S), Phosphorus (P) |
|
Carbon Content |
low (typically < 0.1%) |
very low (typically < 0.08%) |
|
Alloying Elements |
Silicon, Copper, Magnesium |
mainly iron with impurities |
Mechanical Properties (After Die Casting and Forging)
|
Property |
Cast Aluminum | Wrought Iron |
|
Tensile Strength |
180-450 MPa (depending on alloy) | 370-500 MPa |
| Yield Strength | 150-300 MPa (depending on alloy) |
250-450 MPa |
|
Elongation |
5-12% (varies with alloy) |
15-30% |
| Hardness | 50-100 HB (depending on alloy) |
100-200 HB |
Physical Properties
|
Property |
Cast Aluminum |
Wrought Iron |
|
Density |
2.6-2.8 g/cm³ | 7.8 g/cm³ |
| Melting Point | 660°C |
1538°C |
|
Thermal Conductivity |
150-170 W/m·K | 50-60 W/m·K |
| Electrical Conductivity | 35-50% IACS |
10-20% IACS |
|
Specific Heat Capacity |
0.9 J/g·K | 0.45 J/g·K |
| Coefficient of Thermal Expansion | 22 x 10⁻⁶ /°C |
11 x 10⁻⁶ /°C |
Applications
|
Industry/Application |
Cast Aluminum | Wrought Iron |
| Automotive | engine components, wheels, transmission cases |
– |
|
Aerospace |
aircraft parts, structural components | – |
| Construction | lightweight beams & frames, support brackets |
bridges, railings, structural beams |
|
Machinery & Equipment |
machine housings, gears, casings | – |
| Consumer Electronics | computer parts, housings, frames |
– |
|
Decorative and Artistic |
architectural details, sculptures, decorative panels | gates, fences, sculptures, furniture |
| Marine Industry | boat parts, pontoons, fittings |
– |
|
Energy Industry |
heat exchangers, electrical components | – |
| Fluid Control | valves, pump bodies, flanges, connectors |
– |
CEX Casting: Capabilities and Advantages
Comprehensive Equipment
With 7 die casting machines ranging from 160T to 1100T, CEX Casting can produce parts of varying sizes.
We’ve also invested in multiple CNC machining equipment for casting blank fine machining, along with sandblasting and heat treatment equipment for post processing.
Quality Control
We invested an internal testing laboratory with a range of testing instruments that covers all aspects of product quality, including:
-
Elemental Composition Inspection: Spectrometer
-
Internal Structure Inspection: X-ray Machine
-
Surface Defect Inspection: Visual Inspection & Fluorescence Inspection
-
Mechanical Property Inspection: Tensile Tester & Hardness Tester
-
Airtightness Testing: Water Immersion Testing & Helium Leakage Testing
One-stop Service
CEX Casting provides a comprehensive solution from internal mold design, aluminum die casting, and post machining, to surface treatment.
We streamline the delivery process, improving efficiency and ensuring your final product meets all your specifications.
Conclusion
The choice between cast aluminum and wrought iron depends on the specific requirements of your project.
Cast aluminum is ideal for applications where weight, corrosion resistance, and thermal conductivity are crucial.
It is widely used in industries like automotive and electronics.
Wrought iron, on the other hand, excels in strength and plasticity, making it the preferred choice for structural components.
Consider factors such as part weight, strength, cost, and overall performance when making your decision.
With over 29 years of experience, CEX Casting specializes in aluminum alloy die casting.
We offer stringent quality control, comprehensive equipment, and one-stop service to ensure top-quality products.
Contact us today to see how our aluminum casting solutions can enhance your next project.