What are the Differences Between Cast Aluminum and Cast Iron

1.Weight difference: the proportion of cast aluminum is lighter than cast iron, the density of cast iron is about 7.8g /cm3, and the density of cast aluminum is about 2.7g /cm3. The same size as cast iron and cast aluminum, the latter’s weight is lighter. In addition to the weight difference, there are also many differences between cast iron and cast aluminum in the production process.

2.The difference in volume is that the proportion of aluminum is light, and the structural strength of cast aluminum parts per unit volume is less than that of cast iron parts. Hence, the volume of aluminum castings is larger than that of cast iron parts under the same strength. The volume of cast aluminum is smaller for the same volume than that of cast iron.

3.Difference in heat dissipation: the thermal conductivity of cast aluminum parts is more than three times that of cast iron parts. It has been widely used in the industry in radiators, heat exchangers, and cookware.

4.Difference in corrosion resistance: the surface of cast aluminum parts has a layer of corrosion-resistant oxide protective film, which can protect aluminum castings from corrosion, so aluminum castings are also widely used in medical devices, freezing equipment, oil and gas pipelines, petroleum machinery, etc. The corrosion of cast iron is far less than that of cast aluminum.

5.The difference in casting performance: the casting performance of aluminum is higher than that of cast iron. Aluminum is easy to cast, and the casting blank with complex shapes can be cast.

Why is cast aluminum cheaper than cast iron

Aluminum as raw material costs more than iron ore. But casting aluminum parts is cheaper when it comes to casting aluminum and cast iron parts. This is because the most convenient casting method is die casting.

In die casting, the die is made of stainless steel, another iron-carbon composite such as cast iron. However, the melting point of cast iron is close to that of stainless steel, so it is not suitable for die-casting.

But aluminum and its alloys are the most commonly used materials in die casting. Most manufacturers use the sand casting method to make cast iron parts. Sand casting is a manual process that takes longer and requires more labor. Both increase production costs.

Die casting, on the other hand, is an automated process that produces the same product in less time. Aluminum also melts faster than cast iron so aluminum parts can save time in this way. Being an automated process requires less labor, thus reducing overall production costs.

 

The difference between a cast aluminum engine and a cast iron engine

Almost all the engine cylinder head material of aluminum because aluminum cylinder head has the best heat dissipation performance. And the cast-iron engine head is aluminum alloy, but the cylinder block is cast iron. The cast iron engine has a stronger thermal load capacity than the all-aluminum engine, which is more conducive to increasing engine power. For example, a 1.5L displacement of cast iron engine, under the effect of turbocharging, can achieve the power requirements of 2.0L displacement; With an all-aluminum engine, that’s not the case. At present, only a few premium cars use all-aluminum engines.

In addition, the all-aluminum engine is easy to interact with aquatic biochemistry when working, and its corrosion resistance is far less than that of the cast iron cylinder. In contrast, the strength of the aluminum cylinder is far lower than that of the cast iron cylinder. As a result, virtually all turbocharged engines have cast iron blocks. It is worth mentioning that the cast iron cylinder also has the modification strength that the aluminum engine does not have.

In general, by comparison, the biggest advantages of the all-aluminum engine are:

At the same displacement, the weight of the all-aluminum engine is about 20kg lighter than that of the cast iron engine. In addition, the heat dissipation effect of the all-aluminum engine is much better than that of the cast iron engine, which can improve the engine’s efficiency and prolong its service life.

To sum up, the all-aluminum engine has the characteristics of easy processing, lightweight, good heat dissipation, etc. The advantages of cast iron engines are reflected in high-pressure, high-temperature, corrosion, deformation, and low cost.

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