Aluminum Die Casting Vs Other Metal Die Casting – Which Is Better?

Aluminum Die Casting Vs Other Metal Die Casting - Which Is Better?

When it comes to die casting, choosing the right metal is essential for achieving optimal performance, durability, and cost-efficiency in your projects. Aluminum die casting is a popular choice due to its lightweight properties, excellent corrosion resistance, and versatility. However, other metals like zinc, magnesium, and copper alloys also offer unique benefits and can be more suitable for specific applications.

In this comprehensive guide, we’ll compare aluminum die casting with other metal die casting options, examining their strengths and weaknesses, typical applications, and key considerations. By understanding the differences, you’ll be better equipped to select the best material for your die casting needs, ensuring high-quality and cost-effective results

Let’s get started!

Understanding Die Casting

Definition and Process

Before jumping into comparison we need to understand the die casting process. It’s a process in which molten metal is injected into a mold cavity under high pressure. We used this process to produce high-volume, dimensionally accurate metal parts.

Metals Commonly Used in Die Casting

The metals which are commonly used in die casting are:

  • Aluminum
  • Zinc
  • Magnesium
  • Copper.

Each of these metals offers distinct properties that make them suitable for various applications.

Several Advantages of Die Casting

Here are the some common advantages of the die casting:

  • High Production Rates
  • Excellent Dimensional
  • Accuracy
  • Smooth Cast Surfaces
  • Reducing the Need for Post Production Machining

Aluminum Die Casting

Process Specifics

The aluminum die casting process involves injecting molten aluminum into a steel mold under high pressure. This method creates lightweight, complex parts with tight tolerances.

Properties of Aluminum

Aluminum is renowned for being lightweight, having a high strength-to-weight ratio, and offering excellent corrosion resistance. It also boasts good thermal and electrical conductivity.


  • Lightweight

Aluminum is significantly lighter than other metals, making it ideal for weight-sensitive applications.

  • High Strength-to-Weight Ratio

Provides structural strength while keeping the weight low.

  • Corrosion Resistance

Naturally resistant to corrosion, enhancing longevity.

  • Good Thermal and Electrical Conductivity

Efficiently conducts heat and electricity, beneficial for electronic components.


  • Higher Melting Point

Requires more energy to melt, increasing production costs.

  • Potential for Porosity

Aluminum castings may suffer from porosity, affecting their strength and durability.

Other Metal Die Casting

Zinc Die Casting

Properties of Zinc

Zinc is characterized by its low melting point, high ductility, and excellent finishing characteristics.


  • Low Melting Point

Reduces energy consumption and production costs.

  • High Ductility

Can be easily molded into complex shapes.

  • Excellent Finishing Characteristics

Provides a smooth surface finish, reducing the need for additional machining.


  • Heavier than Aluminum

Adds weight to the final product.

  • Less Corrosion Resistance

More prone to corrosion compared to aluminum.

Magnesium Die Casting

Properties of Magnesium

Magnesium is the lightest structural metal, known for its good electromagnetic shielding and excellent machinability.


  • Lightest Structural Metal

Ideal for applications requiring minimal weight.

  • Good Electromagnetic Shielding

Effective for electronic enclosures.

  • Excellent Machinability

Easy to machine and shape.


  • Higher Cost

More expensive than other die casting metals.

  • Flammability Concerns

Requires careful handling due to its flammability.

Copper Die Casting

Properties of Copper

Copper is renowned for its excellent electrical and thermal conductivity and good corrosion resistance.


  • Excellent Electrical and Thermal Conductivity: Ideal for electrical components.
  • Good Corrosion Resistance: Enhances durability in harsh environments.


  • Heavy: Increases the overall weight of the component.
  • Expensive: Higher material cost compared to aluminum and zinc.
  • Higher Melting Point: Requires more energy to process.

Comparison Table

A comparison table summarizes the properties, advantages, and disadvantages of aluminum, zinc, magnesium, and copper die casting.

AluminumLightweight, corrosion resistant, good conductivityHigh strength-to-weight ratio, corrosion resistanceHigher melting point, potential for porosity
ZincLow melting point, high ductilityExcellent finishing characteristics, low energy consumptionHeavier, less corrosion resistance
MagnesiumLightest structural metalGood machinability, electromagnetic shieldingHigher cost, flammability concerns
CopperExcellent conductivity, corrosion resistantIdeal for electrical componentsHeavy, expensive, higher melting point

Applications and Suitability

Automotive Industry

Typical automotive components made from each metal include engine parts, transmission components, and structural elements. Material selection considers weight, strength, and cost.

Various automotive components made from different metals in die casting.

If you want to die casting for your automotive parts manufacturing then click here.

Aerospace Industry

Aerospace components require materials with high strength, low weight, and excellent performance under extreme conditions. Aluminum and magnesium are often preferred due to their favorable properties.

Aerospace components made from aluminum and magnesium.

Consumer Electronics

Precision and intricacy are essential in consumer electronics. Thermal and electrical considerations are crucial, making aluminum and copper ideal choices for many electronic components.

Electronic components showcasing the use of aluminum and copper die casting.

Industrial Equipment

Industrial equipment requires durable and strong materials. Cost and efficiency are also critical factors, with zinc and aluminum being popular choices.

Cost Analysis

Initial Investment

The initial investment in die casting includes mold creation and equipment costs. Aluminum and zinc typically have lower initial costs compared to copper and magnesium.

Production Costs

Production costs are influenced by material cost, efficiency, and cycle time. Zinc’s low melting point reduces energy consumption, while aluminum’s lightweight properties enhance efficiency.

Long-Term Cost Considerations

Long-term costs include maintenance, durability, and recyclability. Aluminum and zinc offer good recyclability, reducing environmental impact and material costs over time.

Table of Cost Analysis

MetalInitial InvestmentProduction CostsLong-term CostsRecyclability
This table compares the initial investment, production costs, long-term costs, and recyclability of aluminum, zinc, magnesium, and copper in the die casting process.

Graph of Cost Analysis

Graph showing initial investment, production costs, and long-term cost considerations in die casting.

Environmental and Sustainability Considerations

Recycling and Recyclability

Each metal has distinct recycling and recyclability properties. Aluminum and zinc are highly recyclable, reducing waste and conserving resources.

Energy Consumption

Energy consumption in the casting process varies with each metal. Zinc’s low melting point reduces energy use, while copper requires more energy due to its higher melting point.

Environmental Impact

The environmental impact of die casting includes emissions and waste. Aluminum and zinc have lower environmental impacts compared to copper and magnesium.

The Final Thoughts

In summary, the choice between aluminum die casting and other metals depends on specific application requirements. Aluminum offers excellent lightweight properties and corrosion resistance, while zinc provides cost efficiency and excellent finishing. Magnesium, with its lightweight and good machinability, is suitable for high-performance applications, and copper’s exceptional conductivity makes it ideal for electrical components. Selecting the right material ensures optimal performance, cost-efficiency, and sustainability.

Ultimately, choosing between aluminum die casting and other metals should be based on the specific needs of your application. This way, you can ensure that you’re getting the best performance and value from the material you select.

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Eric Zhou

Focus on providing squeeze casting, aluminum die casting(hpdc+lpdc), mold making, CNC machining, and sheet metal fabrication solutions. If you need help, please feel free to contact us!

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G and M Codes for CNC Machining

Understanding G and M Codes for CNC Machining

CNC machining is the process of using programming code to automate machining tools. However, for that to happen, the machine must have the correct coded instructions, usually programmed. The g and m codes for cnc do this perfectly.

When you use the correct codes with the proper tooling, a CNC machine can perform repeatable functions accurately. G codes for CNC comprise a letter and two numbers: most are modal, meaning they remain active unless you make changes. The m code for CNC has the same structure: a letter and two numbers.

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