Non-ferrous metals are metals and alloys that do not use iron (Fe) as the base element. Because they’re iron-free, they’re often lighter, more corrosion-resistant, non-magnetic, and better at conducting heat and electricity than ferrous (iron-based) metals. Think aluminum, copper (brass/bronze), zinc, magnesium, titanium, and nickel alloys. This guide explains what “non-ferrous” means, how alloys are named, which metals are most common (with grades), where they’re used, and—most useful for buyers—which non-ferrous alloys are a good fit for die casting.
What does “non-ferrous” actually mean?
lain definition: A non-ferrous metal is a metal or alloy whose base is not iron. Trace iron might be present as an impurity, but iron is not the primary element.
Practical consequences:
- No red rust: they don’t form the flaky red iron oxide typical of plain carbon steels.
- Lower density: big weight savings with aluminum (~2.7 g/cc) and magnesium (~1.8 g/cc) vs steel (~7.8 g/cc).
- Non-magnetic behavior: friendlier for sensors, MRI, and EMI-sensitive assemblies.
- Good conductivity: copper and aluminum lead here.
- Finish versatility: anodize, powder coat, plating—when surface prep is controlled.
What are non-ferrous materials versus non-ferrous metals?
Engineers sometimes say “non-ferrous materials” to cover metals and their alloys (and occasionally ceramics or composites). In real purchasing, “non-ferrous materials for casting” nearly always means non-ferrous metals and alloys such as aluminum, zinc, magnesium, copper-base, titanium, or nickel alloys.
Buyer tip: If a drawing only says “non-ferrous material,” specify the alloy family and process (e.g., Aluminum A380, high-pressure die casting). It saves quoting loops.
What are non-ferrous alloys?
A non-ferrous alloy uses a non-iron base (Al, Cu, Zn, Mg, Ti, Ni) with added elements to tune strength, corrosion resistance, fluidity, conductivity, and castability.
How they’re named (and typical examples)
| Family | Typical designations | Example grades | Die-casting fit | Notes / common uses |
|---|---|---|---|---|
| Aluminum | AA casting (A380, A360, A383, A413), EN casting (EN AC-AlSi10Mg) | A380, A360, A383, A413, AlSi10Mg | Excellent (HPDC) | Light housings/covers, carriers, brackets; good thermal paths |
| Zinc | Zamak / ZA systems | Zamak 3, Zamak 5, Zamak 2, ZA-8, ZA-27 | Excellent (HPDC) | Small precision parts, gears, hinges, latches; plates/powders well |
| Magnesium | AZ / AM / AE families + numbers | AZ91D, AM50A, AM60B, AE44, MRI153 | Good (specialist HPDC) | Ultra-light structures (steering wheels, frames, handheld shells) |
| Copper-base | UNS C + five digits | C11000, C26000, C36000, C83600, C93200 | Rarely die-cast (use sand/investment) | Conductors, wear/corrosion parts, valves, fittings, decorative |
| Titanium | Commercial grades / alloy names | Grade 2, Grade 5 (Ti-6Al-4V), Ti-6Al-2Sn-4Zr-2Mo | Not die-cast | Aerospace/medical; high strength-to-weight; investment/forging |
| Nickel alloys | Trade families | Inconel 625/718, Hastelloy C-276, Monel 400, Nimonic 90 | Not die-cast | High-temperature/chemical service; turbines, process equipment |
Which non-ferrous metals are most common?
Aluminum
- Common grades: A380, A360, A383, A413, AlSi10Mg
- Key traits: Low density, balanced strength, good corrosion resistance, excellent thermal/electrical conduction; very castable in Al-Si systems.
- Typical processes: High-pressure die casting (HPDC) for A380/A360/A383/A413; HPDC + heat treatment or additive for AlSi10Mg in some programs.
- Applications: Motor/inverter/ECU housings, gearbox carriers, pump/valve bodies, lighting housings, heat-sink covers, brackets.
Copper and Copper Alloys (Brass/Bronze)
- Common grades: C11000 (Cu-ETP), C26000 (cartridge brass), C36000 (free-cutting brass), C83600 (leaded tin bronze), C93200 (bearing bronze)
- Key traits: Outstanding electrical/thermal conductivity (Cu), good wear and corrosion balance (brasses/bronzes), attractive appearance; denser than Al/Zn.
- Typical processes: Sand or investment casting, forging, machining; generally not die-cast.
- Applications: Bushings/bearings, valve bodies, plumbing fittings, terminals and busbars, decorative hardware.
Zinc
- Common grades: Zamak 3, Zamak 5, Zamak 2, ZA-8, ZA-27
- Key traits: Superb fluidity, high detail replication, dimensional stability, excellent for plating or powder.
- Typical processes: HPDC is standard.
- Applications: Precision gears, hinges, latches, connectors, appliance and furniture hardware, small enclosures.
Magnesium
- Common grades: AZ91D, AM50A, AM60B, AE44, MRI153
- Key traits: Ultra-light, good stiffness-to-weight, natural vibration damping; needs robust corrosion systems and careful handling.
- Typical processes: HPDC, sometimes thixomolding; project-specific validation.
- Applications: Steering wheels, seat frames, handheld tool and laptop shells, interior brackets.
Titanium
- Common grades: Ti-6Al-4V (Grade 5), CP Ti Grades 2/3/4, Ti-6Al-2Sn-4Zr-2Mo
- Key traits: Exceptional strength-to-weight, great corrosion resistance, biocompatibility; expensive.
- Typical processes: Investment casting, forging, machining, additive; not die-cast.
- Applications: Aerospace fasteners/structures, medical implants, chemical equipment.
Nickel-Based Alloys
- Common grades: Inconel 625/718, Hastelloy C-276, Monel 400, Nimonic series
- Key traits: High-temperature strength, oxidation/corrosion resistance.
- Typical processes: Sand/investment casting, forging, machining; not die-cast.
- Applications: Turbine and hot-zone parts, chemical and energy equipment.
What properties make non-ferrous metals useful?
Corrosion behavior
They don’t red-rust. Aluminum/magnesium form oxides; copper develops patina; zinc can sacrificially protect. With the right alloy and finish, outdoor maintenance drops.
Density and weight saving
Aluminum and magnesium dramatically reduce mass, enabling lighter vehicles, longer EV range, lower actuator loads, and easier handling and shipping.
Electrical and thermal conductivity
Copper and aluminum move current and heat efficiently—vital for power electronics housings, heat sinks, busbars, cable lugs.
Non-magnetic behavior
Safer around sensors, MRI, and EMI-sensitive assemblies; avoids magnetic interference.
Surface finishing flexibility
Aluminum anodizes (decorative/hard) and powder coats well after controlled blasting; zinc takes powder or plating cleanly; copper alloys plate/polish attractively.
Castability and near-net shape
Al and Zn die casting achieve thin walls, integrated features, and repeatability—cutting machining time, part count, and total cost at volume.
Where are non-ferrous metals used?
Automotive and EV
- Components: Inverter/ECU housings (Al A380/ADC12), motor end bells, gearbox carriers, battery pack covers, brackets; small mechanisms and trim in Zn.
- Why it fits: Weight reduction, corrosion resistance, thermal paths, thin-wall casting for complex shapes.
Aerospace and Drones
- Components: Interior brackets and housings (Al), seat frames (Mg), selected fittings (Ti/Cu alloys per spec).
- Why it fits: Strength-to-weight, fatigue performance, non-magnetic behavior, rigorous finishing options.
Electronics and Power
- Components: Heat sinks, inverter housings, RF shields (Al/Zn), connectors and busbars (Cu), junction boxes.
- Why it fits: Conductivity, EMI control, fine features via Zn die casting, efficient heat transfer via Al.
Industrial Machinery and Robotics
- Components: Gearcase covers, pump/valve bodies (Al), cam followers and guides (bronze), precise levers/hinges (Zn).
- Why it fits: Wear/corrosion balance, dimensional stability, weight trimming to reduce inertia.
HVAC and Thermal Equipment
- Components: Blower housings, condenser/evaporator side plates, manifolds, motor mounts.
- Why it fits: Corrosion resistance, thermal conductivity, near-net shapes for airflow and mounting geometry.
Marine and Outdoor
- Components: Lighting housings, sealed enclosures, brackets, deck hardware (Al/bronze).
- Why it fits: Corrosion resistance with the right alloy/finish stack; maintain appearance and service life.
Medical and Laboratory
- Components: Non-magnetic instrument bodies (Al/Zn), housings and frames, implant-adjacent hardware (Ti).
- Why it fits: Non-magnetic behavior, sterilization-friendly finishes, biocompatibility (Ti).
Architecture and Fixtures
- Components: Window/door hardware, decorative trims, lighting fixtures, signage bodies.
- Why it fits: Premium cosmetics via anodize/powder, stable fit/finish outdoors.
Energy and Renewables
- Components: Inverter/PCS housings, cable lugs (Cu), cooling plates, enclosure hardware.
- Why it fits: Conductivity, thermal management, sealed outdoor performance.
Consumer and Appliances
- Components: Handles/knobs, hinge systems, gearbox shells for small appliances, phone/laptop frames (Mg in select programs).
- Why it fits: Consistent fit/finish, pleasant touch/appearance, weight feel.
How do non-ferrous and ferrous metals really differ?
Ferrous vs Non-Ferrous at a glance
| Factor | Ferrous (iron-based) | Non-ferrous (iron-free) | Buyer takeaway |
|---|---|---|---|
| Base composition | Fe is primary | Al, Cu, Zn, Mg, Ti, Ni bases | Different corrosion/weight behavior |
| Corrosion | Red rust without protection | Protective oxides; no red rust | Lower maintenance with proper finish |
| Magnetism | Usually magnetic | Usually non-magnetic | Friendlier to sensors/MRI/EMI |
| Density | Higher (~7.8 g/cc) | Lower (Al ~2.7, Mg ~1.8) | Major weight cuts |
| Conductivity | Moderate | Often high (Cu, Al) | Better thermal/electrical paths |
| Cost band | Often cheaper raw | Often higher raw | Total cost = process + yield |
| Die-casting fit | Rarely die-cast | Al, Zn widely die-cast | Near-net shapes at volume |
Which non-ferrous alloys work best for die casting?
Aluminum die-casting alloys
- Grades: A380, A360, A383, A413, AlSi10Mg
- Why they work: Excellent fluidity (A380/A383/A413), balanced properties, corrosion resistance; AlSi10Mg allows strength-oriented routes.
- Typical parts: Housings and covers (motor, ECU, inverter), carriers, brackets, lighting, pump/valve bodies.
- Notes: Thin-wall friendly; manage porosity; pair controlled blast → powder/anodize for adhesion and cosmetics.
Zinc die-casting alloys
- Grades: Zamak 3, Zamak 5, Zamak 2, ZA-8, ZA-27
- Why they work: Very fine detail, high dimensional repeatability; easy plating or powder after prep.
- Typical parts: Precision gears, hinges, latches, connectors, knobs, appliance/furniture hardware.
- Notes: Higher density than Al but unbeatable for micro-features and small complex parts.
Magnesium die-casting alloys
- Grades: AZ91D, AM50A, AM60B, AE44, MRI153
- Why they work: Best mass reduction with useful stiffness; ideal for interior structures and handheld products.
- Typical parts: Steering wheels, seat frames, brackets, handheld electronics shells.
- Notes: Needs robust corrosion system and careful handling; program-specific validation and finishing.
Not sure which family fits your part? Share loads, wall targets, and finish needs—we’ll return an alloy × process × finish shortlist with cost/weight trade-offs.
What finishes make sense for non-ferrous die castings?
Aluminum finishing (most common for us)
- Preparation: controlled blasting—glass bead for a uniform satin look, or aluminum-oxide (AO) 120–150 for stronger coating adhesion. Aim for even, glare-free surfaces with no residue.
- Coatings: powder coat (durable color/texture) or anodize (decorative or hard).
- Timing: best results when coated within 4–24 hours after blasting; handle with gloves only.
Zinc finishing
- Preparation: light bead or media clean; degrease thoroughly.
- Coatings: powder for durable appearance, or plating (Ni/Cr/Brass) for premium metal look and wear resistance.
Magnesium finishing
- Preparation: gentle blast followed by conversion coating (per your spec), then powder or paint.
- Reason: magnesium is reactive; the conversion layer protects and improves coating adhesion.
We keep media × grit × PSI recipes per part so Ra and adhesion remain consistent from lot to lot.
Quick buyer checklist before you choose a non-ferrous alloy
- Environment: salt, humidity, chemicals → set corrosion target and finish early.
- Mass budget: aggressive weight targets favor Al/Mg.
- Thermal/electrical: heat or current paths → Al/Cu families.
- Feature size & tolerance: very fine features → zinc; thin walls at mid-size → ADC12/A380.
- Finish: cosmetic satin vs heavy-duty protection → choose the blast + coating combo up front.
YongzhuCasting From definition to production
We run 800–2000-ton aluminum die-casting lines and supply A380 / ADC12 / AlSi10Mg parts with controlled finishing (AO or bead blast → powder/anodize), CMM inspection, and material traceability.
→ Upload your drawing to get a 24-hour alloy/process suggestion and a quote plan.
FAQs
Is stainless steel non-ferrous?
No. Most stainless steels are ferrous (iron-based) with chromium and other elements for corrosion resistance. They don’t red-rust easily, but they do contain iron.
Why doesn’t aluminum “rust” like steel?
Aluminum forms a tight oxide film that protects it; it doesn’t form red rust like iron. In harsh exposure, pick the right alloy and finish stack.
Which non-ferrous metal is most common in casting?
Aluminum for general housings/covers and zinc for small precision parts. For higher strength-to-weight, some programs use AlSi10Mg with tailored process routes.
Can non-ferrous alloys be magnetic?
Most are non-magnetic. Common non-magnetic families include aluminum, copper, brass, bronze, zinc, and magnesium alloys.
What’s the fastest way to pick an alloy for die casting?
Define environment, loads, weight, and finish; then request an alloy shortlist (A380 vs ADC12 vs AlSi10Mg) with a coating/test plan.
