Understanding Ferrous and Non-Ferrous Metals and Alloys Used in Contemporary Foundries

Contemporary foundries play a vital role in manufacturing by transforming raw metals into strong, durable, and precisely engineered components. One of the most important decisions in any casting project is the selection of material.

Broadly speaking, metals used in foundries fall into two categories: ferrous and non-ferrous, each with distinct properties, advantages, and applications.

Understanding how these materials perform helps with choosing the most appropriate metal for strength, longevity, appearance and environmental conditions.

Aluminium is a non-ferrous metal commonly used in metal castings.

What are ferrous metals?

Ferrous metals are metals that contain iron as their primary element. They are widely used in industrial and structural applications due to their strength, toughness, and load-bearing capabilities.

At Adelaide Brass Castings, the preferred ferrous metals are:

• cast iron, which boasts excellent compressive strength, wear resistance, and vibration damping. Cast iron is frequently used in machinery components, drainage products, and infrastructure.

• spheroidal graphite iron, which offers a unique combination of strength, toughness, and versatility. It is often the preferred material for many structural and industrial applications where traditional grey cast iron or steel may be unsuitable.

Ferrous metals are generally cost-effective for large-scale production but can be susceptible to corrosion if not treated or alloyed appropriately, making project requirements a key consideration in material selection.

What are non-ferrous metals?

Non-ferrous metals contain little to no iron and are valued for their corrosion resistance, durability and ability to produce fine detail in castings. These metals are commonly used in architectural, industrial, marine and commemorative applications.

The non-ferrous metals used at Adelaide Brass Castings are:

• aluminium and aluminium alloys, which are corrosion-resistant and lightweight;

• bronze alloys, which are known for strength, wear resistance, and long service life; and

• gunmetal and leaded gunmetal, both of which offer reliability, machinability, and corrosion-resistance.

While brass is often mentioned in discussions about non-ferrous metals, it is no longer used at Adelaide Brass Castings.

Why other metals are preferred over brass

The term 'brass' remains part of our name – Adelaide Brass Castings – in reference to our beginnings more than 75 years ago. Since then, the manufacturing landscape and industries we support with metal castings have evolved, and so we have adapted our services accordingly. Today, we specialise in casting metals and alloys other than brass, carefully selected for their superior durability, performance, and long-term stability.

Brass does have its purposes, however, because it is primarily an alloy of copper and zinc, it is relatively softer and more susceptible to dezincification (weakening) and environmental degradation over time, particularly in outdoor or marine environments.

At Adelaide Brass Castings, we prefer the use of other metals and alloys, such as aluminium, bronze, iron and gunmetal, ensuring cast products maintain their integrity, appearance, and performance for decades.

The role of alloys in metal casting

Pure metals are less common than alloys in foundry work. Carefully formulated alloys allow foundries to tailor properties such as strength, hardness, corrosion-resistance, and finish.

Examples of the alloys available at Adelaide Brass Castings include:

• aluminium bronze (AB1, AB2);

• copper magnesium aluminium (CMA1);

• gunmetal (G1) and leaded gunmetal (LG2);

• cast iron and spheroidal graphite iron (SG);

• leaded tin bronze (LB1, LB2); and

• phosphor bronze (PB1, PB2, PB3).

Selecting the correct alloy is critical to achieving reliable performance and long-term durability.

Choosing the right metal for your project

When selecting between ferrous and non-ferrous metals, key considerations include:

• mechanical strength and load requirements;

• exposure to weather, moisture, or corrosive environments;

• desired appearance and surface finish; and

• expected lifespan and maintenance needs.

  
  

Contemporary foundries combine metallurgical expertise with precision casting techniques to ensure each project uses the most suitable material for its intended purpose.

Today’s foundries are precision manufacturing partners, not just metal producers. By understanding the differences between ferrous metals, non-ferrous metals, and specialised alloys, clients can make informed decisions that result in stronger, longer-lasting, and higher-quality cast products.

At Adelaide Brass Castings, material selection is driven by performance, durability, and craftsmanship, with a strong focus on high-quality metals and alloys that deliver cost-effective and desired results.

Unsure which metal or alloy is right for you?

Choosing the correct ferrous or non-ferrous metal can significantly extend performance and longevity as well as reduce maintenance.

Talk to the specialists at Adelaide Brass Castings. To contact us, simply click here or email admin@abcast.com.au.