Corrosion-Resistant Metals for Die Casting

Stacked Metal

With die casting being an efficient way to manufacture complex components, it is important to understand the benefits of commonly used metals for die cast parts. The best die casting methods and metals will be largely determined by your component’s complexity and functionality.

Aluminum, zinc, and magnesium are common metal materials used for die cast metal parts. While each metal type offers corrosion resistance, the levels of rust protection vary. Less common die cast metal includes brass, copper, or other specialty alloy materials.

Aluminum Die Casting

As a well-known metal for its corrosion-resistance, aluminum is a popular die cast metal option. Aluminum’s mechanical properties of lightweight with high strength-to-weight ratio make it an ideal choice for a wide range of components and parts.  Aluminum can also withstand high heat temperatures making it a versatile choice for different die casting methods.

With little to no iron in its chemical composition, aluminum is a rust-proof alloy. While aluminum does not rust, it can corrode depending on environmental factors.

Zinc Die Casting

Ideal for automotive or electoral applications, zinc alloys provide excellent corrosion-resistance. Due to its smooth surface finish, zinc works best for applications that will not be subjected to high temperatures.

Marine and atmospheric environments with salt will eventually corrode zinc die cast components. While zinc can corrode in harsh atmospheric environments, it is well suited for most die cast components including automotive die cast parts.

Magnesium Die Casting

While magnesium provides benefits including lightweight composition and recyclability, it is not inherently corrosion-resistant like aluminum or zinc. Sprays or coatings for magnesium die cast components can provide the galvanic corrosion protection needed for most components.

Choosing the Best Alloy for Your Die Cast Project

Aluminum, zinc, and magnesium all offer different levels of corrosion resistance. However, the best alloy for your die casting project depends on other factors for consideration.


  • Exceptional corrosion-resistance
  • High strength-to-weight ratio
  • Thermal and electrically conductive
  • Tolerates high temperatures


  • Smooth surface finishes
  • Good corrosion resistance when not subjected to marine or atmospheric salt content
  • Durable
  • Thermally conductive


  • Lightweight
  • Easy to machine
  • RFI shielding
  • High strength
  • Ideal for thin-walled components/tight tolerances
  • Should be coated or sprayed for corrosion resistances

Get the Corrosion-Resistant Die Cast Components You Need

Call us at 408-205-1319 or contact us to discuss your corrosion resistant die casting project. We can help find you the best die casting manufacturer for your project requirements.

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