Aluminum or steel forgings? The difference is bigger than you think.

When it comes to industrial forgings, material selection is one of the most important decisions in product development.

At Extra Forge doo, we produce boutique, small and medium series of forgings made of steel, aluminum, alubronze, titanium and copper for customers across Europe.

One of the most common questions we receive is:

Should you choose aluminum or steel forging?

Property	AW7075 aluminum	S355J2 steel
Density	2.81 g/cm³	7.85 g/cm³
Weight	64% smaller	Reference
Tensile strength	510–570 MPa	470–630 MPa
Yield strength	≈ 500 MPa	355 MPa
Material price	Approximately 4x higher	Lower

The biggest advantage of aluminum is its weight. Aluminum forgings are almost three times lighter than steel, which is why they are found in aviation, automotive, robotics and other applications where every kilogram affects the efficiency of the system.

On the other hand, steel forgings remain indispensable in heavy-duty applications, mechanical engineering, energy, and heavy industry.

Many are surprised to learn that AW7075 aluminum can achieve mechanical properties comparable to many structural steels. This is why aluminum forgings are increasingly used as an alternative to steel when weight reduction is desired without significant compromises in strength.

Why choose forging at all?

Because compared to casting it has:

• higher mechanical strength,

• better resistance to material fatigue,

• fewer internal errors,

• longer lifespan.

  
  

At Extra Forge doo, we help customers choose the optimal material and manufacture custom forgings from steel, aluminum, titanium, aluminum bronze and copper for various industrial applications across Europe.

The right choice of material at the beginning of a project often means lower costs, less weight and a longer product life.