Working with Metals: Aluminum

In the long history of tools and metals, the Iron Age was actually a pretty recent era. Large machines were made from tons and tons of cast iron, which in turn made more machines. A few of these eventually ended up becoming that mess of parts (otherwise referred to as your resto project) in your garage that your spouse harasses you about. Now aren't you grateful for the Iron Age and the Industrial Revolution? Look at where it has gotten you!


At some point, someone decided that iron was just too heavy—probably some middle-aged blue collar worker with a bad back like myself. Fortunately for this person, and the rest of the world, we have aluminum. We're not talking about the soda cans picked out of your trash for recycling money. Aluminum has had a major impact on the world and, of course, the aforementioned vehicle in your garage.


It has not been until relatively recent times that the processes for manufacturing aluminum were developed. It was always easier to mine and melt and cast iron, so that is what the world did. However, the need for a strong and lightweight metal was always there—enter aluminum.

The New Standard
The advantages of a material that is strong and lightweight in the automotive world are obvious. For example, many early engines were built with cast-iron pistons. It was soon found that replacing these heavy pistons with lightweight aluminum copies would produce some very desirable results. Vibration could be reduced dramatically, higher RPMs could be attained and the longevity of the engine was increased dramatically.


Over the last several years aluminum has been replacing more and more components in vehicles that were traditionally cast iron or steel. If you are restoring an older American car with a large cast-iron engine, it is possible to purchase aftermarket parts like cylinder heads or engine blocks made from aluminum.