We've all heard about aluminum and Kovar, but how do these two materials compare? In this article, we'll take a closer look at the physical and chemical properties of these two metals, their applications, and a cost comparison. We'll also consider the advantages that each one offers. Read on to discover which metal is best suited for your project or application.

To understand the differences between aluminum and Kovar better, it's important to start by looking at their physical and chemical properties. Aluminum is lightweight yet durable, while Kovar has excellent strength characteristics. Both materials have good heat resistance, but they differ in terms of electrical conductivity: aluminum is an excellent conductor, while Kovar is much less conductive.

Knowing these details can help you make an informed decision when choosing between the two materials.

Physical and Chemical Properties

Whether it's melting point, hardness, or tensile strength, this section looks at how these two materials stack up against each other in terms of their physical and chemical properties.

Aluminum and Kovar have some similarities: both are solid, nonmagnetic materials that are relatively lightweight. However, they also differ in many ways.

Aluminum has a higher thermal conductivity compared to Kovar and is much softer than the latter material. In addition, aluminum has a low modulus of elasticity (around 10 GPa) while Kovar has a much higher value (around 200 GPa).

In terms of their melting points, aluminum melts at around 660°C whereas Kovar melts at around 1410°C, making it ideal for use in high-temperature applications.

Lastly, aluminum is highly corrosion-resistant while Kovar can corrode quickly when exposed to certain chemicals or environments.

Overall, both materials offer different advantages depending on the application, so it's important to carefully consider the pros and cons before making a decision.

Applications of Aluminum and Kovar

Applications of Aluminum and Kovar

You may be wondering what these two materials can be used for. Aluminum an Kovar have quite different applications.

Aluminum is a lightweight metal with excellent corrosion resistance, high thermal and electrical conductivity, and good formability. It's often used in the production of aircrafts, cars, tools, electronics, cans, utensils, and window frames.

Kovar is an alloy composed of nickel-cobalt-iron that has a coefficient of thermal expansion similar to that of borosilicate glass or quartz. This makes it ideal for use in hermetic seals with these materials, such as those found in electronic components like transistors and integrated circuits. It is also widely used in aerospace components such as satellites because its low outgassing rate prevents corrosion to delicate parts from air and water vapor.

Here are some key uses for aluminum and Kovar:

  • Aluminum - Aircrafts, cars, tools, electronics, cans, & utensils
  • Kovar - Electronic components & hermetic seals; Aerospace components & satellites

Cost Comparison

When it comes to cost, aluminum and Kovar can vary greatly - it's important to do your research to find the best option for your project. Generally speaking, aluminum is far more cost-effective than Kovar when it comes to raw materials. It also requires less intensive labor costs in its production.

On the other hand, Kovar tends to be more expensive due to its specialty alloy composition and manufacturing process that uses multiple metals. In terms of maintenance costs, aluminum is typically cheaper than Kovar because it is corrosion resistant and doesn't require special coatings or treatments over time. However, Kovar  may have a longer lifespan than aluminum in certain applications which could save on long-term repair costs.

When evaluating the cost of either material for a specific application, it's important to consider both upfront and long-term expenses for a comprehensive understanding of value.

Advantages of Aluminum

Advantages of Aluminum

With its low cost and easy maintenance, aluminum is a great choice for many projects. In fact, it's the second most used metal in the world after iron, making up 8% of global production.

It has many advantages over other metals like Kovar:

  • Strength: Aluminum has excellent strength-to-weight ratio and is one of the strongest metals available. This makes it perfect for applications where weight needs to be reduced without sacrificing structural integrity.
  • Durability: Aluminum is highly corrosion resistant and won't rust like steel or corrode like brass or copper. This makes it an ideal material for outdoor structures that will be exposed to harsh elements.
  • Cost Effectiveness: Aluminum is much less expensive than Kovar and can be fabricated quickly, making it a cost-effective solution for projects with tight deadlines.
  • Recyclability: Aluminum can be melted down and reused multiple times without losing any of its properties, making it one of the most sustainable materials available on the market today.

Advantages of Kovar

Advantages of Kovar

We understand the importance of finding the right material for projects that require superior strength and durability. Kovar is a premium material that offers these features, making it an ideal choice over aluminum.

It has strong thermal expansion properties which enable it to maintain dimensional stability when exposed to varying temperatures. Additionally, Kovar's high electrical resistivity makes it suitable for use in electrical components such as transistors and relays.

Kovar also offers excellent weldability compared to other metals, allowing you to join components together with ease and precision. Its magnetic properties make it an ideal choice for applications where high levels of magnetic permeability are required.

Lastly, its corrosion resistance ensures long-term reliability in harsh environments without sacrificing any of its superior strength or durability characteristics. All these advantages make Kovar a great choice when looking for a more heavy-duty solution than aluminum can provide.


We've covered a lot of ground in this comparison between aluminum and Kovar . We've looked at their physical and chemical properties, the applications they're suited for, and even the cost differences between them.

While both can be useful materials in certain situations, it's clear that aluminum has a major advantage over Kovar when it comes to its versatility. Aluminum is also considerably more cost-effective than Kovar , making it an ideal choice for many projects.

Ultimately, choosing which material to use will come down to what your specific needs are - but we'd bet our bottom dollar that aluminum will be the go-to choice most of the time.