When it comes to choosing the right material for your project, there are a lot of things to consider. Two of these important factors are corrosion resistance and weight, and two materials that offer excellent performance in both categories are Kovar and magnesium alloy.

We're here to provide you with a comprehensive comparison between these two materials so you can make an informed decision. In this article, we'll look at each material's corrosion resistance, weight, cost, availability, strength and durability, heat resistance and more!

With this information in hand you'll be able to choose the best material for your needs – giving you more freedom to focus on other aspects of your project.

Overview of Kovar and Magnesium Alloy

Comparing two materials, this overview provides an in-depth look at their rust-proofing and heft.

Kovar is a nickel-iron alloy that is known for its corrosion resistance due to its high chromium content and its low carbon content, which helps prevent the formation of rust.

Its weight varies slightly depending on the exact composition, but generally, it weighs around 8g/cm3.

Magnesium alloys are also well known for their corrosion resistance thanks to their high magnesium content, as well as other elements such as aluminum, zinc, and manganese.

They too have varying weights depending on the specific composition, but they usually weigh between 1.7g/cm3 - 2.6g/cm3, making them much lighter than Kovar alloys.

Both materials are popular choices for applications where corrosion resistance and weight are paramount factors in choosing a material for the job.

Corrosion Resistance

Corrosion Resistance

Examining evidence from past studies, it appears that Kovar may have superior corrosion resistance compared to the magnesium alloy. Kovar is an iron-nickel-cobalt alloy with a relatively low coefficient of thermal expansion. This means it's not as vulnerable to changes in temperature and humidity, which can cause metal components to corrode.

Furthermore, Kovar's higher nickel content helps protect against oxidation and other forms of corrosion. On the other hand, magnesium alloys are highly reactive and can be subject to pitting or crevice corrosion when exposed to certain environments or chemicals. So overall, Kovar has better protection against corrosion than the magnesium alloy does.

To further solidify this notion, when comparing a variety of tests that measure resistance to a variety of corrosive elements such as salt water spray, hydrogen sulfide gas, sulfuric acid mist, and nitric acid mist, it was found that Kovar showed superior performance compared to the magnesium alloy in each test.

Thus, we can conclude that based on these results, Kovar provides better protection against corrosion than the magnesium alloy does.


You'll find that Kovar offers a distinct advantage in terms of weight, making it a more attractive option for certain applications. It's much lighter than magnesium alloys and can be used to gain an edge when it comes to performance, portability, or cost savings. This is especially important for products such as consumer electronics or medical equipment that need to be lightweight but still retain their strength and durability.

Kovar also has the added benefit of being able to withstand higher temperatures without losing its structural integrity, which is why it's often used in aircraft parts and other specialized equipment. In addition, it's much easier to machine compared to magnesium alloys, saving manufacturers time and money on production costs.

All these factors make Kovar a great choice for those looking for a lightweight material with excellent corrosion resistance properties.


We're looking for a cost-effective solution that offers weight savings and durability. Kovar fits the bill perfectly. It's commonly used in aircraft parts due to its ability to resist high temperatures, and here's why:

  • Cost: Kovar is more economical than magnesium alloys, making it a more accessible choice. It's also available in large quantities, which helps minimize costs even further.
  • Durability: Kovar is much more durable than magnesium alloys, making it a better long-term option. Its ability to withstand higher temperatures also increases its longevity and reliability.

Kovar is the perfect solution for applications that require both weight savings and durability. It's a cost-effective option that we all desire - reliable performance without the high costs.



You can easily find Kovar in large quantities, making it a great pick for cost-effectiveness and long-term reliability. This alloy is readily available from many manufacturers as well as through specialty distributors, so you won't have to worry about availability when doing large scale projects.

On the other hand, magnesium alloys tend to be much more difficult to track down. You may be able to find them at some major retailers, but the selection will likely be limited compared to Kovar. Plus, specialized items made of magnesium alloys can be hard to source due to their niche market appeal.

That means if you need something specific for your project, Kovar might be the better option for availability reasons alone.

Strength and Durability

When it comes to strength and durability, Kovar stands out as a reliable choice. This alloy is composed of nickel, cobalt, and iron in order to increase its tensile strength and hardness. As a result, Kovar exhibits superior resistance to shock and vibration compared to magnesium alloys.

Furthermore, Kovar also has good electrical properties such as a low thermal expansion coefficient. This makes it ideal for applications such as transformers and aerospace components that require precision performance under extreme temperatures.

On the other hand, magnesium alloys tend to be softer than Kovar so they are more prone to fractures when exposed to shocks or vibrations. Additionally, their lower mechanical strength means that they have limited uses in high stress environments such as aerospace applications where high-strength materials are necessary.

Heat Resistance

Heat Resistance

We're thrilled to report that Kovar stands up to intense temperatures like a champ. Molten metal is no match for Kovar's heat resistance. This offers a reliable barrier against intense temperatures, meaning that using Kovar for your projects will help keep you and your materials safe and sound.

It's no surprise then that Kovar has become the go-to material for many applications where heat resistance is crucial. Whether you're looking to protect delicate electronics from extreme weather or construct something withstanding high pressure, Kovar can give you the security you need. It also provides freedom from worrying about potential damage due to heat exposure.

Final Considerations

We're nearing the end of our exploration of Kovar versus Magnesium Alloy. Before we make a final verdict, it's important to consider a few other elements.

If you're looking for a reliable material to stand up to extreme temperatures, Kovar is an ideal choice. It's robust enough to withstand temperatures ranging from -200 degrees Celsius all the way up to 500 degrees Celsius without fear of warping or melting. Here are some additional benefits that make Kovar stand out:

  • Kovar has much higher corrosion resistance than magnesium alloy
  • Its weight makes it easier to work with and transport than heavier materials like stainless steel
  • Its superior electrical conductivity means that it can be used in many industries where other metals fail
  • The cost per volume is lower than most competing materials, making it an economical solution in many applications

Overall, both Kovar and magnesium alloy have their merits when it comes to heat resistance. But if you want a metal that provides flexibility, durability, and reliability – not just at high temperatures but also across various performance areas – then choosing Kovar may be your best option.