Is Brass Stronger Than Aluminum

Is brass really stronger than aluminum, or does it just seem that way? These two metals are everywhere—from plumbing parts to aircraft frames. 

In this post, you’ll learn how their strength, weight, cost, and corrosion resistance compare—and which one is better for your next project.

What Does “Stronger” Mean?

When people say one metal is stronger than another, what do they actually mean? In materials science, strength isn’t just one thing. It comes in a few forms, and each one tells us how a material behaves under different types of stress.

The first is tensile strength. This measures how much pulling force a metal can handle before it breaks. Brass usually has higher tensile strength than aluminum, which makes it better in parts that need to resist stretching or tension.

Next is compressive strength. That’s how much force a material can take when being pushed or squeezed. Brass also tends to win here. It holds its shape better when pressed, which makes it a good fit for valves, bushings, and other high-pressure components.

Then there’s yield strength. This one tells us the point at which a metal stops bouncing back and starts to bend for good. Aluminum, especially in some alloys like 7075, can have decent yield strength, but brass is often more resistant to permanent bending under load.

But here’s the thing: being strong doesn’t always mean being better. Just because one metal handles more stress doesn’t make it the right choice every time. For example, aluminum is much lighter. That can be a huge advantage in cars, planes, or anything that needs to be fast or fuel-efficient.

We also have to think about machinability, cost, and corrosion resistance. Sometimes a slightly weaker metal makes life easier and cheaper overall. So when we talk about strength, we have to look at the whole picture.

Brass vs Aluminum: Strength Comparison

Tensile Strength: Is Brass Stronger Than Aluminum?

Tensile strength tells us how much pulling force a material can handle before it snaps. Brass tends to come out ahead here. Depending on the alloy, brass usually ranges from 300 to 500 MPa. Some high-strength versions may even reach 600 MPa. Aluminum, in comparison, covers a wider range. A softer alloy might only offer 90 MPa, while tougher grades like 7075 can go up to 570 MPa.

So brass isn’t always stronger in every case, but on average, it is. This matters in parts that stay under constant tension, like mechanical connectors or fittings that can’t afford to stretch or fail. Brass holds its shape better under these conditions. Aluminum can still be strong, but you have to pick the right alloy for the job.

Hardness and Durability

Let’s talk about how tough each metal is when you press on it, scratch it, or drop something on it. On the Mohs hardness scale, brass scores around 3. Aluminum sits a bit lower at roughly 2.5. That may not sound like a big gap, but it makes a difference in real use.

Now, if we use the Brinell scale, which is better for metal parts, brass hits around 200 HV. Aluminum usually stays near 70 HV unless it’s specially treated. This makes brass much more resistant to dents, scratches, and general wear and tear.

That’s why you’ll see brass used in things like bushings, gears, and fasteners—places where metal rubs against metal or sees repeated contact. Aluminum, while softer, can still last long if coated, anodized, or used in lower-stress areas.

Compressive Strength

When a metal is squished instead of pulled, compressive strength kicks in. Brass can take a lot of pressure without losing shape. That makes it perfect for valves, hose ends, and plumbing parts where the metal gets squeezed tight.

Aluminum has decent compressive strength too, but it’s not as solid as brass. It’s more likely to deform if the pressure goes up too much. That’s why in high-pressure settings, brass gets the job.

If you're working on a part that needs to resist squeezing forces—especially when weight isn't a big issue—brass will usually be the better call. Also, if you have other needs, welcome to see more of our products such as round steel, steel wire and so on.

What Makes Brass Strong?

Brass isn’t just one metal. It’s actually a mix. Most brass alloys combine copper and zinc, but some also add small amounts of lead or tin. This combination changes how the metal behaves. When more zinc is added, the material becomes harder and stronger. Copper brings corrosion resistance and a bit of flexibility. Lead boosts machinability, making it easier to cut and shape.

Its strength doesn’t only come from the ingredients. It also depends on how the atoms bond inside the metal. Brass has a solid internal structure. This helps it resist stress without cracking. It can hold up against both tension and pressure. That’s why it works well in tight-fitting parts or connectors under load.

We can look at a few examples. Brass 260 is known for its high strength and is used in heavy-duty components. It has about 70 percent copper and 30 percent zinc. This mix gives it better durability than softer brasses like Brass 360. Brass 260 can handle more wear, which makes it great for gears, fasteners, or anything that needs to last under stress.

There’s also Brass 270. It has a bit more zinc than 260 and adds excellent corrosion resistance. That makes it useful outdoors or near water. These different types let designers and engineers pick the right balance of strength, workability, and cost.

Brass might not be as hard as stainless steel, but it fills a middle ground. It’s stronger than aluminum in most cases and still easy to work with. When a part needs to be tough and resist damage over time, the right brass alloy can do the job.

How Strong is Aluminum in Comparison?

Aluminum on its own is soft. Pure aluminum doesn’t offer much strength. But once it's mixed into an alloy, it changes a lot. These aluminum alloys can become surprisingly tough, and that’s where the real strength shows up. For example, 6061 aluminum is popular because it's easy to work with, yet strong enough for structural parts. It balances strength, corrosion resistance, and machinability all in one package.

Then there’s 7075 aluminum. This one’s built for performance. It’s much stronger than 6061, often used in aerospace and military parts. It can reach tensile strength levels close to 570 MPa. That gets it near the bottom range of some brass alloys, which is impressive for a material that's much lighter.

Aluminum’s true power isn’t always in raw strength. It’s in its strength-to-weight ratio. That means it can carry a lot of load without weighing much. This makes a big difference in planes, drones, bicycles, and even laptops. You don’t want heavy parts slowing things down. So they choose aluminum for both performance and efficiency.

You’ll find aluminum in aircraft frames, car hoods, heat sinks, and electronics casings. It handles vibration well and resists rust if treated. When the goal is to reduce weight without giving up too much strength, aluminum is often the first choice.

Strength vs Weight: Which is Better for Your Application?

Brass is heavy. Aluminum is not. That’s the starting point. Brass has a density of about 8.5 grams per cubic centimeter. Aluminum sits closer to 2.7. So for the same size, brass parts weigh over three times more. If you’re designing something that needs to fly, float, or move fast, weight matters a lot.

That’s why aluminum dominates in aerospace, automotive, and electronics. Airplanes need materials that won’t drag them down. Cars use aluminum panels to improve fuel efficiency and cut emissions. Laptops and phones use it to stay light without cracking under pressure. In these fields, strength alone isn’t enough. You need performance without extra mass.

But there are times when the extra weight of brass actually helps. In plumbing or mechanical systems, that weight means stability. Brass fittings won’t shift easily. They hold their position and stay sealed tight under stress. Brass is also more rigid, so it resists bending or deforming when something pushes against it.

So, if your part will stay put, take a hit, or last for years without moving, brass might be worth the extra weight. If your part needs to move, fly, or save energy, aluminum usually wins. It depends on what the part has to do—and where it's going to live.

Corrosion Resistance and Environmental Strength

When metals face water, salt, or harsh chemicals, not all of them hold up the same. Brass and aluminum each have their own ways of dealing with the elements. Brass resists corrosion well thanks to its copper content. It forms a protective surface that blocks further damage. That’s why you see it in plumbing systems, especially where moisture is constant.

Aluminum reacts differently. When exposed to air, it quickly builds a thin oxide layer. This helps it resist rust. But in harsh environments, like those with salt or industrial chemicals, that layer can break down. That’s where anodizing comes in. Anodized aluminum has an enhanced oxide layer that makes it tougher and more resistant to corrosion. It looks clean and lasts longer outdoors.

If we compare them in real-life settings, the differences show up fast. Brass fittings work great in marine and underground plumbing. They can handle water pressure and won’t rot or weaken easily. Aluminum parts are lighter, so they’re used in boat hulls and railings, but only if they’re treated or coated. Otherwise, saltwater can wear them down.

In outdoor fixtures, both metals appear often. Brass is a favorite for garden taps and decorative lights. It ages slowly and gets a nice patina. Aluminum shows up in things like mailbox posts, window frames, and bike parts. It’s light, modern, and stays sharp-looking if you take care of it.

Machinability and Manufacturing Considerations

If you're cutting, drilling, or shaping metal, how it handles tools matters. Between brass and aluminum, aluminum is generally easier to machine. It’s soft, light, and creates less resistance, which means tools last longer and work faster. But that doesn’t mean it’s trouble-free. Aluminum often forms long, stringy chips. These can tangle or jam tools, especially in high-speed CNC setups. It’s also prone to forming built-up edges. That’s when bits of aluminum stick to the cutting tool and ruin the surface finish.

Brass, on the other hand, is harder and heavier. It wears down tools faster, especially if you’re working with tougher grades like Brass 260. But its chips are usually short and break cleanly, making chip removal easier. Brass also stays cooler during cutting. That reduces the need for intense cooling or special lubricants. Alloys like Brass 360, often called free-machining brass, are made specifically for easy cutting.

When using CNC machines, aluminum prefers high speeds and sharp tools. Carbide inserts work well. You’ll want to keep feeds high and avoid too much coolant, especially on 6061. For tougher alloys like 7075, slow things down to avoid overheating. Brass can be machined at moderate speeds. It benefits from steady feed rates and occasional lubrication to reduce tool chatter. Some machinists even run it dry in short cycles, depending on the setup.

If the job involves lots of deep cuts or fine detail, both metals can work. The choice depends on your machine, your tooling, and how many parts you need to make.

Decorative and Aesthetic Strength

Brass and aluminum both bring more to the table than just mechanical performance. They each have a distinct look that makes them useful for projects where appearance matters just as much as function. Brass has a warm, gold-like shine that changes over time. As it ages, it develops a natural patina. Some people like this antique finish, especially in vintage or classical design. You’ll see it used in signage, medals, labels, and decorative plates where a timeless look fits the mood.

Aluminum gives off a very different vibe. It starts out bright and silver, almost icy in tone. When anodized, it becomes even more attractive. The anodizing process adds a layer of protection and allows for color finishes. You can get blues, reds, or matte silvers that stay clean-looking even after years outside. Unlike brass, aluminum doesn’t tarnish. It stays crisp, modern, and minimal—perfect for sleek architecture, display systems, or brand nameplates.

If a product needs to be strong and good-looking, both metals can work. Brass is great for heritage-style fixtures, award medals, or museum-grade tags. Aluminum fits better in tech, sports gear, or lightweight structures that still need to look sharp. They’re used in decorative panels, lighting fixtures, sculpture bases, and even custom signage that balances durability with design.

Which is Better for CNC Machining Projects?

CNC machinists often have to choose between different grades of brass and aluminum, and the right choice depends on what the part needs to do. Brass 360 is one of the easiest metals to cut. It machines fast, creates clean finishes, and doesn’t wear out tools too quickly. That’s why it’s often used for fittings, connectors, terminals, or parts with tight tolerances where surface quality matters. It’s a good pick when you need precision and high output.

Brass 260, while not as easy to cut as 360, offers more strength. It holds up better in high-stress or load-bearing parts. That makes it useful for gears, bushings, and threaded components in demanding environments. You give up a bit of machinability, but you get more toughness in return.

Now compare that to aluminum. If the part needs to be light and still strong, 6061 aluminum is a common choice. It’s easy to machine, weld, and finish. It works well in brackets, frames, or casings. You’ll find it in general-purpose mechanical parts, housings, and consumer products.

7075 aluminum, on the other hand, is much harder and stronger. It’s used in aerospace and defense because of its high strength-to-weight ratio. It’s tougher to machine than 6061, so it needs slower speeds and sharper tools. This grade is often chosen for structural components, drone parts, and military-grade hardware.

Here’s a quick look at when to use each:

Pros and Cons Summary Table

When comparing brass and aluminum, it helps to see everything side by side. Each metal offers different advantages depending on what your project needs. Some people care most about strength, others about weight or corrosion resistance. Use this table as a quick way to figure out which one fits better for your application.

This kind of chart gives a quick overview. If you’re unsure which one to use, match your priority—like weight or corrosion resistance—to the column that fits best.

Conclusion

Brass is usually stronger than aluminum in terms of tensile and compressive strength. But that doesn’t always make it the better choice. The right material depends on your needs—whether it’s strength, weight, cost, or looks. Each metal has its own advantages. Think about your project’s environment, budget, and design before making a final decision.

FAQs

Is brass always stronger than aluminum?

Not always. While brass is typically stronger, some aluminum alloys like 7075 can match or exceed its strength in specific situations.

Which metal is better for lightweight parts?

Aluminum is much lighter than brass. It’s ideal for aerospace, electronics, and automotive applications where weight matters.

Does brass resist corrosion better than aluminum?

Brass resists corrosion very well, especially in wet environments. Anodized aluminum also offers good protection but may need coatings in tough conditions.

Which is easier to machine: brass or aluminum?

Aluminum is generally easier to machine, but Brass 360 is also known for excellent machinability. Brass 260 requires more care due to its added strength.

Can I use brass and aluminum together in one assembly?

It’s possible, but not ideal in wet or corrosive settings. Contact between the two can cause galvanic corrosion unless properly isolated.