Aluminum vs Copper Crush Washers

Choosing the right materials for car maintenance can make a significant difference. The right crush washer can be critical to any car’s performance. From sealing fluids to preventing corrosion. It can be confusing between aluminum and copper crush washers. Which is the right choice? In this blog post, we’ll look at both materials’ advantages and disadvantages to help you decide which is best for your vehicle.

What Is a Crush Washer?

Crush Washers are designed to provide a tight seal between two components and are often used in automotive, plumbing, and industrial applications.

Crush Washers are typically made from soft metals such as aluminum, steel, etc. The smooth metal is then stamped to form the washer’s shape and size. When the washer is compressed, the metal compresses, creating a tight seal between the two parts.

Crush Washers are often used for sealing fuel, oil, hydraulic, or other components on a car, truck, or vehicle. Because they are softer metal, they close better than a traditional flat washer. Crush Washers also work well in plumbing applications, especially when pipes are not perfectly aligned.

We are going to discuss aluminum and copper crush washers. We will help you with these two types of crush washers’ differences and their pros and cons to choose the better one you need in your vehicle.

Comparison of Aluminum and Copper Crush Washers

There are several factors to consider when choosing between aluminum and copper crush washers. These include strength and durability, cost, corrosion resistance, heat resistance, and fitting. Let’s take a look at each one in more detail.

A. Strength and Durability

Aluminum crush washers are the clear winner. The aluminum alloy is highly resistant to wear and tear, making it an ideal material for crush washers. Aluminum is much lighter, making it easier to work with and install.

B. Cost

In question of cost, aluminum crush washers are generally more expensive than copper washers. Aluminum is a much more versatile material, which can be used in various applications, making it a more cost-effective option in the long run. However, aluminum washers can often be found at a discounted price, making them an excellent choice for those on a budget.

C. Corrosion Resistance

Both aluminum and copper are highly resistant to corrosion. However, aluminum is slightly more corrosion-resistant than copper, making it the better choice. Aluminum crush washers are highly resistant to corrosion, making them an ideal choice for projects that will be exposed to the elements. On the other hand, copper washers are slightly vulnerable to decay. But they can resist for long enough, making money worth it.

D. Heat Resistance

Copper has a higher melting point than aluminum, making it more heat-resistant. Because of this, copper crush washers can withstand higher temperatures, making them an ideal choice for applications that involve high temperatures. This makes it suitable for high-temperature use, like automotive engines and exhaust systems.

F. Fitting

Aluminum is much softer than copper and is frequently seen on sump bolts, fuel fittings, etc. On the other hand, copper is much more rigid and is often used on precision joints like brake banjos, etc.

Overall, when it comes to choosing between aluminum and copper crush washers, it is crucial to consider the various factors discussed above. Depending on the application, either material can be a great choice.

Advantages of Aluminum Crush Washers

There are many advantages to using aluminum crush washers. Let’s look at these features and why they make aluminum crush washers the ideal choice for car parts.


Aluminum crush washers are incredibly lightweight. They are easy to transport and install. This makes them ideal for use in tight spaces or where weight is a primary concern. Additionally, aluminum is strong yet flexible enough to ensure a secure seal.
Excellent Sealing Ability

Aluminum crush washers provide an excellent sealing ability. This is because they are designed to crush when they are tightened, forming a tight seal between the two components. This tight seal prevents any leaks.

Corrosion Resistant

Aluminum is naturally corrosion-resistant, meaning it won’t rust or corrode even when exposed to harsh chemicals or other corrosive elements. This makes aluminum crush washers the ideal choice for applications where corrosion could be a problem.

Cost Effective

Aluminum is an affordable material, making aluminum crush washers an economical choice. They are also highly durable, so you won’t need to replace them often, making them even more cost-effective in the long run.

Disadvantages of Aluminum Crush Washers

Limited Reuse

Aluminum crush washers are limited in terms of reuse. Unlike other types of washers, aluminum crush washers cannot typically be reused, as they are designed to be a one-time-use item.

Advantages of Copper Crush Washers

Copper crush washers are a reliable choice for a variety of applications. These washers are made of a durable material that offers several advantages. Here are just a few of the benefits of using copper crush washers.

High Strength

Copper crush washers are robust and durable compared to other metals. They are designed to withstand the pressure of a running car. Also, compatible with the force of mechanical impact. This makes them ideal for use in a variety of automotive applications.

Temperature Control

Copper crush washers also provide temperature control. The natural properties of copper allow it to absorb and release heat more efficiently than other metals, helping to keep the temperature of your car’s engine within the optimum range. It reduces the risk of damage to your car’s engine and helps improve its performance.

Resists Corrosion

The copper in copper crush washers provides excellent corrosion resistance. This means that the washers are resistant to the elements, such as salt water, road salts, and other corrosive elements. Copper can also naturally resist oxidation, preventing the washers from rusting. This makes them an ideal choice for cars exposed to harsh weather conditions.

Disadvantages of Copper Crush Washers


Copper crush washers are much heavier than alternatives such as aluminum or nylon washers. Copper crush washers can add significant weight to the car’s suspension system and other components. This can lead to increased damage to the car’s suspension system and other parts.

Wrap Up

Aluminum and copper both have their advantages and disadvantages. Aluminum is lightweight, corrosion-resistant, and non-magnetic, whereas copper is strong and has excellent thermal and electrical conductivity. Ultimately, it comes down to personal preference and application when determining which type of crush washer is most suitable for car use.

Leave a Comment