Aluminum vs. Copper/Brass
Aluminum prevails as the most common material used for passenger car and light truck radiators today. Though you may think aluminum radiators are relatively new, the first ones were used way back in 1913 by Rolls Royce. Copper/brass has been the material of choice for most radiators until recently because of its superior ability to conduct heat (twice as good as aluminum), greater strength/corrosion resistance and lower cost.
In the 1960s General Motors introduced aluminum radiators on the Corvette as a means of reducing weight. A typical radiator that weighs 15 lbs. in copper/brass weighs only about five and a half pounds when made of aluminum. European auto makers began using some aluminum radiators in the 1970s, but use here was very limited until the 1980s when the push to improve fuel economy began to tip the scales in favor of aluminum because of its lighter weight.
Ford started what would soon become a full-scale transition to aluminum radiators with the Escort/Lynx and Tempo/Topaz. General Motors put aluminum radiators in its then-new front-wheel drive X-cars (Chevy Citation, Pontiac Phoenix, Olds Omega and Buick Skylark). Since then the use of aluminum has steadily grown. Today, Ford uses aluminum radiators in nearly all of its cars and light trucks. General Motors is also using mostly aluminum. Chrysler made the switch with the introduction of its LH-cars (Dodge Intrepid, Chrysler Concord and Eagle Vision), restyled Ram series trucks and latest minivan. Among the Japanese manufacturers, the use of aluminum has also been rapidly expanding with Nissan and Toyota leading the way.
In 1985, only about 24 percent of all new domestic and import vehicles were equipped with aluminum radiators. Today, that percentage is well above 90 percent....................................
..............................................Aluminum is more vulnerable to electrolytic corrosion than either copper/brass or cast iron because aluminum is a highly reactive metal. When the corrosion inhibitors are used up and the pH of the coolant drops to 7 or below, aluminum becomes a sacrificial anode and is eaten away.
This same type of corrosion can also occur even when the coolant is in good condition if the engine does not have a good ground connection. Voltage from the charging system will flow through the coolant to ground, creating electrolysis corrosion that attacks the components in the cooling system.