DIE CASTING ALLOYS

By Siddharth Baraskar
PGTE 04116
1

INTRODUCTION
DIFFERENT ALLOY SYSTEMS
Aluminium alloys
Zinc alloys
Magnesium alloys
Copper alloys
Tin alloys
Lead Alloys
Ferrous alloys
2

IMPORTANCE
(GOVERNING FACTORS FOR SELECTION)

Cost
Die life
Physical properties flowability, corrosion
resistance, wear resistance, etc.
Mechanical properties tensile strength,
hardness, elongation, impact strength, etc.
Thermo-phy. properties thermal expansion,
melting range, density, sp. heat capacity, etc.
3

COST
Aluminium and Magnesium are abundant
but their extraction is a long process
making them costly.
Copper and Zinc are less abundant and are
less costly to extract. But their yield from
ore is less than 1% and in future we may
face problems in obtaining them.

DIE LIFE
Cold Chamber Process
There is less time exposure of the melt to the plunger
walls or the plunger. This is particularly uses metals
such as Aluminum and Copper that tend to easily alloy
with Iron at the higher temperatures.

Hot Chamber Process

The metals used for this process are of low melting
point and high fluidity such as Tin, Magnesium, Zinc,
and Lead that tend not to alloy easily with steel at their
melt temperatures.
5

Alloys used in die casting have freezing ranges, from a

few degrees for the zinc alloys with 4% aluminum to over
a hundred degrees for magnesium alloys.
Alloys

Liquidous Solidous

Freezing
Range

Zinc alloy (4.1% AI)

387

382

8%Si 605

577

28

10%Si 590

577

13

11%Si 585

577

12%Si 582

577

520

60

Aluminum-silicon alloys

Aluminum-silicon
copper alloy
(10.5% Si, 3.5% Cu)

580

Aluminum-magnesium
alloys
5%Mg

635

590

45

7,5% Mg

625

560

65

10.0% Mg

610

525

85

596

468

128

Brass (60% Cu, 39.5% Zn,

910
0.5% AI)

900

10

Aluminum bronze
(89% Cu, 10% AI, 1% Fe)

1053

1040

13

Lead alloy (5% Sb)

310

270

40

Magnesium alloy (9% AI)

Die insert making the outside shape of an aluminum

alloy die casting will be expected to last in good
condition over 150 000 shots.
If the die insert lasts more than 300 000 shots, it is a
sign of excellent design of part, tool and selection of
process parameters.
Magnesium has a similar melting point to that of
aluminum but it erodes die steels to a lesser extent, so
die lives are expected to be at least 25 per cent longer
for equivalent designs and production conditions.
Cu alloy pressure die inserts are usually made of
special materials which give greater resistance to high
temperature, but even so die lives of only 20 000 shots
are to be expected.

ALUMINIUM ALLOYS
Aluminium die castings are lightweight and can
withstand the highest operating temperatures of all die
cast alloys.
Ideal for demanding environments, they offer high
strength and rigidity along with good corrosion
resistance and heat dissipation.

Pure Aluminum is rarely cast due to high shrinkage,

and susceptibility to hot cracking.
Aluminum is cast at a temperature of 650 C (1200 F).
It is alloyed with Silicon 9% and Copper about 3.5%.
Silicon increases the melt fluidity, reduces
machinability. A high silicon alloy gives high wear
resistance.
Copper increases hardness and reduces the ductility.
By greatly reducing the amount of Copper the
chemical resistance is improved, formulated for use in
marine environments.
10

Alloy

A380

383

B390

ISO

Al-Si8Cu3Fe

AlSi17Cu4M
g

USA

ASTM

380

383

390

Europe

EN

46500

France

NF

A-S9U3A-Y4

Germany

DIN

G-AlSi8Cu3

Italy

UNI

5075

Norway

NS

Portugal

NP

Spain

UNE

Sweden

SIS

UK

BS

LM24

LM30

Japan

JIS

ADC10

ADC12

11

Common aluminum alloy systems for die casting :

Silicon

Copper

Tensile
Strength
MPa (ksi)

AA 380
(UNS A03800)

8.5 %

3.5 %

324
(47)

Fair easy to fill

AA 384
(UNS A03840)

11 %

4%

331
(48)

Easy to fill

AA 386
(UNS A03860)

9.5 %

0.6 %

317
(46)

Good corrosion
resistance

AA 390
(UNS A03900)

17 %

4.5 %

283
(41)

Good wear
resistance

Material

Properties

AMERICAN STANDARD SPECIFICATIONS

12

Aluminium alloy characteristics:

Highest operating temperatures
Outstanding corrosion resistance
Light weight
Very good strength and hardness
Good stiffness and strength-to-weight ratio
Excellent thermal conductivity
High electrical conductivity
Good finishing characteristics
Full recyclability
13

Aluminium Alloy A380 (LM24)

Alloy A380 is one of the most commonly specified
aluminium alloys, since it offers the best combination of
casting and mechanical and thermal properties. Fluidity,
pressure tightness and resistance to hot cracking are all
very good. Room temperature tensile strength is largely
retained up to temperatures in the order of 150C, and
approximately halved at 250C.
Machinability
Although the machinability of A380 alloy is considered
to be quite good, the alloy does have a tendency to be
somewhat abrasive due to the fairly high silicon content.
14

Corrosion resistance
Resistance to attack under normal atmospheric
conditions is fairly good. In marine atmospheres, or
under other severe conditions, castings should be
protected by painting.
Applications
Die castings in LM24 are suitable for most engineering
applications. It is used for a wide variety of products
including chassis for electronic equipment, engine
brackets, gearbox cases, household furniture, power and
hand tools.
15

Aluminium Alloy 383

This alloy is an alternative to A380 and is often specified
when very intricate components require improved die
filling characteristics and improved resistance to hot
cracking. 383 Alloy also has better corrosion resistance.

16

Aluminium Alloy B390 (LM30)

B390 is a aluminium-silicon alloy, which was originally
developed as a wear-resistant alloy for automotive
engine blocks. Resistance to wear is excellent. However,
the alloy has very low ductility with elongation around
1%.
Its use in other applications has expanded to include
valve bodies, compressor housings and other
components subject to abrasion and wear, such as
bearings.
Surface treatment systems actually allow engine pistons
to run directly on the alloy, opposing the need for iron
liners in the cylinder block. Machining of this alloy
requires special considerations.
17

Characteristic

Aluminium Die casting Alloy

A380

383

(LM24)

B390
(LM30)

Resistance to Hot Cracking A

Pressure Tightness

Die-filling Capacity B

Anti-Soldering to the Die F

Corrosion Resistance G

Machining Ease and Quality C

Polishing Ease and Quality E

Electroplating Ease and Quality D

Anodising (Appearance) H

Chemical Oxide Protective coating I

Strength at Elevated temperature J

Relative scale: 1 = most desirable, 5 = least desirable.

18

A Resistance to hot cracking. The ability of an alloy to withstand the stresses generated
during contraction, while cooling through the hot-short or brittle temperature change.
B Die-filling capacity. Ability of molten metal to flow readily in the die and fill thin sections.
C Machining ease and quality. A composite rating based on ease of cutting, chip
characteristics, quality of finish and tool life.
D Electroplating ease and quality. The ability of a diecasting to take and hold an
electroplate applied by standard methods.
E Polishing ease and quality. Composite rating based on ease and speed of polishing and
quality of finish, based on typical polishing procedure.
F Anti-soldering to the die. Ability of molten alloy to flow without sticking to the die
surfaces. Ratings given for anti-soldering are based on nominal iron compositions of 1%.
G Corrosion resistance. Based on resistance of alloy in a standard salt spray test.
H Anodising (appearance). Rated on lightness of colour, brightness, and uniformity of clear
anodised coating applied in sulphuric acid electrolyte. Generally aluminium diecastings are
unsuitable for light colour anodising where a pleasing cosmetic appearance is necessary.
I Chemical oxide protective coating. Rated on combined resistance of coating and base
alloy to corrosion.
J Strength at elevated temperature. Rating based on tensile and yield strengths at
temperatures up to 260C (500F), after prolonged heating at testing temperature.

19

Comparison Table of Casting Characteristics of Major

Aluminium Casting Alloys
BRITISH STANDARD SPECIFICATIONS

LM6

LM24

LM31

Tensile Strength (N/mm2)

160-190

180

215

Elongation (%)

1.5

Brinell Hardness

50-55

85

70

Density (g/cm3)

2.65

2.79

2.81

Freezing range (C approx.)

575-565

580-520

615-570

E = Excellent G = Good F = Fair P = Poor U = Unsuitable

20

LM6

LM24

LM31

Thermal Con (cal/cm2/cm/C @ 25degC)

0.34

0.23

0.35

Electrical Con (% copper std. @ 20C)

37

24

35

Machinability

Corrosion Resistance

Electro Plating Suitability

F (1)

Casting Characteristics

E = Excellent G = Good F = Fair P = Poor U = Unsuitable

1 = These alloys, containing Silicon, require a modification treatment for good adhesion
2 = Can be plated, but not recommended

21

Aluminium Alloy LM6

Alloy LM6 is another commonly specified aluminium
alloys. It offers good corrosion resistance properties with
excellent fluidity.
Tensile strength and hardness decrease fairly regularly
with increasing temperature and become relatively poor
at 250C.
Machinability
Alloys of this and similar compositions are rather difficult
to machine, due to their tendency to drag and to the
rapid tool wear caused by their high Silicon content.

22

Corrosion Resistance
LM6 exhibits excellent resistance to corrosion under both
ordinary atmospheric and marine conditions. For the
severest conditions, this property can be further enhanced
by anodic treatment.
Application and General notes
LM6 is suitable for most marine castings, water-cooled
manifolds and jackets, motor car and road transport
fittings, thin section and intricate castings such as motor
housings, meter cases and switch boxes, for very large
castings, e.g. cast doors and panels where ease of casting
is essential, for chemical and dye industry castings, e.g.
pump parts, and for paint industry and food and domestic
castings. It is especially suitable for castings that are to be
welded.
23

Other major alloying elements

The aluminium alloys with lower magnesium content
can be pressure die cast. Heat treatment to improve
mechanical properties is possible with the AI-Mg8 and
AI-Mg10 alloys.
The most widely used alloy system in which
magnesium is present at a relatively low but very
important level is the AI-Si-Mg0.3 type. The alloy
shows a good combination of castability, mechanical
properties and corrosion resistance and is widely used
in general engineering and for aluminum wheels.

24

Where high strength and high ductility are required it is

common to find iron contents of 0.2% or less being
specified. In pressure die casting, iron helps to prevent
the soldering which causes castings to stick in the die.
Manganese up to 0.5% is alloyed.
The embrittling effect of iron can be countered by
manganese additions which change the structure of the
intermetallic phase.
Nickel is limited to a maximum of 0.5% or even lower
limits. It improves the high temperature strength of the
alloy.
25

Machinability Ratings of the Common

Aluminum Casting Alloys
Rating
Group

Alloys

Class A

AI-Mg5, AI-Mg10,AI-Cu10-Si2

ClassB

AI-Si5-Cu3, AI-Si6-Cu4-Zn,
Cu3, AI-Si7-Mg0.3,

AI-Si8-

AI-Si9-Cu3-Mg, AI-Si7-Cu2
Class C

99.5AI, AI-Si 1 0-Cu2-Fe, AI-Si 12-Mg,

AI-Si 11-Mg-Cu

Class D

AI-Si12, AI-Si12-Fe. AI-Si5

Alloys in Class A are easiest to machine, the

machinability decreasing through to Class D.
26

APPLICATIONS

27

HUB

BRAKEDRUM

CRANKCASE
COVER
HUB
COVER

TRANSMISSION
CASE

CRANKCASE
28

CYLINDER HEAD

CYLINDER BLOCK

CYLINDER HEAD COVER

29

30

ZINC ALLOYS
Zinc can be made to close tolerances and with thinner
walls than Aluminum, due to its high melt fluidity.
Zinc is alloyed with Aluminum (4%), which adds
strength and hardness.
The casting is done at a fairly low temperature of
425 C (800 F) so the part does not have to cool
much before it can be ejected from the die. This, in
combination with the fact that Zinc can be run using a
hot chamber process allows for a fast fill, fast cooling
(and ejection) and a short cycle time.
31

Zinc Alloy Characteristics:

High strength and hardness
Excellent electrical conductivity
High thermal conductivity
Lowest cost raw material
High dimensional accuracy and stability
Excellent thin wall capability
Ability to cold form, which eases joining
High quality finishing characteristics
Outstanding corrosion resistance
Full recyclability
32

Common Zinc Alloys

Characteristic

Zamak
Diecasting Alloy

ZA Diecasting Alloy

ZA-8

ZA-12

ZA-27

Resistance to Hot
Cracking

Pressure Tightness

Casting Ease

Part Complexity

Dimensional
Accuracy

Dimensional
Stability

Relative scale: 1 = most desirable, 5 = least desirable.

33

Characteristic

Zamak Diecasting
Alloy

ZA Diecasting Alloy

ZA-8

ZA-12 ZA-27

Corrosion
Resistance

Machining Ease and

Quality

Polishing Ease and

Quality

Electroplating Ease
and Quality

Anodizing (Protection)

Chemical Coating

(Protection)
Relative scale: 1 = most desirable, 5 = least desirable.

34

Zinc Alloy 2 (Al 3.5-4.3%, Cu 2.5-3.0%)

Zinc Alloy 2 is sometimes referred to as Kirksite. This
alloy offers the highest strength and hardness of the
family. However, due to the high copper content (3%),
changes to the material properties occur with long-term
ageing.
Although this alloy exhibits excellent casting
characteristics, it has seen limited use by diecasters. Its
creep performance is rated higher than the other zinc
alloys and it maintains higher strength and hardness
levels after long-term ageing.
Designers of structural components should be aware of
the creep limitations of zinc alloys, which do not have a
single value for elastic modulus or yield strength.
35

Zinc Alloy 3 (Al 3.5-4.3%, Cu 0.25%max.)

No. 3 Alloy is the most widely used zinc alloy in North
America.
Its excellent balance of desirable physical and
mechanical properties, superb castability and longterm dimensional stability are the reasons why most
diecastings are made from this alloy.
No. 3 Alloy also offers excellent finishing
characteristics for plating, painting and chromate
treatments. In terms of diecasting, it is the standard
by which other zinc alloys are rated.
This alloy exhibits excellent damping capacity and
vibration reduction in comparison with aluminium die
casting alloys.
36

Zinc Alloy 5 (Al 3.5-4.3%, Cu 0.75-1.25%)

No. 5 Alloy is the most widely used zinc alloy in Europe,
with its higher copper content resulting in higher strength
and increased hardness at the expense of some loss of
ductility (increased elongation) compared to Alloy 3. This
can affect formability during secondary operations such
as bending, riveting, swaging or crimping operations.
However, when a measure of tensile performance is
needed, alloy 5 castings are recommended.
This alloy is readily plated, finished and machined,
comparable to alloy 3.
Where temperatures above normal are involved and the
component has to undergo structural loads, Alloy 5 is
likely to be a better choice.
37

Zinc Alloy 7 (Al 3.5-4.3%, Cu 0.25%max.)

Alloy 7 is a modification of Alloy 3. It is a high-purity
alloy containing lower magnesium content and has a
tighter impurities specification. This results in improved
casting fluidity, ductility and surface finish. Most alloy 7
is used for special hardware applications, or when
castings require extra formability. The higher fluidity
also allows thinner walls and intricate detail to be cast.
In order to avoid excessive flashing along the tool
parting lines, good die fit and close control of casting
process parameters is necessary.
The high ductility exhibited by this alloy also has an
impact on processing, but mainly in secondary
operations for flash removal and trimming.
38

Zinc Alloy ZA-8 (Al 8.0-8.8%, Cu 0.8-1.3%max.)

The ZA alloys contain significantly more aluminium
than the Zamak group of alloys.
It is particularly suitable for decorative applications.
Although this alloy does not exhibit quite as good
casting characteristics as the other zinc alloys, it
offers significantly improved strength, hardness and
creep properties.
In terms of mechanical performance, this alloy has
the highest creep strength of any zinc alloy and the
highest strength of any hot-chamber diecast zinc
alloy. ZA-8 contains approximately 8.4% aluminium
and is the only ZA alloy that can be hot-chamber
diecast.
39

Zinc Alloy ZA27 (Al 25-28%, Cu 2.0-2.5%max.)

ZA-27 contains approximately 27% aluminium. Due to
the high aluminium content of this alloy, it must be
cold-chamber die cast.
This alloy has the highest strength, and the lowest
density of the ZA alloys. ZA-27 provides the highest
design stress capability at elevated temperatures of all
the commercially available zinc-based alloys.
This alloy also has excellent bearing and wear
resistance properties.

40

Zinc Alloy ACuZinc5

(Al 2.8-3.3%, Cu 5.0-6.0%)
This is an alloy researched and developed by General
Motors, which exhibits greatly improved strength,
hardness and creep performance due to the high
copper and low aluminium contents. This alloy also
has excellent bearing properties.

41

Comparison Table of Casting Characteristics of Major

Zn Alloys

ZA3

ZA12

ZA27

Tensile Strength (N/mm2)

283

276-310

400-440

Elongation (%)

15

3-4

3-6

Brinell Hardness

83

105-125

110-120

Density (g/cm3)

6.7

6.03

5.0

Freezing range (C approx.) 387-382

430-380

490-380

Thermal Con. (cal/cm2/cm/C 0.27

@ 25C)

0.21

(112.5)

Electrical Con. (%copper std. 26

@ 20C)

25

28

E = Excellent G = Good F = Fair P = Poor U = Unsuitable

42

ZA3

ZA12 ZA27

Machinability

Corrosion Resistance

Electro Plating Suitability

Non Spark

Yes

Yes

No

Casting Characteristics - Sand G

Casting Characteristics - Gravity

High E

Casting CharacteristicsPressure

E = Excellent G = Good F = Fair P = Poor U = Unsuitable

43

APPLICATIONS

44

45

46

47

MAGNESIUM ALLOYS
Magnesium is the ideal material for applications
where weight saving is a priority, having the lowest
density of all structural metals.
Almost as light in weight as plastic, magnesium has
the advantage of greater strength and rigidity along
with inherent EMI shielding, durability, heatdissipation and full recyclability.

48

Magnesium Alloy Characteristics:

The lightest of all structural metals
Excellent stiffness and strength-to-weight ratio
Outstanding EMI shielding properties
High conductivity, electrical and thermal
Withstands high operating temperatures
Cost-effective against plastics
High dimensional accuracy and stability
Exceptional thin wall capability
Good environmental corrosion resistance
Good finishing characteristics
Full recyclability

49

Characteristic

Magnesium Die casting Alloy

AZ91D

AM60A

Resistance to Cold Defects

Pressure Tightness

Resistance to Hot Cracking

Machining Ease and Quality

Electroplating Ease and Quality

Surface Treatment

Die Filling Capacity

Anti-Soldering to the Die

Corrosion Resistance

Polishing Ease and Quality

Chemical Oxide Protective Coating

Strength at Elevated Temperatures

Relative scale: 1 = most desirable, 5 = least desirable.

50

Magnesium Alloy AZ91D

(Approx. 10% Al + Zn,Cu,Si,Mn,Fe,Ni less than 0.3%
each)
Alloy AZ91D is the most widely specified magnesium die
casting alloy. This high-purity alloy has an excellent
combination of mechanical properties, corrosion
resistance, and castability. Corrosion resistance is
achieved through the enforcement of very strict limits on
three metallic impurities: iron, copper and nickel. These
are limited to very low levels making it necessary to use
primary magnesium in the production of this alloy. As
with all magnesium alloys, special precautions must be
taken when machining.
51

Magnesium Alloy AM60A

(Approx. 6% Al + Zn,Cu,Si,Mn less than 0.3 % each)
Magnesium alloy AM60A is used in applications
requiring good elongation, toughness and impact
resistance combined with reasonably good strength and
excellent corrosion resistance.
The increased ductility exhibited by this alloy is a
consequence of the reduced aluminium content.
However this also results in a reduction of strength and
poorer castability. As with all magnesium alloys, special
precautions must be taken when machining.

52

Effects of Temperature, Time and Environment on

Mechanical Properties of Magnesium alloys
It is important that when designers are selecting the
appropriate magnesium alloy for a particular
environment that all of the factors are considered. In
addition to environmental effects, there is a change in
the metallurgical structure of the alloy over a period of
time, and/or at elevated temperatures, that affects the
mechanical properties. So, creep is an important
consideration in magnesium parts for elevated
temperature use, stresses and times of operations
should be known for both peak and normal conditions.

53

APPLICATIONS

54

SMALL PARTS
CUTTING M/C COVER

MOTORCYCLE REAR COVER

MOTORCYCLE PARTS

55

SHELLS FOR IT PRODUCTS

STEERING WHEEL

56

COPPER ALLOYS
The preferred alloys for diecasting are basically those
with good fluidity and low melting point to reduce die
wear and good hot tear resistance to overcome the
stresses arising during solidification.
The alloys with about 40 per cent zinc are suitable for
diecasting. The addition of further alloying elements
may alter the proportion of each phase.

57

Common additives:
Lead is added to improve machinability.
Aluminum provides resistance to oxide formation by
producing a surface film of aluminum oxide on the
brass in both the molten and solid states.
In low concentrations silicon reduces loss of zinc and
improves fluidity.
Iron is a common impurity. It increases strength but is
detrimental to corrosion resistance and can produce
hard spots if it segregates.
Manganese also increases strength and its presence
increases the amount of iron that can be taken into
solution.
Tin can improve mechanical properties. Tin lowers the
melting point and increases fluidity.

58

Copper alloys for die casting

Compositions shown as % maximum unless shown as a range or minimum
Specification Cu

Zn

Sn

Pb

Ni

Fe

Mn

Si

US alloys
C 85800

57min

Bal

1.5

1.5

0.50

0.55

0.25

0.25

C 86500

55-60

36-42

1.5

0.30

0.8

2.5

1.5

--

C 86800

54-57

31-39

1.5

0.20

0.8

2.5

2.54.0

--

C 87800

80-83

12-16

0.25

0.15

0.20

0.25

0.15

3.8-4.2

C 81900

63-67

30-36

0.25

0.25

0.50

0.50

0.15

0.751.2

C99750

55-61

17-23

0.35

2.5

5.0

1.5

17-23

-59

Specification

Cu

Zn

Sn

Pb

Ni

Fe

Mn

Si

DCB1

59-63

Bal

--

--

--

--

--

DCB3

58-63

Bal 1.0

0.5-2.5

1.0

0.8

0.5

0.05

PCB1

57-60

Bal 0.5

0.5-2.5

--

0.3

--

--

HTB1

55min Bal 1.0

0.50

1.0

A Metal1

64.5

Bal 1.0

2.5

OM Metal2

63.5

Bal 0.5

Bronwite3

59.5

Bal 0.5

UK alloys
0.25

0.7-2.0 3.0'

0.10

--

0.15

0.3

0.5

2.0

--

0.5

0.5

0.7

1.5

--

0.5

19.5

60

Proprietary
alloys

0.5

The rate at which the die deteriorates

depends mainly upon the following factors:
1.Casting design is probably most important.
2.Most of the crazing occurs in the area of the gate and
it is found to be advantageous if the direction of feed is
along the casting wall rather than across the wall.
3.The surface temperature of the die affects the
process in two ways. Higher die temp. reduces temp.
gradient and lower die temp. reduces thermal fatigue
4.Pouring temperature should be controlled.

61

Points to remember:
1. Component design should avoid, as far as possible,
changes in wall thickness.
2. Allowances for subsequent machining should not exceed
0.5 mm.
3. Gating should be into the thicker sections and along the
wall of the component, avoiding turbulence.
4. Maximum injection pressures should be used. Pressures
up to 2000 kg/ cm2 are commonly applied.
5. The cavity should be well vented. Vents up to 0.2 mm
deep and 10 mm wide are provided along the parting
surface.
6. Slug length should be at least 25 mm to ensure pressure
is maintained at the gate until it solidifies.
7. The slowest injection speed that avoids misruns, etc.,
should be used.
62

APPLICATIONS
Copper alloys are used in plumbing, electrical and marine
applications where corrosion and wear resistance is important.

63

Brass PDCs for

automobiles:
1
3

1,3,7 and 8 are

gearbox parts;

4 and 6 are
battery parts;
6

2 connecting
lever;
5 heating valve.

64

Brass PDCs
for plumbing
and sanitary
fittings

65

Parts for sprinkler and pump

Water circulator rotors

66

Minimum wall thicknesses and minimum draft

angles for die casting are :
Min. Thickness
mm (in)

Min. Draft Angle ()

Aluminum
alloys

0.9 mm
(0.035 in)

0.5

Zinc alloys

0.6 mm
(0.025 in)

0.25

Copper alloys
(Brass)

1.25 mm
(0.050 in)

0.7

Material

67

Typical Mechanical Properties

Aluminum

Brass

Magnesium

Zinc

Tensile strength,
(Mpa)

324

400

235

280-420

Yield strength, (MPa)

228

200

160

220-370

Shear strength,
(MPa)

200

260

138

215-325

Fatigue strength,
(MPa)

140

170

80

48-145

Elongation,
(% in 50 mm)

1-4

20

3-8

2 - 13

65 - 120

133

63

80-120

Hardness (Brinell)

68

Aluminum

Brass

Magnesium

Zinc

2.7

8.4

1.8

6.7

Melting Range (oC)

510-650

880-900

470-615

380-460

Thermal conductivity,
(W/moC)

96-134

109

62-72

100-125

20.0

21.0

27.0

27.4

Electrical conductivity,
(%IACS)

27

26

12

27

Modulus of elasticity,
(GPa)

71

100

45

85.5

3-6

16

3-6

48-65

Density (gm/c.c.)

Coeff. of Thermal
expansion,(m/m/oC)

Impact strength (J)

69

Finishing: Decorative
Aluminum

Brass

Magnesium

Zinc

Chrome plating

Fair

Excellent

Fair

Excellent

Black chrome plating

Fair

Excellent

--

Excellent

Colored plating

Fair

--

--

Excellent

Mechanical-polishing
& buffing

Excellent

Excellent

Excellent

Excellent

Lacquers, enamels,
epoxies & acrylics

Excellent

Excellent

Excellent

Excellent

Fair

--

--

--

Anodizing

70

Protective
Aluminum

Brass

Magnesium

Zinc

Anodizing-corrosion &
abrasion protection

Excellent

--

Good

Excellent

Chromate conversioncorrosion

Excellent

--

Excellent

Excellent

Heavy paint, wrinkle,

matte finishes-abrasion,
corrosion protection & to
hide imperfections

Excellent

Excellent

Excellent

Excellent

The most satisfactory methods of finishing each specific metal.

71

Processing and Production

Machine Types:

Aluminum

Brass

Magnesium

Zinc

Hot chamber (Plunger)

No

No

Yes

Yes

Cold chamber

Yes

Yes

Yes

Yes

40-200

40-200

75-400

200550

125

20

200

500

Production range,
shots/hr
Average tool life, no. of
shots x 1000

72

Characteristics of Die Casting Alloys

Aluminum

Brass

Magnesium

Zinc

Dimensional
stability

Good

Excellent

Excellent

Good

Corrosion
resistance

Good

Excellent

Fair

Fair

Casting ease

Good

Fair

Good

Excellent

Part complexity

Good

Fair

Good

Excellent

Dimensional
accuracy

Good

Fair

Excellent

Excellent

Medium

High

Medium

Low

Machining cost

Low

Medium

Low

Low

Finishing cost

Medium

Low

High

Low

Die cost

73

SOURCES:
The Die Casting Book by Arthur Street
www.dynacast.com
www.mrt-castings.co.uk
www.IndianIndustry.com
www.China-magnesium.com

(Yongkang Tesheng Wheel Co.)

www.eazall.com

(Eastern Alloys Co.)

www.us.sgs.com

(Premier Die Casting Co.)

www.Key-to-Metals.com
74

THANK YOU

75