High-Pressure Die casting materials

Die casting offers an efficient and low-cost solution for the mass production of complex parts,
however, the quality of the finished product depends on the materials used in the die casting process.
Selecting the right material with the right properties is critical to achieving the desired result.

Aluminum alloys

Die-casting aluminum alloys have good performance and process performance, so the die-casting of aluminum alloys has developed rapidly and has been widely used in various industrial sectors.

Material properties:

Strong and durable: Aluminum alloys are tough, hard, and resist corrosion. For instance, parts made from ADC12 are both sturdy and wear-resistant.
Efficient heat transfer: Aluminum alloys boast exceptional thermal conductivity. This efficiently spreads and dissipates heat, enhancing parts’ ability to withstand high temperatures.
Easy to mold: Aluminum alloys are highly fluid, allowing them to effortlessly fill molds and solidify rapidly to create desired parts. This ease of molding enables efficient mass production of numerous identical or diverse parts within a short timeframe.

common types: ADC7,ADC10, ADC12,ADC14 A380, A360, A353

Magnesium alloys

Magnesium alloy is an alloy composed of magnesium and other elements. The main alloying elements are aluminum, zinc, manganese, cerium, thorium and a small amount of zirconium or cadmium.

Material properties:

Light weight, high specific stiffness, high specific strength, strong thermal conductivity
Good machining performance, good impact resistance and compression resistance
Good die-casting performance, good dimensional accuracy and stability
Good regeneration, can be completely recycled
Low corrosion resistance, flammable and explosive

Mainly used in aerospace, military, automobile, motorcycle and 3C electronic products.

Type: AZ91D， AZ80M， AZ31B， AM60B， M2M

Zinc alloys

Zinc alloy is an alloy composed of zinc and other elements. Often added alloying elements are aluminum, copper, magnesium, cadmium, lead, titanium and other low-temperature zinc alloys.

Material properties:

Large specific weight; good casting performance, can die-cast precision parts with complex shapes and thin walls, and the surface of the castings is smooth;
Surface treatment methods: electroplating, spraying, painting, electrophoresis, polishing, etc.;
It has good mechanical properties and wear resistance at room temperature;
Poor corrosion resistance, not suitable for use in high or low temperature (below 0°C) environment

Mainly used in toys, lamps, decorations, auto parts, mechanical and electrical parts, electrical components and their casings.

Type: AZ91D, AZ80M, AZ31B, AM60B, M2M, etc.

Mechanical & physical properities

High pressure casting offers more options for machine designers and significant cost advantages in high volume manufacturing.
Our proprietary thin-wall aluminum technology makes aluminum die casting the best choice for more customers.

Aluminum alloys

Aluminum Alloy	Elongation	Tensile Strength	Yield Strength (0.2%)	Impact Strength	Shear Strength	Hardness	Density	Melting Point (Average +/- 50)	Thermal Conductivity	Coefficient of Thermal Expansion	Process
Aluminum Alloy	% in 50mm	MPa	MPa	J	MPa	Brinell (HB)	g/cm³	°C	W / m K	µm/m°K	Process
A380	3.5	324	160	4	190	80	2.71	566	96	21.8	Cold Chamber
383 (ADC12)	3.5	310	150	4	–	75	2.74	549	96	21.1	Cold Chamber
B390	1	317	250	–	–	120	2.71	580	134	18.0	Cold Chamber
A413	3.5	290	130	–	170	80	2.66	578	121	21.6	Cold Chamber
413	2.5	295	145	–	170	80	2.66	578	113	20.4	Cold Chamber
K-Alloy	5	295	172	–	–	80	2.63	680	113	–	Cold Chamber
A360	3.5 .5	317	170	–	180	75	2.63	577	113	21.0	Cold Chamber

Magnesium alloys

Magnesium Alloy	Elongation	Tensile Strength	Yield Strength (0.2%)	Impact Strength	Shear Strength	Hardness	Density	Melting Point (Average +/- 50)	Thermal Conductivity	Coefficient of Thermal Expansion	Process
Magnesium Alloy	in 50mm	MPa	MPa	J	MPa	Brinell (HB)	g/cm³	°C	W / m K	µm/m°K	Process
AZ91D	3	34	23	2	20	63	0.066	990	41.8	14.0	Hot Chamber

Zinc alloys

Zinc Alloy	Elongation	Tensile Strength	Yield Strength (0.2%)	Impact Strength	Shear Strength	Hardness	Density	Melting Point (Average +/- 50)	Thermal Conductivity	Coefficient of Thermal Expansion	Process
Zinc Alloy	% in 50mm	MPa	MPa	J	MPa	Brinell (HB)	g/cm³	°C	W / m K	µm/m°K	Process
Zamak 2	7	359	283	47	317	100	6.60	385	105	27.7	Hot Chamber
Zamak	10	283	221	58	214	82	6.60	384	113	27.4	Hot Chamber
Zamak 5	7	328	228	65	262	91	6.60	383	109	27.4	Hot Chamber
Zamak 7	13	283	221	58	214	80	6.60	384	113	27.4	Hot Chamber
ZA 8	10	374	290	42	275	103	6.30	390	115	23.3	Hot Chamber
ACuZinc5	5	407	338	–	–	115	6.85	452	106	24.1	Hot Chamber
EZAC	6.7	414	393	–	–	–	6.49	396	–	–	Hot Chamber
ZA 27 – Zinc Aluminum	3	425	376	12.8	325	119	5.00	431 /td>	123	26.0	Cold Chamber

How to Make the Right Choice

Different materials can bring different performance characteristics to structural parts, so we must be very careful when choosing materials.

First, we need to consider the application environment of the structural member. If structural parts are going to be used in extreme environments, then we need to choose materials that can withstand these environments.

For high-temperature environments, heat-resistant alloy materials are usually selected, such as copper alloys or aluminum alloys; while for low-temperature environments, stainless steel or other alloy materials are good choices.

Second, we need to consider the loading conditions of the structural members. If the structural parts need to withstand high-strength loads, we need to choose high-strength materials, such as aluminum alloys, magnesium alloys or titanium alloys. Conversely, if the structural part needs to withstand lighter loads, we can choose lightweight materials such as aluminum or magnesium.

Finally, we need to consider the cost of the structural components. Different materials have different prices, and some high-performance materials are more expensive, so we need to make a trade-off between material performance and cost.

For some structural parts with low load and low requirements, we can choose materials with lower prices, such as aluminum or zinc;

When choosing a material, there are many other factors to consider, such as material availability, machinability, etc. However, the above factors are the key considerations when selecting suitable die-casting structural parts materials.

By taking these factors into consideration, we can select the most suitable material to ensure the performance and service life of the structural part.

Relative Standard Data

Some standards related to die casting: ASTM B85 outlines the specifications; ISO 3522:2007 covers the chemical composition and mechanical properties of aluminum and aluminum alloys; ISO 8062:1994 indicates the tolerance of castings, including die casting.

Japanese Industrial Standards Data – Aluminum alloy die casting

Aluminium alloy ingots & castings for general engineering purposes

Designations&Chemical Composition Limits in the Form of Castings and Ingots

Japanese Industrial Standards Data – Magnesium alloy castings

NADCA Product Specification Standards for Die Casting

Other

Materials are an essential basic capability in the industry, and their development can promote technology and innovation and society’s development. The current trend of material development is to be more environmentally friendly and energy-saving.