DIE CASTING ALLOYS

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

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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.

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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.

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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.

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CLASSIFICATION OF DIE CASTING ALLOYS

High Fusion Alloys

The alloys having a melting point temperature more

than 500 degrees come under this group, they are – Al;
Mg; & Cu alloys.

Low Fusion Alloys

The alloys having a melting point temperature less

than 500 degrees fall under this group, & they are Zn;
Sn; Pb alloys.
 DIE CASTING ALLOYS
The most commonly used alloys are,

Aluminium Alloys :-
LM-2; LM-4; LM-6; LM-24;

Zinc Alloys :-
Mazak – 3; Mazak – 5

Magnesium Alloys:-
Mg-Al-91 & Mg-Al-911

Copper Based Alloys:-

A; B; & C Categories
DESIRED PROPERTIES OF DIE CASTING ALLOYS

 Good Mechanical Properties:

 Tensile strength (Resistance to breaking under tension)
 Ductility (Can be easily casted)
 Hardness
 Should have good dimensional stability
 Should have low melting point
 Less & Even shrinkage
 Should be corrosion resistance & acidic resistance
 Ability to take up finishing(Plating; Painting)
 It’s adaptability to casting process (i.e.) castability & fluidity
 All the above properties are not found in single alloy. Selection of alloy depends on its
suitability for the operation to perform.

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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.

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 ALUMINIUM ALLOYS

The chemical composition in % of various grades of Al alloys are ,

IS617 BS Cu Si Mg Fe Mn Ni Zn Pb Sn Al
1959 149
A – LM-2 0.7- 9.0- 0.3 1.0 0.5 1.0 1.2 9.3 0.3 rest
2M 2.5 11.4
A – LM-4 2.0- 4.0- 0.15 0.8 0.3- 0.3 0.5 0.1 0.005 rest
4M 4.0 6.0 0.7
A – LM-6 0.1 10-13 0.10 0.6 0.5 9.1 0.1 0.1 0.1 rest
6M
A– LM- 3.0- 7.5- 0.10 0.3 0.5 0.5 1.0 0.3 0.2 rest
8M 24 4.0 9.5
MECHANICAL & PHYSICAL PROPERTIES OF Al ALLOYS

PROPERTY UNITS LM2 LM4 LM6 LM24

Brinell Hardness BHN 65 75 80 80

Tensile Strength Kg/mm^2 22 24 26 27

Melting Point centigrade 595 616 580 585

Solidification Point centigrade 570 520 570 525

Casting centigrade 660-720 640-700 630-710 650-720

Temperature
Shrinkage % 0.6 0.6 0.6 0.6

Specific Gravity or gms/cc 2.7 2.77 2.65 2.75

Density
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

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APPLICATIONS

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 BRAKEDRUM

HUB

CRANKCASE
COVER
HUB
COVER

TRANSMISSION
CASE CRANKCASE

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 CYLINDER HEAD

CYLINDER BLOCK

CYLINDER HEAD COVER

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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 ºC (800 ºF) 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.

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 ZINC ALLOYS
The chemical composition in % of various grades of Zn alloys are,

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MECHANICAL & PHYSICAL PROPERTIES OF Zn Alloy

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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

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APPLICATIONS

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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, heat-
dissipation and full recyclability.

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 MAGNESIUM ALLOYS

The chemical composition in % of various grades of Mg alloys are,

Alloy Al Zn Mn Si Cu Fe Mg
Grade

Mg-Al-91 7.70- 0.10- 0.10-0.50 0.30 0.20 --- Rest

8.80 0.80

Mg-Al- 7.6- 0.10-1.0 0.10-0.50 0.40 0.35 0.0003- Rest

911 10.0 0.001

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MECHANICAL & PHYSICAL PROPERTIES OF Magnesium ALLOY

PROPERTY UNITS Mg Al --91 Mg Al –911

Brinell BHN 55 55
Hardness
Tensile Kg/mm^2 16-23 15-22
Strength
Melting Point centigrade 599 599
Casting centigrade 620-670 620-670
Temperature
Shrinkage % 0.6 0.6
Specific Gms/cc 1.8 1.82
Gravity or
Density

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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

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APPLICATIONS

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 SMALL PARTS

CUTTING M/C COVER

MOTORCYCLE PARTS
MOTORCYCLE REAR COVER

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SHELLS FOR IT PRODUCTS

STEERING WHEEL

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COPPER ALLOYS
Cu based alloys brass & bronze

Provides best mechanical properties than any of the die casting alloy.

Expensive.

High strength & toughness

Good wear resistance

Excellent corrosive resistance

Major disadvantage shorter die life –

 due to thermal fatigue of the dies @ higher casting temp.

For complex parts – high die cost Add substantially to manufacturing

cost.

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 COPPER ALLOYS

The chemical composition in % of various grades of Mg alloys are

Alloy Cu Si Pb Sn Mn Al Fe Mg Zn Other
Grad
e
A 57.0 0.25 1.50 1.50 0.25 0.25 0.3 0.5
Min Max Max Max Max Max 0 max
Min
B 63.0- 0.75- 0.25 0.15 0.15 0.15 0.15 0.5 Res --
67.0 1.25 Max Max Max Max Max 0 t
Max
C 80.0- 3.75- 0.15 0.25 0.15 0.15 0.1 0.1 Res 1.25
83.0 4.25 Max Max Max Max Max 5 t
Max
D

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 ADVANTAGES OF Cu ALLOYS

 Excellent Mechanical Properties

 Good Thermal & Electrical Properties

 Good Resistance to corrosion

 DISADVANTAGES

 High melting point

 Die Life is short

 High Density

 Poor castability

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

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Brass PDCs
for plumbing
and sanitary
fittings

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 2

Brass PDCs for

automobiles:
1 4 1,3,7 and 8 are
3 gearbox parts;
4 and 6 are
battery parts;
2 connecting
7 5
6 lever;
5 heating valve.

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Brass PDCs
for plumbing
and sanitary
fittings

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Parts for sprinkler and pump

Water circulator rotors

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Minimum wall thicknesses and minimum draft
angles for die casting are :

Min. Thickness
Material Min. Draft Angle (º)
mm (in)
Aluminum 0.9 mm
0.5
alloys (0.035 in)
0.6 mm
Zinc alloys 0.25
(0.025 in)
Copper alloys 1.25 mm
0.7
(Brass) (0.050 in)

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 Typical Mechanical Properties

Aluminum Brass Magnesium Zinc

Tensile strength,
324 400 235 280-420
(Mpa)

Yield strength, (MPa) 228 200 160 220-370

Shear strength,
200 260 138 215-325
(MPa)
Fatigue strength,
140 170 80 48-145
(MPa)
Elongation,
1-4 20 3-8 2 - 13
(% in 50 mm)

Hardness (Brinell) 65 - 120 133 63 80-120

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 Aluminum Brass Magnesium Zinc
Density (gm/c.c.) 2.7 8.4 1.8 6.7
Melting Range (oC) 510-650 880-900 470-615 380-460
Thermal
conductivity, 96-134 109 62-72 100-125
(W/moC)
Coeff. of Thermal
expansion,(Чm/m/oC) 20.0 21.0 27.0 27.4

Electrical
conductivity, 27 26 12 27
(%IACS)
Modulus of elasticity,
71 100 45 85.5
(GPa)
Impact strength (J) 3-6 16 3-6 48-65
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 Finishing: Decorative
Aluminum Brass Magnesium Zinc

Chrome plating Fair Excellent Fair Excellent

Black chrome plating Fair Excellent -- Excellent

Colored plating Fair -- -- Excellent

Mechanical-polishing Excellent Excellent Excellent Excellent

& buffing
Lacquers, enamels, Excellent Excellent Excellent Excellent
epoxies & acrylics
Anodizing Fair -- -- --

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 Protective
Aluminum Brass Magnesium Zinc

Anodizing-corrosion & Excellent -- Good Excellent

abrasion protection
Chromate conversion- Excellent -- Excellent Excellent
corrosion
Heavy paint, wrinkle, Excellent Excellent Excellent Excellent
matte finishes-abrasion,
corrosion protection & to
hide imperfections

The most satisfactory methods of finishing each specific metal.

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 Processing and Production
Machine Types: Aluminum Brass Magnesium Zinc

Hot chamber No No Yes Yes

(Plunger)
Cold chamber Yes Yes Yes Yes

Production range, 40-200 40-200 75-400 200-

shots/hr 550
Average tool life, no. 125 20 200 500
of shots x 1000

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 Characteristics of Die Casting Alloys
Aluminu Brass Magnesiu Zinc
m m
Dimensional Good Excellent Excellent Good
stability
Corrosion Good Excellent Fair Fair
resistance
Casting ease Good Fair Good Excellent

Part Good Fair Good Excellent

complexity
Dimensional Good Fair Excellent Excellent
accuracy
Die cost Medium High Medium Low
Machining cost Low Medium Low Low

Finishing cost Medium Low High Low

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