Material Selection

The main die casting alloys are: aluminium, zinc, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is also possible. Specific die casting alloys include: zinc aluminium; aluminium to, e.g. The Aluminum Association standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium. The following is a summary of the advantages of each alloy:
1. Aluminium: lightweight; high dimensional stability for very complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at high temperatures.
2. Zinc: the easiest metal to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.
3. Magnesium: the easiest metal to machine; excellent strength-to-weight ratio; lightest alloy commonly die cast.
4. Copper: high hardness; high corrosion resistance; highest mechanical properties of alloys die cast; excellent wear resistance; excellent dimensional stability; strength approaching that of steel parts.
5. Silicon tombac: high-strength alloy made of copper, zinc and silicon. Often used as an alternative for investment cast steel parts.
6. Lead and tin: high density; extremely close dimensional accuracy; used for special forms of corrosion resistance.
As of 2008, maximum weight limits for aluminium, brass, magnesium, and zinc castings are estimated at approximately 70 pounds (32 kg), 10 lb (4.5 kg), 44 lb (20 kg), and 75 lb (34 kg), respectively. By late-2019, press machines capable of die casting single pieces over-100 kilograms (220 lb) were being used to produce aluminium chassis components for cars.

Material Selection