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Brief Introduction of Different Die Casting Alloys

Introduction of Die Casting Alloy

The alloys usually selected for die casting are aluminum alloy, magnesium alloy, and zinc alloy. Other metal alloys can also be used for die castings, such as copper alloy, brass alloy, tin alloy, and lead alloy, but these alloys are rare used in the die casting industry and are specialty materials. Since we are dealing with elements in alloys or mixtures, you will find metal die castings that contain multiple metals. Each alloy has different properties, which makes it suitable for different types of applications.

Die Casting Aluminum Alloy

Aluminum alloy die casting was mainly used in surgical instruments in the early stage, but now it is also widely used in auto parts and gears. They are generally stronger and lighter than most zinc-based materials but tend to be more expensive to manufacture. The use of aluminum alloy can reduce the need for finishing such as electroplating. Common grades are made of a mixture of 92% aluminum and 8% copper. Magnesium can be added to the alloy to increase its tensile strength from about 21,000 pounds per square inch to about 32,000 per square inch, while nickel alloy can be added to increase stiffness and provide a higher surface finish. The melting point of aluminum casting alloy is about 1150 degrees Fahrenheit.

Aluminum Die Casting Characteristics

  • Higher working temperature
  • Excellent corrosion resistance
  • Lightweight
  • Good strength and hardness
  • Good stiffness and strength to weight ratio
  • Excellent EMI and RFI shielding performance
  • Excellent thermal conductivity
  • High conductivity
  • Good finishing properties
  • Fully recyclabe capacity

Aluminum Die Casting Advantages

One of the most significant advantages of custom aluminum die casting parts is that compared with other die casting alloys, it makes lighter parts and has more surface treatment options. Aluminum can also withstand the highest operating temperature of all die-cast alloys. Besides, cast aluminum is versatile and corrosion-resistant. The thin wall can maintain high dimensional stability, and aluminum alloy can be applied in most industries.

Aluminum Die Casting Applications

Aluminum castings improve the fuel efficiency of automobiles by meeting lightweight requirements.

Because of the RF filter box and housing need to dissipate heat, aluminum die casting alloy is widely used in network and infrastructure equipment in the telecommunications and computing industries.

In handheld devices, aluminum castings provide EMI/RFI shielding with minimal weight, robustness, and durability.

Because aluminum has excellent electrical properties and shielding properties, even in high-temperature environments, die-cast aluminum is an ideal choice for electronic connectors and housings.

Die Casting Zinc Alloy

In addition to aluminum, zinc alloy is another popular metal alloy in die casting. When customizing die casting products for aesthetic purposes, zinc die castings are often the best choice. The material can be electroplated or sprayed as required. It also provides a smooth surface for processing. Zinc casting alloy enables manufacturers to produce components with customized aesthetic qualities and strict and narrow tolerances for shape and form.

Zinc Die Casting Characteristics

  • High strength and hardness
  • Excellent conductivity
  • High thermal conductivity
  • Low-cost raw materials
  • High dimensional accuracy and stability
  • Excellent thin wall ability
  • The ability of cold forming makes it easy to connection
  • High-quality finishing characteristics
  • Excellent corrosion resistance
  • Fully recyclable

Zinc Die Casting Advantages

Die casting zinc alloy has a low melting point, which means less energy for production. The low melting point helps extend the mold service life, which is another key factor in the value of die casting to medical equipment.

Finally, the corrosion resistance of precision casting zinc alloy is impressive, and the thermal conductivity is higher. Therefore, this material is durable, strong, and stable.

Zinc Die Casting Applications

Intricate reticulated zinc housing with precise thin walls, zinc die casting alloy providing excellent electrical performance and shielding performance.

Our proprietary multi-slide die-casting process and excellent thin-wall capability make us the premier supplier of zinc components for various consumer electronic equipment.

Zinc’s castability, wear-resistance, and structural integrity make it ideal for creating multi-faceted, highly complex shapes for the automotive safety and electronics industry.

Die Casting Magnesium Alloy

Magnesium die casting alloy is another metal alloy commonly used in die casting. Magnesium alloy is the easiest alloy to produce, it has an excellent strength-to-weight ratio, and is the lightest alloy usually die-casted.

Magnesium Die Casting Characteristics

Magnesium casting alloys have various unique characteristics, such as excellent fluidity, less sensitivity to hydrogen pores, and better castability compared to other cast metals such as aluminum and copper. Magnesium also has EMI and RFI shielding performance, which is very suitable for connectors and electrical enclosures.

Magnesium Die Casting Advantages

There are many advantages to casting with magnesium. Magnesium is not only the lightest alloy but also has excellent stiffness and strength-to-weight ratio. Besides, it has excellent EMI and RFI shielding performance, which is very suitable for connectors and electrical enclosures. It can also be used in medical and laboratory equipment to protect other interference signals in hospital wards.

Magnesium Die Casting Applications

Magnesium has a wide range of applications. In addition to connectors and electrical enclosures, magnesium alloy is often used in medical and laboratory equipment, because it can prevent signal interference.

Magnesium alloy is also 75% lighter than steel, but its strength is not worse than steel. This makes it a better material for thin-walled, complex mesh castings. It also has greater dimensional stability.

Die Casting Steel Alloy

For stainless steel die castings, die casting molds must be carefully selected. If the melting temperature of steel is close to the mold material melting temperature, the mold cannot withstand the impact of high temperature and high pressure.

Steel Die Casting Characteristics

It has good thermal fatigue resistance, anti-tempering stability, and good smelting, forging, heat treatment, and mechanical processing performance.

Steel Die Casting Advantages

It has good thermal fatigue resistance, anti-tempering stability, and good smelting, forging, heat treatment, and mechanical processing performance. It is a new high-strength and toughness hot-work die steel with excellent comprehensive performance in China and line with my country’s resource conditions.

Steel Die Casting Applications

Steel casting is mainly used in hot work molds for pressure casting, squeeze casting, gravity casting, and forging in industrial production such as automobiles, motorcycles, military electronics, agricultural machinery, and general machinery manufacturing.

Die Casting Brass Alloy

Copper alloy die casting parts have the highest mechanical properties and corrosion resistance of all die-casting parts. Due to the higher metal temperature and shorter die-casting die life, the die-cast brass alloy is not regarded as a good die casting alloy. Among the die casting brass alloys, the yellow brass die-casting alloy is the most common die-casting part in this country and abroad. Like other die casting alloys, the advantages of brass die casting parts include good surface finish, precise dimensional control, and high productivity.

Brass Die Casting Characteristics

  • High strength
  • Preservative
  • Heat resistance
  • High conductivity
  • Beautiful appearance
  • Low price for the complex and precise shapes

Brass Die Casting Advantages

  • Corrosion resistance, even it is in saltwater.
  • It has high-temperature resistance even in burning buildings.
  • Excellent conductivity.
  • The pressure tightness of brass can reach up to 300psi.
  • Easy polished or electroplated to obtain attractive decorative effects.
  • Cost-effective durability.

Brass Die Casting Applications

Brass is commonly used to make washers, camshaft components, and decorative products (due to their unique color and potential for surface finish).

ACE Machinery is an ISO 9001 certified manufacturer for OEM casting and forging service, including China CNC machiningcustom die castingchina investment castingforging services, etc. Contact us for more custom casting services!

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If you would like to have a question then get in touch today, we are ready to assist 24/7.
We welcome your cooperation and we will develop with you.

 Factory-direct Connectivity Solutions.
 High quality, Competitive Price.
 Custom-tailored solutions.
 Problem-solving approach.